Full Report

ANIMESH UNIYAL 1000116019 Page 1
MAJOR PROJECTS / AMR SCHEMES:

Some of the major projects / schemes / latest technologies to improve
production from concept to commissioning (implemented or in the process of
implementation) carried out by Design and Engineering department are
indicated below:

Use of excellent materials for plastic production

Water enrichment for cooling purpose

Ensuring availability of utilities like cooling water during total &
extended power failure.

Implementation of water pumping scheme through recycling.

Implementation of automation in various units of plastic
manufacturing.

Replacing the oldmolding machines with latest moundingmachines at
Continuous Casting Department.

Up gradation / modernization to increase the speed of machine and
there by production.

Modification of water box for proper work maintenance.

Augmentation of used water system to facilitate up for cooling during
manufacturing.


Expand plastic plant capacity to 5 million ton by 2011-12 with the
mission to attain 10 million ton capacity in two subsequent phases

Wipe out accumulated losses by 2010-11

Be amongst top five lowest plastic producers in the world by 2010-11

Achieve customer satisfaction levels on par with world class
organizations by 2010-11

Make CIPET the employer of choice by caring for employees.
Develop people As knowledge workers by 2010-11 and achieve an
improvement of 5 percent Points in employee satisfaction levels every
alternate year

Be ranked as an excellent business organization by 2010-11

Ensure zero effluent discharge by 2010-11 and contribute to
improving Quality of life (health, literacy and water) in at least one
village every year


Last few years have been tumultuous for plastics and petrochemical sector due
to steep rise in oil prices, which has adversely affected the global economies.
However, considering the feed stock advantage and abundance of oil reserves
newer petrochemical complexes are being established in Middle-east countries.
i.e. Oman, Saudi Arabia, UAE, etc. It is projected that by the end of 2010,
Ethylene capacity in Middle-East would reach to about 35 million tons per
annum and Polypropylene (PP) capacity to touch about 7 million tonnes per
annum. The US Petrochemical sector may lose Export competitiveness as most
of the Ethylene capacities in USA are Ethane based, which are not cost
competitive and are capable to produce only Polyethylene (PE). Similarly, the
revamping of European Petrochemical Complexes would be imperative as they
are based on old and expensive technology and are not cost competitive with
the Middle-East companies having the biggest advantage of raw material at
their door-step. China, Middle-East and India would be the major global
players, where expansion and augmentation of existing petrochemical capacity
would take place in the next 5 years.

Worldwide Plastics Industry witnessed a steady growth in the year 2007 which
is reflected in the increased consumption figures of all types of Plastics
materials.

Asia has been worlds largest plastics consumer for several years, accounting
for about 30% of the global consumption excluding Japan, which has share of
about 6.5%. Next to Asia is North America with 26% share, then Western
Europe with 23% share in the global market.

The key growth segment remains Packaging which accounted for over 35%
of the global consumption. Amongst the individual Plastics Materials,
Polyolefin accounted for 53% of the total consumption, (PE with 33.5%, PP
with 19.5%) followed by PVC 16.5%, PS-8.5%, PET & PU - 5.5%, Styrene
copolymers (ABS, SAN, etc) 3.5% other engineering & high performance &
speciality plastics, blends, alloys, thermosetting plastics 13%.

In recent years, significant aspect of plastics material growth globally has been
the innovation of newer application areas for plastics such as increasing plastics
applications in automotive field, rail, transport, defence & aerospace, medical
and healthcare, electrical & electronics, telecommunication, building &
infrastructure, furniture, etc.


Plastics have become the key drivers of innovations & application
development. Polymer-Electronics is one such area which has opened up new
avenues for plastics; from organic light emitting diodes to electro-optical and
bio-electrical complements, from low-cost plastic chips to flexible solar cells.
New plastics can conduct electricity and emit light. While polymers will not
replace silicon as semiconductors, they do offer completely new opportunities
for low-priced mass-manufactured products. Radio-frequency identification
(RFID) tags in smartcards for identification and access control, payment and
ticket systems, price labels, product tracking systems in the logistics chain or
packaging that monitors product quality many things are in offing. Growth-
trend of plastics has proved that there has been a quiet Plastics revolution
taking place in the material sector.


INTRODUCTION OF INDUSTRY/ORGANISATION

Central institute of Plastics Engineering and Technology (CIPET) is an
autonomous Institute under the Ministry of Chemicals and Fertilizers,
Government of India. CIPET centers are located at Chennai, Ahmadabad,
Bhopal , Guwahati Hyderabad, Lucknow, Panipat, Jaipur &Mysore. CIPET
centers across the country are very well equipped with State of art
infrastructure and machinery in testing , processing, tooling , calibration and
CAD/CAM/CAE to develop the manpower for plastics and allied industries in
terms of Training, Technical services .R&D and consultancy.

CIPET has been actively involved in inculcating awareness about environment
and Plastics waste management issues at National and International level. To
address various environmental issues and to create an awareness about "Plastics
& Environment", CIPET has conducted series of National Seminars in different
parts of the country:
Indian Centre for Plastics in the Environment(ICPE) and Central Institute of
Plastics Engineering & Technology (CIPET) have brought out a comprehensive
monograph entitled "Plastics for Environment & Sustainable Development"
with an objective to propogate advantages of Plastics in modern society by
focusing on various contentious issues concerning sustainability of Plastics
materials and assessment of the impact on environment.
CIPET laboratory have equipments;

Differential scanning calorimeter
Universal testing machine
Impact tester
Thermogravemetric Analyzer
HDT!VST Tester
Abrasion Tester
Surface and volume resistivity tester


U.V Weatherometer
MFI testing machine
Density by density gradient column
HAAKE Rheocord 9000
Injection moulding machine
Extrusion Machine
Compression Machine
Absorption Spectroscopy
Carbon black content equipment
Rockwell hardness testing machine
Environmental chamber for conditioning
CNC Machine for Mechanical work
Viscometer

Central institute of plastics Engineering and Technology (CIPET) is an institute
under the department of Chemicals and Petrochemicals, Ministry of Chemicals
and fertilizers , Government of India . CIPET Head Quarters was established at
Madras in 1968 with UNDP assistance .this is the only institute of its kind in
India where all the facilities like design. Tooling, processing and
CAD/CAM/CAE, Testing , consultancy, advisory and Development services.

In order to meet the growing demand of trained man power and technical
services in Northern region in general and the state of Uttar Pradesh, CIPET
Lucknow was the first Established in 1986-87 by Government of India with the
assistance of Government of Uttar Pradesh for supporting the plastics &allied
industries in the state . CIPET LUCKNOW has NABL accreditation as well as
BIS recognition for conducting plastics materials and products testing for
quality assurance.

The centre of CIPET has been equipped with state-of-the-art machinery in the
area of mould/product design and development, CAD, plastics processing and
testing/quality control .
Apart from developing training man power and technical services for plastics
industries Specializes in application development in the field of auto mobile and
teletronics .

CIPET Centre at Lucknow was established in 1986-87 by Government of India
with the assistance of Government of Uttar Pradesh for supporting the plastics
& allied industries in the state. CIPET Lucknow has been contributing its
valuable service to the industry and helped in the growth of Plastics Industry in
the region.

Accreditation and Quality Management System

The Plastics Testing Centre of the Institute accredited by NABL,
Department of Science and Technology, Govt.of India for performing
Mechanical and Chemical Tests on raw material and plastics products
Recognition by Bureau of Indian Standards (BIS) for the Testing and
evaluation of plastics materials and products
The Indian plastic processing industry is highly fragmented and comprises
25,000 firms. Barring 10% - 15% of the firms, which can be classified as
medium scale operations, all the units operate on a small-scale basis.
The top 100 players account for just 20% of the industry turnover. The total
number of players in the sector is more than 25,000. However, the degree of
fragmentation, worldwide, is a large and despite the small size of operations of
the players, they are able to operate profitably. Further, the high growth in
demand ensures that the market is able to absorb the excess capacity in quick
time. Overall, the degree of competition can be considered high in the Indian
plastic processing industry.

The sector has a significant presence of the unorganised sector, which accounts
for more than 70% of the industry turnover. More than 95% of the firms in the
industry are partnership, proprietorship or private limited companies. Further,
these small companies get significant advantages in taxes. These firms thus
provide significant level of competition to the organised sector companies,
which combined together are making losses. The organised sector companies
thus need to build up significant brand image to survive against the competition
from the unorganised sector. The key organised sector players include
Nilkamal Plastics Limited and Supreme Industries Limited.


TABLE 1- Current Indian Petrochemicals Capacities (in
KT)

Producer & Location

PP

HDPE

LDPE

HD/LL

PTA

PS

PVC

RIL, Hazira

350

-

-

400

-

-

300

RIL, Jamnagar

600

-

-

-

800

-

-

RIL Patalganga

60

-

-

-

300

-

-

IPCL, Nagothane

60

-

80

220

-

-

-

IPCL, Vadodara

75

-

80

-

-

-

55

IPCL, Gandhar

-

160

-

-

-

-

-

GAIL, Auriya

-

100

-

160

-

-

150

HPL, Haldia

210

200

-

260

-

-

-

BRPL, Bongaigaon

-

-

-

-

-

-

-

Finolex, Pisranpar

-

-

-

-

-

-

130

LG Poly, Vizag

-

-

-

-

-

80

-

Supreme, Mumbai

-

-

-

-

-

240

-

ChemPlast, Metturdam

-

-

-

-

-

-

60

DCW, Sahupuram

-

-

-

-

-

-

60

BASF Styrenics,
Bharuch
-

-

-

-

-

60

-
DCM, Shriram, Kota

- - - - 400 - 35

RPRL, Abu

-

-

-

-

-

16

-

Mitsubishi, Haldia

-

-

-

-

-

-

-

TOTAL

1355

460

160

1040

1500

360

790

Grand Total

5665


Typical Polymer consumption pattern of different
polymers

Polymer

KT

LDPE/EVA

275

LLDPE

550

1745

HDPE

920

PP

1300

PVC

1000

PS

225

PET Film

135

Bottle

100

235

SAN/ABS

90

Polyamide

35

Polycarbonate

72

Polyacetal

8

125

PET/PBT

7

Others

3

Thermoset

100

Total

4820

To manufacture finished products, polymers are processed through
various types of techniques namely extrusion, injection moulding, blow
moulding and rotomoulding. Various products manufactured through
these processes are highlighted in the following exhibit.


Classification of Plastic Products by Type of process used

Extrusion

Films and Sheets, Fibre and Filaments Pipes,
Conduits and profiles, Miscellaneous
applications

Plastic Products

Injection Moulding

Industrial Injection Moulding, Household
Injection Moulding and Thermo-ware/
Moulded luggage

Blow Moulding

Bottles, containers, Toys and Housewares

Roto moulding

Large circular tanks such as water tanks

The polymer consumption in India according to various processes is
provided as follows :

Process

(%) Share in Total consumption in
India

Extrusion

60.0

Injection Moulding

25.0

Blow Moulding / Stretch Moulding

06.0

Rotomoulding

01.0

Other Processes

08.00


Statistics of Plastics Industries in India :

Current Status

Major Raw Material Producers

15 Nos.

Processing Units

25,000 Nos.

Turnover (Processing Industry)

Rs.85,000 Crores

Capital Asset (Polymer Industry)

Rs.55,000 Crores

Raw Material Produced approx

5.3 MMT

Raw Material Consumed approx

5.1 MMT

Employed Direct/Indirect

3.3 Million

Export Value approx

US $ 1.90 Billion

Revenue to Government approx.

Rs.7300 Crores

By 2011 - 12

Demand Potential

12.5 MMT

Additional Employment

4.0 Million

Investment Potential

Rs.84,000 Crores

VISION 2015 Indian Plastics Industry :

Consumption of Polymers @ 15% CARG

18.9 Million tonnes

Turnover of plastics Industries

Rs.1,33,245 crores

Additional Employment Generation

7 Million

Requirement of Additional
Plastics Processing Machines
68113 Nos

Additional Capital Investment
In Machines (2004-2015)
Rs.45,000 crores

For more information on Indian Plastics Industry, please visit

Plastindia Foundation - www.plastindia.org


All India Plastics Manufacturers Association - www.aipma.net

Indian Plastic Federation - www.plasticfederation.org

Organization of Plastics Processors of India - www.oppindia.org

The Plastics Export Promotion Council - www.plexconcil.org



Deputy Director(head of institute)

Chief Manager (professor) (looks after academic &
placement activity)

Manager (asst. professor) (head of departments)

Sr. tech officer (sr. lecturer) (faculty member)

Technical officer (lecturer)(faculty member)



Mud flap for automobile industries

Steering seals

Defense application products

Telephone buttons

Telephone dial tone button

Soap and tooth brush case

Polythene bags for 1-5 kg


ACTIVITES

Tooling on CNC machines-CNC milling. CNC lathe CNC EDM for
different machining jobs receive from reputed customers.

Engraving by pantograph.

Fabrication of single impression injection mould for domestic products.

Development of mining props from plastic materials.

Consultancy provided on setting up of HDFC pipes manufacturing plant.

Climating testing of plastic products.

Characterization of lamination rolls terminal logic.

Technical evaluation and study of the properties of HDFC and PP.

Testing and quality assessment of plastic materials and products as per
national and international standards.

Formulation and supplement of testing standards.

Design and development of testing equipments as per testing
requirements.

3-Dimentional solid modeling

Process simulation and mould design.

3D digitizing and 2D digitizing.


Required design

No.of pieces/time

Selection of machine

No.of cavities

Selection of module

Placement of cavities

Selection of gating

set temperature

control placement of cavity

Modeling

Machine placement

Booking and loading

delivery


(BASED ON STUDY AND OBSERVATION IN DIFFERENT
DEPARTMENTSTS AND SECTIONS)

(FIRST WEEK IN CIPET)

PROCESSING DIVISION

Plastic Processing has broad range of practical training facilities in the form of
conventional processing machines. In addition to the training activities the
processing division is also competent enough to undertake mould providing and
moulding jobs in different processing machines.

The following customer services are provided by processing division:

Job-work on moulding of plastic products and providing of mould
To conduct tailor-made/modular training programs on the specific topics
as per the requirements of plastic industry.
To organize Awareness Orientation & Entrepreneurship Development
Program (EDP5) on Plastic Processing Techniques
Consultancy and Advisory services to the plastic industries
To provide consultancy services to the new entrepreneurs on Setting up
of a Plastic Industry

FACILITIES AVAILABLE

Modern Injection Moulding Machines of following manufacturers:- JSW-
Japan, ELECTRONICA- India, ENGEL- Austria, WINDSOR- India
Multilayer Blow Film Plant of Dr. Collin Germany
Pipe & Blown Film Extruders-Kolsite, India
Extruder for Tubing -DGP-Windsor
Compression Moulding Machine
Thermoforming Machine
Rotational Moulding machine
Blow Moulding Machine
FRP-Demonstration Facility


PLASTICS

Materials derived from carbon are termed as organic materials . range of the
organic materials is in thousand owing to vast variety of hydro carbons and their
derivatives .organic materials may be natural or synthetic . from nature we
obtain inform of crude oil . after fractional distillation in different stages we
obtain petrol diesel kerosene petroleum jelly etc.

A plastic is the name given to a materials which is a mixture of resin catalyst
accelerator and pigment. Resin forms a major part this mixture and hence the
properties of plastic are mostly governed by the properties of resin used.

Plastics are classified in to two categories.

1. Thermosetting Plastic
2. Thermoplastic

1. thermosetting plastic- they have a three dimensional network of primary
bonds in all the directions. These types of plastics. On applications of
heat first become soft and then hard and after that they can not be soften
against by application of heat. This permanent hardening called curing is
a chemical change. egphenolics, epoxies, melamine, and bakelite etc. they
generally require both heat and pressure be moulded into any shape if
intensely heated, they breakdown by degradation.

2. thermoplastics- their chain molecules are secondary bonded which break
more readily due to increase in thermal energy. They become soft when
heated ( generally with pressure ) but require cooling to set into a definite
shape. Since no chemical hardening action takes place the shaped articles
re-soften on reheating. Only a physical change is involved with them .e.g.
cellulose polystyrene, polyvinylchloride, nylon, Teflon, polysulfone,
acrylic, polyurethane, acetal etc.


MACHINE NAME- TEXAIR

SPECIFICATIONS

It is a screw type injection moulding machine
Model name : JTS-40

INJECTION MOULDING
CYCLE

1.Mould opening
2.Mould closing
3.Mould safety
4.Mould locking
5.Injection unit forward
6.Injection
7.Hold down time
8.Refilling
9.Injection unit reverse! cooling
10. Mould opening
11. Ejection

Injection unit
screw diameter:-32mm
L/D ratio:-20:1
Screw stroke:-145+5
Maximum swept volume:-100cc
Shot capacity:-40gms
Maximum screw speed:-200rpm
Number of heating zone:-4

Clamping unit
Clamping force :- 40 tons
Maximum mouldopening :- 250mm
Maximum height of mould: - 300mm
Day light :- 550mm
Number of tie bars:- 4
Distance between tie bars: 305 x 225 mm x m
Platen size : 450 x 395 mm


Maximum hydraulic ejection force :- 3 tons
Maximum stroke of hydraulic ejector :- 60mm

SEMI AUTOMATIC INJECTION MOULDING MACHINE SP-130

SPECIFICATIONS

Screw diameter : 45 mm
Injection stroke : 190 mm
LID ratio : 20:1
Screw speed : 0-205 rpm
Plasticizing capacity : 75 kg/hrs
Maximum calculated shift volume : 300cc
Maximum rate of injection : 175 cc/sec
Injection pressure : 2200 kg/cm
Refraction stroke : 200 mm
Nozzle contact force : 6.2 tons
Hopper capacity : 4.5 liters

Locking unit :-
Mould clamping force:-130tons
Size of mould platen:-585x585
Distance b/w tie bar:-380x380
Diameter for tie bar:-70mm
Minimum mouldheight :-200mm
Maximum mould opening:-550mm
Maximum day light:-750mm

TECHNICAL DATA

Screw dia:-50mm
L/D ratio:-24:1
Drive motor:-20/2HP, 1500/150RPM Dc motor
Screw speed:-12-120RPM
Main speed reducer:-worm reducing gear box having reduction
Ratio:-15:1
Thrust capacity:-30.000hrs at 100rpm
B-10 life of bearing 375 kg/cm ( 5300psi ) head pressure in hrs
Hopper block:-water cooling type
Heating zones on barrel :-3-5 KW each


Cooling blower motor hp:-1 number of 0.1HP
Number of die zones:-3
Heating capacity:- maximum capacity to be 3 KW for each zone
Electrical supply :-415V+5%, 50 C/S phase, neutral and
Cooling water:-inlet, 1/2 BSP-1 Numbers, outlet BSP-2 Numbers


(SECOND WEEK IN CIPET)

TESTING LAB

The Plastic Testing Centre (PTC) in CIPET is well equipped with all modern
plastic testing facilities. These facilities are being utilized effectively to improve
the standard and quality of plastic materials .
The PTC has been providing very useful services to the plastic conversion
industries by testing of raw materials and finished products like pipes,
containers etc. The testing services also include identification and
characterization, composition of materials etc. The centre is closely associated
with Bureau Of Indian Standards (BIS) for establishing standards and to issue
certificates for various plastic materials and products .The PTC also has an
interaction with International Standard Organization (ISO) in the formulation of
standards.

The PTC in CIPET is recognized by following organization

1. Bureau of Indian Standards
2. Department of Family Welfare, Govt. of India
3. Department of Science & Technology, Govt. of India
4. Various state Government departments for quality assurance
5. Underwriters Laboratories Inc., USA
6. American Association for Laboratory Accreditation on behalf of Asia Pacific
Laboratory Accreditation and Co-operation (AP LAC)

The PTC is presently in the process of getting NABL Accreditation.
The PTC provides basic service to the industries and Government Agencies for
Quality through:

Identification and characterization of Plastics and composites
Testing and quality assessment of plastic materials and products as per
national and international standards
Formulation and Supplementation of Tests standards
Design & development of testing equipments as per testing requirements.
Undertakes development projects and special assignments

TYPE OF TESTING


To determine the mechanical properties of materials certain tests are carried out
.depending on the nature of tests. These are grouped into following categories.

Non destructive tests
Destructive tests

In non destructive tests the materials of their specimens are not broken. In
destructive tests. The specimens of materials or fractured or deformed.

Soft and weak material

Low modulus.
Low yield stress.
Moderate elongation at break point.

E.g. Polytetrafluoroetsylene ( PTFE ) is a good example of one such type of
plastic material.

Soft But Tough Material

Low modulus
Low yield stress
very high elongation
high stress at break

e. g. polyethylene is a classic example of these types of plastics

Hard & Brittle Material

High modulus
Low elongation
It may or may not yield before breaking

e.g. one such type of polymer in this group general purpose phenolics .

Hard & Strong Material

High modulus
High yield stress

High ultimate strength
Low elongation

e.g.polyacetal is a good example of this class of materials.

Hard and tough Material

High modulus
High yield stress
High elongation at break
High ultimate strength

E.g. Polycarbonate ( PC ) is considered hard & tough material.

Type of Mechanical properties

Short term mechanical properties
Long term mechanical properties
Surface term mechanical properties

TENSILE TEST

Tensile test in a broad sense is a measurement of the ability of a material to with
stand forces that tend to pull it apart and to determine to what extent the
material stretches before breaking
Significance:- To produce data for the control and specification of polymers.
To provide useful data for plastics engineering design
purpose.

Standard:- ASTM D 638 , ISO 527-1
Factor:-Temp. , RH Speed, Grips & Specimen preparation.

Resistance of plastic material against the tension called tensile strength.

Test specimen:-Dumb- bell shaped.

Specimens:-

Film:-cutting punch
Sheet:-counter forming
Foam:-cutting punch
Liquid:-coasting
Thermostat:- C. M., I M. T. M.

Thermoplastic

Factor affecting the test results

Temperature:-Tensile strength and modulus are decreased while elongation is
increased as the temp increase.

Rate of straining:-As the strain rate is increased the tensile strength and modulus
increases . However the elongation is inversely proportional to the strain rate.

Humidity:-Tensile strength is increased as the humidity decrease.

FLEXURAL TEST

The ability of a material to withstand bending forces applied perpendicular to
the longitudinal axis.

Significance:-The polymer used in the form of a beam and if the services failure
occurs in bending.

Standard:-ASTM D 790, ISO 178
Factor:- Temp. , RH, speed and specimen preparation.

Factor Affecting the Test Result
Temperature:-At higher testing temperature flexural strength and modulus
values are significantly lower.

Speed:-At higher speed flexural strength is also high.

Molecule orientation:-The molecule orientation in the specimen has a
significant effect on the test result.


COMPRESSION TEST

Compression Strength: We describe the behavior of the material when it is
subjected to a compressive load at a relatively low and uniform rate of loading.

Significance:
To provide standard data for R&D.
-To know about deformation in compression for engineering application

Standard
- ASTM D 695 , ISO 178

Factor :
- Temp. , RH , speed & specimen preparation

Compressive Properties:-ASTMD-695

Test specimen size:-
For rectangular specimen = x x 1 inch
For cylindrical specimen = inch diameter and 1 inch long

IMPACT TEST

In manufacturing of locomotive wheels, coins, and connecting rods etc., The
components are subjected to impact loads. These loads are applied suddenly.
The stressed induced in components is many times more than the stressed
produced by the gradual load. Hence the material should be able to sustain such
loads. Therefore impacts test are performed to access shock absorbing capacity
of materials subjected to suddenly applied shock loads.
These capabilities are expressed as

1. Rupture energy
2. Modulus of rupture
3. Notch impact strength

In this test a notched specimen placed as a beam is given an impact, and the
energy required to propagate the specimen is measured. The impact test is
performed on Izod Testing Machine. Specimen is broken by swing of hammer.


Types of Impact Test

1. Pendulum Impact
Izod
Charpy
Tensile
2. High Rate Tension Impact Test
3. Free weight Drop Impact Test
4. Instiented impact test

Significance :- to provide information about toughness & brittleness of
the metals
Standard :- ASTM D 256, 5628 , 5420 , 1709.

IMPACT TEST

Charpy Impact Test:-

Specimen size : - 127 x 12.7 x 6.4 mm
= 5 x x 1/8 inches
Specimen thickness : - 1/8 inch
Notch = 2.54 mm depth

Izod Impact Test

Specimen size : - 635 x 12.7 x 6.4 mm
= 5 x x 1/8 inches
Specimen thickness : - 1/8 inch

FACTORS AFFECTING IMPACT STRENGTH

Rate of loading
Notch sensitivity
Temperature
Orientation
Processing condition and type
Degree of crystallinity and molecular weight

Method of loading

TYPES OF LONG TERM MECHANICAL PROPERTIES

Creep properties ASTMD 2990
Stress -Relaxation properties
Fatigue resistance ASTMD-671
Creep properties ASTMD- 2990

The permanent deformation of material under the steady load as a function of
time is called creep. a very common experience in which the length of our waist
belt increases after some duration is due to creep effect. It is thermally actuated
process.
Creep occurs at room temperature in many materials such as lead , zinc etc. For
an insight , consider zinc whose melting point is 420 C. Its creep rate is
considerably above a temperature I.e. at about 4 C only.
Consideration of creep is very important in application such as

1. Industrial belts
2. Blade of gas turbines
3. Blade of steam turbines
4. Piston of I.C engines
5. Polymeric and elastomeric constructions
6. Rocket & missiles
7. Nuclear reactors
8. Tubes of heat exchangers etc

Creep is sometime desirable also in metal forming operations such as hot rolling
, extrusion , forging. These process are carried out at high temperatures where
deformation follows creep law. The forces required in operations are reduced
due to raise temperature.
The values are refered as tensile creep compression creep or flexural creep.

TENSILE CREEP

Tensile Creep is measured by applying constant load of a tensile test specimen
and measuring its extension as a function of time.
In order to show initially mark the specimen at two points which is considered

as a gauge length as specified time interval & measured the distance between
marks at specified time interval.
thepercent creep strain is determined by dividing the extension by initial guage
length and multiplying by 100

FLEXURAL CREEP

Flexural creep measurement are also made by applying a constant load to the
standard flexural test specimen and measuring at mid span is measured using
dial indicator gauge

r = 6 x D x d x 100/l

r = maximum percent creep strain ( in un)
D = maximum deflection at mid span (in un)
d = depth (in)
l = span (in)

FACTORS AFFECTING THE CREEP RESISTANCE

Temp. Is inversly proportional to the creep resistance I.e. if temp. Is high then
creep is low.

1. Humidity creep resistance
2. Plasticizer creep resistance
3. Filler creep resistance
4. Cross linking creep resistance
5. Cross linking -% of creep resistance filler loading

STRESS - RELAXATION PROPERTIES

The gradual decrease in with time under a constant deformation is called strain.
Test specimen and preparation : Injection molded - dia 12.82, 9.06, or 6.40 mm.
Specimen from sheet or plate.
Specimen for compression test - according to the ASTM - D-695


FATIGUE RESISTANCE - ASTMD-671

The behavior of materials under fluctuating and reversing loads is known as
fatigue. This behavior is different from that under steady load. Fatigue is
however not a dynamic effect. The rate loading is usually not a factor in fatigue
behavior. Fatigue behavior is experienced by all material whether metals,
plastic, concretes or composites. The main effect of fatigue on the properties of
the materials are

1. Loss of ductility
2. Loss of strength
3. Enhanced uncertainity in strength and service life of materials

Fatigue occurs at stresses well within elastic limits.
A fatigue life is defined as the no. of cycles of deformation required to bring
about the failure of the test specimen under a given set of oscillating condition.,

Stress = 1/No of cycle

TYPE OF FATIGUE TEST

Flexural Fatigue Test (ASTMD-.671)
Flexural fatigue test is the ability of material to resist detoriation from the cyclic
stress is measured in this test by using a fixed cantilever type testing machine.

Tensile Fatigue Test :- Unlike the flexural fatigue test which uses the constant
deflection principle. The tensile fatigue test is conducted under constant load
condition.
Factor Affecting the Fatigue Resistance
1. Temp. fatigue resistance
2. Humidity fatigue resistance
3. Thermal conductivity = 1
....
Fatigue endurance limit
4. Fatigue resistance = 1
..
Stress

SPECIMEN PREPARATION

The specimen is dumbbell shaped about 2 in long with cylindrical cross section
. The test is conducted by mounting both the ends of the dumbbell shaped
specimen in the testing machine . The specimen is rotated between to spindles
and stress in the form of tension and compression is applied. The specimen is
subjected to the no. of stress specified.

SURFACE RELATED MECHANICAL PROPERTY

Surface mechanical property based on surface test and it is measure change the
dimension of the surface of change weight with respect to original specimen
weight. It is classified in to four basic type on the basis of surface test for e.g.
1. Friction - ASTMD -1894
2. Abrasion - ASTMD- 1044

3.Hardness - ASTMD- 785, 2240, 2583
4 FRICTION ASTMD -1894

The relative resisting force with the surface of one material will slide over an
adjoining surface of itself or another material.

Static coefficient of friction is the measured force required to begin
movement
Kinetic coefficient of friction is related to the measured force required to
sustain the movement.

TEAR RESISTANCE

To determine the force necessary to propagate a tear in plastic sheets

Significance
actual end application
Standard : - ASTMD 1004, 1922, 1938
Factor:
- temp, RH ,speed & specimen preparation, MWD
Creep Resistance : - To determine deformation under load
Stress Relaxation : - to determine gradual decrease in stress with time

under constant deformation
Permanent Deformation : -Ratio between creep &stress relaxation
Significance :-
- High performance &extreme reliable applications
Standard : - ASTMD -2990
Factors : - temp. RH, speed & specimen preparation , MWD
To determine the repeated cycling loading
Significance:-
- High performance &extreme reliable applications
Standard ASTMD - 671
Factors : -
- Temp, RH, speed & specimen preparation ,MWD

ABRASION RESISTANCE

To determine the material loss through frictional force, load , true contact

Significance : -
High performance &extreme reliable applications
Standard : - ASTMD -1242, 1044

Factors : -
Temp, RH ,Wheel of Abrader , MWD
HARDNESS
Hardness : - Resistance of material to deformation
Type of Hardness : -
- Rockwell Hardness
- Durometer Hardness
- Barcol Hardness
Significance : -
Standard : - ASTMD -785,2240,2583
Factors : -
Temp, RH ,Surface Condition , MWD & Additives
Determination of Sliding Friction of Plastics.
Significance : -

Standard : - ASTMD -3028
Factors : -
Temp, RH ,Surface Condition , MWD & Additives


(THIRD WEEK IN CIPET)

CAD / CAM DESIGN

The design department with CAD has latest software for Imparting effective
training on product and mould design. The department provides following
services to the plastic Industries:

3- Dimensional solid moulding

Product design and mould validation of Injection Moulding

Compression Moulding and Transfer Moulding process

Process simulation and mould design validation of Blow moulding

Extrusion Die Design : Pipe Die , Sheet Die & Co -Extrusion Dies

3-D & 2-D Digitising

A-A plotting services using inkjet/laser plotters

Generation of CNC part programming

Scanning of Drawing/ Profiles

Short term training program for skill upgradation


(FOURTH WEEK IN CIPET)

TOOL ROOM

CIPET-TOOL ROOM at Lucknow has excellent CNC machining facilities for
taking up commercial job assignment for mould fabrication , high precision
machining and
manufacturing of standard mould bases. The facilities of tool room are given
below:

CNC MACHINES

Universal Milling and Boring Machines with SUSCAM Software
UME 600-MIKRON SWITZERLAND

Die Sinking-EDM ROBOFORM 40 -CHARMILLS
SWITZERLAND

Universal Lathe with Hydrobar feeder TORNADO 300
COLCHESTER,ENGLAND U.K

High Precision Surface and Profile Grinder ELBSCHILFF-PERFECT
FUTURE
GERMANY

INSPECTION FACILITIES

Co-ordinator measuring machine ACCURATE -INDIA
Profile Project -EPO LP10-JAPAN
Ultra Sonic Flaw Detector USK5-GERMANY
Surf Test -3 Mitutoyo-JAPAN

SPECIAL PURPOSE MACHINES

Jig Boring Machine with DRO B3-DR-HAUSER

SWITZERLAND

Coordinator Drilling & Boring Machine with DRO AD40-DRO
ACCUMAXINDIA
Rigid Die Sinking Machine KA200-RORSCHACH
SWITZERLAND
Center Lathe with Hydro Copying Attachment H22-HMT-INDIA
Rotary Surface Grinding RUSSIA
Cylindrical Grinder K130U-HMY-INDIA
Optical Profile Grinding Machine GLS 80A WASINO JAPAN

CNC(Computerized Numerical Control)MACHINE

CNC MILLING MACHINE
UME-600 , MIKRON (SWISS) MACHINE

SPECIFICATIONS

Controller :Heidenhain TNC-415-B
Travel : 600 X 500 X 45
Resolution : 0.001
Spindle rpm : 600 rpm
NC Rotary Table dia : 600 mm
Universal Table : 750 X 425
Turning/Tilting : 360 deg
Swilling angle : 45 deg

Features : 2D,3D,Profile milling ,pocket milling, slot milling, drilling, boring
,mirroring, scaling, datum shifting,etc.

CNC-SPARK EROSION MACHINE
ROBOFORM-40
CHARMILLES(SWISS) EDM MACHINE

SPECIFICATIONS:
Table : 700 X 500 mm
Travel : 500 X 400 mm
Max. part dim : 370 X 700 X 1000 mm
Max. part weight : 1000 kg
Max Electrode weight : 100 kg

CNC- LATHE MACHINE
TORNADO-300, COLCHESTER (U K ) MACHINE

SPECIFICATIONS:

Controller Fanuc OTC
Max. Spindle speed : 300 rpm
Travel : 240 X 500 mm
Number of Tools on turret : 12
Spindle bore : 90 mm
Features : Turning, Facing, Profile turning , Threading , Boring


MILLING MACHINE

A milling machine is a machine tool that removes metal as the work is fed
against a rotating multipoint cutter. The cutter rotates at a high speed and
because of the multiple cutting edges it removes metal at very fast rate. The
machine can also hold one or more number of cutter at a time .this is why a
milling machine finds wide application in production work. This is superior to
other machine as regards accuracy and better surface finish, and is designed for
machining a variety of tool room work.

TYPES OF MILLING MACHINE
1. COLOUMN AND KNEE TYPE
Hand milling machine
Plain milling machine
Universal milling machine
Omniversal milling machine
Vertical milling machine

2. MANUFACTURING OF FIXED BED TYPE
Simplex milling machine
Duplex milling machine
Triplex milling machine

3. PLANAR TYPE

4.SPECIAL TYPE

Rotatory table milling machine
Drum milling machine
Planatory milling machine
Pantograph, profiling and tracer controlled milling machine


BORING MACHINE

The boring machine is one of the most versatile machine tools used to bore
holes in large and heavy parts such as engine, frames etc. which are practically
impossible to hold and rotate in an engine lathe or drilling machine. Boring
machines have therefore, been developed primarily to do this. In addition to its
primary purpose of boring the range of speeds and feeds provided to the
various traversing components allow drilling, milling and facing to be
performed with equal facility. by the fitting of simple attachments the use
machine can be extended still further to include screw cutting turning, planetary
grinding, or gear cutting.

TYPES OF BORING MACHINE
1) HORIZONTAL BORING MACHINE
Table type
Floor type
Planar type
Multiple head type

2) VERTICAL BORING MACHINE

Vertical turret lathe
Standard vertical boring machine

3) PRECISION BORING MACHINE

DRILLING MACHINE

The driving machine is one of the most important machine tools in workshop.

As regard its importanceit is second only to lathe.Although it was primarily
designed to originate hole ,
it can perform a number of similar operations. In a drilling machine holes may
be drilled quickly at low cost the hole is generated by rotating edge of cutting
tool known as the drill which exerts large force on the work clamped on the
table.

TYPES OF DRILLING MACHINE:

1.Portable drilling machine
2.Sensitive drilling machine:
Bench mounting
Floor mounting
3. Upright drilling machine:
Round column section
Box column
4. Radial drilling machine:
Plain
Semi Universal
Universal
5.Gang drilling machine
6.Multiple spindle drilling machine
7. Automatic drilling machine

THE LATHE

The lathe is one of the oldest machine tools and come into existence from the
early tree lathe which was then a novel device for rotating and machining a
piece of work held between two adjacent trees. A rope wound round the work
with its one end attached to flexible branch of a tree and other been pulled by a
man caused the job to rotate intermittently hand tools were then used . With its
further development a strip wood called lathe was used to support the rope
and that is how the machine came to be known as lathe. This device continued
to developed through centuries and in the year 1797 Henry Maudslay , an
Englishman . designed the first screw cutting lathe which is for runner of the
present day high speed, heavy duty production lathe, a machine tool which ha

practically given shape to our present day civilization by building machine and
industries.

FUNCTION OF LATHE

The main function of a lathe is to remove metal from a piece of work to give it
the required shape and size this is accomplished by holding the work securely
and rigidly on the machine and then turning it against cutting to which will

remove 43 from the work in the form of chips . to cut the material properly the
toll should be harder than the material of the work piece should be rigidly held
on the machine and should be fed or progressed in definite way relative to the
work .

TYPE OF THE LATHE:-

1. SPEED LATHE
wood working
cantering
polishing
. spinning
2: ENGINE LATHE/CENTRE LATHE:

belt drve
Individual motor drive

gear head lathe

3:- BENCH LATHE

4:TOOL ROOM LATHE

5: CAPSTAN AND TURRET LATHE


6:SPECIAL PURPOSE:
wheel lathe
gap bed lathe
T- lathe
Duplicating lathe

7: AUTOMATIC LATHE

GRINDING MAACHINES

Grinding is metal cutting operation performed by means of a rotating abrasive
wheel that act as a tool . This is used to finish work pieces which must show a

high surface quality, accuracy of shape and dimension. Mostly grinding is the
finishing operation because it removes comparatively little metal,025, to 0.50
mm in most operations and the accuracy in dimensions in the order of 0.000025
mm. Grinding is also done to machine materials which are to hard for other
machining methods that use cutting tools.

Kinds of grinding:
1.Rough or non-precision grinding
2. Precision grinding

ROUGH GRINDING: The common forms of rough grinding are snagging and
off hand grinding where the work is held in the operators hand .
The work is pressed hard against the wheel . The accuracy and
surface finish obtained are of secondary importance. Snagging is done where a
considerable amount of metal is removed without regard to the accuracy of the
finished surface.

PRECISION GRINDING: This is connected with producing good surface finish
and high degree of accuracy .The wheel or work both are guided in precise
paths.

Grinding in accordance with the type of surface to be ground is

classified as

1.External cylindrical grinding
2.Surface grinding
3.Internal cylindrical grinding
4.Form grinding

External cylindrical grinding produces a straight or tapered surface on a work
piece .the work piece must be rotated about its own axis between centres as it
passes length wise across the face of a revolving grinding wheel .

Internal cylindrical grinding produces internal cylindrical holes and tapers the
work pieces are chucked by precisely rotated about their own axes the grinding
wheel or in the case of small bore holes the cylinder wheels rotates against the
sense of rotation of the work piece .

Surface grinding produces flat surface the work may be ground either by the

periphery or by the end face of the grinding wheel the work piece is
reciprocated at a constant speed below or on the end face of grinding wheel.

Form grinding is done with specially shaped grinding wheels that grind the
formed surfaces as in grinding gear teeth , threads , splined shaft, holes and
spheres etc.


MARKETING STRATEGIES

The performance of the CIPET during the last decade, though spectacular, has
not been altogether smooth. The euphoric developments in the first few
deregulation years were cut short when deceleration set in from the autumn of
1997. The external global environment worsened progressively under pressure
from a series of financial meltdowns in various parts of the world while our
domestic economy also stagnated. Prices started falling continuously even as
the world plastic industry strained under conditions of extreme oversupply and
cut-throat competition. The domestic market also dwindled on the back of slow
growth in construction and other forms of capital formation/investment. At the
present juncture, one can say that the industry has successfully made the
transition from a controlled to a market-driven economic environment.

There is a paradigm swift in plastic markets from controlled regime to
deregulation. The ambience has opened up the aggression of the international
players and allowed plastic Industry the access to international markets. The
Marketing Department in CIPET sustained the cyclic the world under the
dynamic leadership of its Management. The growths in sales in leaps and
bounds in Marketing Department have been achieved in volatile, dynamic and
highly competitive business environment. The structure of the Department, its
operations in Domestic as well as International Markets, the quality of
operations and services to the customers, Marketing techniques adopted for
image building are no less than the best in the class.


Finance & Accounts Functions centre round arranging the Finances, facilitating
and accounting the operations and compliance with various statutes. Finance
function is general discipline having universal application. As such, it has its
role in all forms and types of business i.e. from a sole trader to the joint Stock
companies, whether it is Indian or Multi-National Company. The function
encompasses broadly, Finance, Accounting, MIS, and Audit and taxation areas.
Function covers the areas of rising of Finances viz., Capital, loans, working
capital and servicing thereof. Finance also covers areas of controls viz.,
Budgetary Control and Cost Control.

Accounting deals with recording of daily transactions, compilation of Annual
Accounts and their audit by various agencies, via, Statutory Auditors appointed
under the companies Act, Audit by Comptroller & Auditor General of India in
case of Government Companies, Internal Audit and special Audits.

Taxation includes tax planning and complying with provisions of various tax
laws such as sales Tax, Central Excise, Income Tax Act, Wealth Tax Act,
Service Tax etc.

Though Finance & Accounts function is a general function having universal
application, it becomes necessary to modulate it to suit the requirements of the
specific industry it serves and accordingly formulate suitable systems and
procedures. For instance, in the area of costing, appropriate costing system is
required to be laid down keeping in view the manufacturing process.
Accordingly, the costing system in VSP is based on process costing. Similarly,
Budgeting is done department wise. Various products manufactured by VSP are
sold through its all India Branch network. For this purpose, materials are moved
from the plant to various branches. This calls for proper documentation for
dispatches, receipt of stocks, issue of stocks and stock balancing apart from
handling of money on sales, monitoring of outstanding debtors for credit sales,
payment of Excise Duty while clearing the material from the plant.


This report is basically an overview of the operations done at CIPET, Lucknow.
The study of various machines, testing equipment, tools and designing items
would be of great help for purpose of increasing ones knowledge of plastic
industry.

Related study of petrochemicals, polymers and plastics should be done for
complete understanding of the industry and its functioning.

This report is flexible enough to accommodate any changes, corrections of error
and suggestions in the near future.


The development and growth of plastics processing industry is dependent upon
the availability of skilled & technically trained manpower. With a rapid
development in the field of plastic processing using modern machines, there has
been increased demand of manpower for designing, tool making, plastic
processing and quality assurance (Total Quality Management - TQM) to meet
the diverse requirement of industries.

Hence, the manpower demand will also increase as the polymer material
consumption increases in the coming years. Since, CIPET is the only institute
of its kind in South Asia having state-of-art facilities and excellent infrastructure
in the field of Plastic Engineering &Technology, necessity of CIPET services in
terms of development of trained manpower for the plastic industry & technical
support in different technologies areas will be more relevant and synonymous
with future growth of plastics and allied industries.

CIPET services would be more congruous for the plastic and allied industries in
the years to come in terms of specialized training man power support
technology support, quality and productivity improvement, developmental
activities to newer technologies etc.

During the period of my training I felt that I am not a student doing training but
an employee working in CIPET by doing training here I was exposed to the
environment of an organization and felt It practically.
I came to know how to work in organization? and what an organization
wants from an engineer?

I enriched my knowledge and interpersonal skills during conduct of my training
and gained deep understanding of various systems of an organization.
The experience of my training in CIPET is a great experience of my life and it
will prove to be a stepping stone of success in my professional career.


The Book referred for this report are :

>Elements of workshop technology by : H.Chowdhary

>Industrial engineering and management by : O.P. Khanna

Internet was the main source of getting various ideas, information, pictures and
designs

>www.cipetindia.com

>www.google.com

>http://chemical.nic.in/petcipet.htm

Above all the intelligent and guidance of the officers of the CIPET,Lucknow
was involved. They have given me full support in making of this report.

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