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CONTENTS
CONTENTS
1. SYNOPSIS
2. INTRODUCTION
3. LITERATURE SURVEY
5. BLOCK DIAGRAM
6. WORKING PROCEDURE
7. APPLICATION
9. LIST OF MATERIAL
10.COST ESTIMATION
11.CONCLUSION
BIBLIOGRAPHY
PHOTOGRAPHY
MACHINE GEAR TYPE INJECTION MOULDING
SYNOPSIS
The project deals about the injection molding machine. The main
into molten state. The molten plastic is injected through the nozzle in barrel
to the die by the compressing force. After completing this process, we will
get the product from the die. Commercial products like bushes, couplings,
Heater
Funnel
Plastic material
Gear box
A.C Motor
FABRICATION TECHNIQUES:
The polymer material are converted into plastics and used as tubes,
tempering, stability, the size and shape are important in describing the
1. MOULDING PROCESS
2. FOAMING PROCESS
MOULDING PROCESS:
In this process the plastics are fabricated under the effect pressure and heat
by heating and the hot softened plastic is forced under high pressure into the mold,
FOAMING PROCESS:
through the hopper at definite time intervals into the hot horizontal cylinder
piston to push the molten material through a cylinder into a mould fitted at
the end of the cylinder. While moving through the hot zone of the cylinder,
a device called torpedo helps spread the plastic material uniformly around
the inside wall of the hot cylinder sand thus ensures uniform heat
distribution. The molten plastic material from the cylinder is then injected
through a nozzle material from the cylinder is then injected through a nozzle
movable part and the other stationary. The stationary part is fixed to the end
of the cylinder while the movable part can be opened or locked on to the
After the mould is filled with the molten material under pressure, then
molded article. The whole cycle could be repeated several time either
part is fed into a heated barrel, mixed, and forced into a mold cavity where it
facilitate the molding process; the material used for the part, the desired
shape and features of the part, the material of the mold, and the properties of
the molding machine must all be taken into account. The versatility of
possibilities.
PROCESS CHARACTERISTICS
plastic material into a mold cavity; this solidifies into a shape that has
suitable for injection molding, such as the ease with which they may be
manner, chemical crosslinking may occur causing the screw and check
material into a mold which shapes the polymer into the desired shape. Molds
cavity can be identical and form the same parts or can be unique and form
suitable for certain applications. Aluminum molds typically are ill-suited for
have inferior mechanical properties and are more prone to wear, damage,
and deformation during the injection and clamping cycles; but are cost
effective in low volume applications as mold fabrication costs and time are
considerably reduced. Many steel molds are designed to process well over a
million parts during their lifetime and can cost hundreds of thousands of
dollars to fabricate.
APPLICATIONS
instruments (and parts of them), one-piece chairs and small tables, storage
same object.
EQUIPMENT
ram or screw-type plunger, and a heating unit. They are also known as
presses, they hold the molds in which the components are shaped. Presses
are rated by tonnage, which expresses the amount of clamping force that the
machine can exert. This force keeps the mold closed during the injection
process. Tonnage can vary from less than 5 tons to over 9,000 tons, with the
total clamp force needed is determined by the projected area of the part
being molded. This projected area is multiplied by a clamp force of from 1.8
to 7.2 tons for each square centimeter of the projected areas. As a rule of
thumb, 4 or 5 tons/in2 can be used for most products. If the plastic material is
very stiff, it will require more injection pressure to fill the mold, thus more
clamp tonnage to hold the mold closed. The required force can also be
determined by the material used and the size of the part; larger parts require
Mold or die are the common terms used to describe the tool used to
only used in mass production where thousands of parts were being produced.
mold from is primarily one of economics; in general, steel molds cost more
to construct, but their longer lifespan will offset the higher initial cost over a
higher number of parts made before wearing out. Pre-hardened steel molds
are less wear-resistant and are used for lower volume requirements or larger
Hardened steel molds are heat treated after machining; these are by far the
MOLD DESIGN
Standard two plates tooling – core and cavity are inserts in a mold
The mold consists of two primary components, the injection mold (A plate)
and the ejector mold (B plate). Plastic resin enters the mold through a sprue
or gate in the injection mold; the sprue bushing is to seal tightly against the
nozzle of the injection barrel of the molding machine and to allow molten
plastic to flow from the barrel into the mold, also known as the cavity. The
sprue bushing directs the molten plastic to the cavity images through
channels that are machined into the faces of the A and B plates. These
channels allow plastic to run along them, so they are referred to as runners.
The molten plastic flows through the runner and enters one or more
specialized gates and into the cavity geometry to form the desired part.
The amount of resin required to fill the sprue, runner and cavities of a
mold is a shot. Trapped air in the mold can escape through air vents that are
ground into the parting line of the mold; if the trapped air is not allowed to
escape, it is compressed by the pressure of the incoming material and
squeezed into the corners of the cavity, where it prevents filling and can also
cause other defects. The air can even become so compressed that it ignites
To allow for removal of the molded part from the mold, the mold features
must not overhang one another in the direction that the mold opens, unless
parts of the mold are designed to move from between such overhangs when
Sides of the part that appear parallel with the direction of draw (The axis of
the cored position (hole) or insert is parallel to the up and down movement
of the mold as it opens and closes) [13]:406 are typically angled slightly (with
draft) to ease release of the part from the mold. Insufficient draft can cause
dependent on the depth of the cavity: the deeper the cavity, the more draft
necessary. Shrinkage must also be taken into account when determining the
draft required.[13]:332 If the skin is too thin, then the molded part will tend to
shrink onto the cores that form while cooling and cling to those cores, or the
part may warp, twist, blister or crack when the cavity is pulled away.[8]:47
A mold is usually designed so that the molded part reliably remains on the
ejector (B) side of the mold when it opens, and draws the runner and the
sprue out of the (A) side along with the parts. The part then falls freely when
ejected from the (B) side. Tunnel gates, also known as submarine or mold
gates, are located below the parting line or mold surface. An opening is
machined into the surface of the mold on the parting line. The molded part is
cut (by the mold) from the runner system on ejection from the mold. [13]:288
Ejector pins, also known as knockout pins, are circular pins placed in either
half of the mold (usually the ejector half), which push the finished molded
a series of holes drilled through the mold plates and connected by hoses to
form a continuous pathway. The coolant absorbs heat from the mold (which
has absorbed heat from the hot plastic) and keeps the mold at a proper
To ease maintenance and venting, cavities and cores are divided into pieces,
More complex parts are formed using more complex molds. These may have
sections called slides, that move into a cavity perpendicular to the draw
direction, to form overhanging part features. When the mold is opened, the
slides are pulled away from the plastic part by using stationary “angle pins”
on the stationary mold half. These pins enter a slot in the slides and cause
the slides to move backward when the moving half of the mold opens. The
part is then ejected and the mold closes. The closing action of the mold
plastic layer to form around the first part. This is often referred to as
overmolding. This system can allow for production of one-piece tires and
wheels.
molding machines with two or more injection units. This process is actually
an injection molding process performed twice. In the first step, the base
color material is molded into a basic shape, which contains spaces for the
into those spaces. Pushbuttons and keys, for instance, made by this process
have markings that cannot wear off, and remain legible with heavy use.[8]:174
A mold can produce several copies of the same parts in a single "shot". The
Some extremely high production volume molds (like those for bottle caps)
In some cases multiple cavity tooling will mold a series of different parts in
the same tool. Some toolmakers call these molds family molds as all the
Tool materials
Tool steel or beryllium-copper are often used. Mild steel, aluminum, nickel
or epoxy are suitable only for prototype or very short production runs.
Modern hard aluminum (7075 and 2024 alloys) with proper mold design,
can easily make molds capable of 100,000 or more part life with proper
mold maintenance.
MACHINING
Molds are built through two main methods: standard machining and
molds with more accurate mold details in less time than traditional methods.
shapes that are difficult to machine, the process allows pre-hardened molds
graphite, is very slowly lowered onto the mold surface (over a period of
between tool and mold causes spark erosion of the mold surface in the
COST
factors ranging from number of cavities, size of the parts (and therefore the
and many others. The initial cost is great, however the per-piece cost is low,
hopper into a heated barrel. As the granules are slowly moved forward by a
nozzle that rests against the mold, allowing it to enter the mold cavity
through a gate and runner system. The mold remains cold so the plastic
called the injection molding cycle. The cycle begins when the mold closes,
followed by the injection of the polymer into the mold cavity. Once the
shrinkage. In the next step, the screw turns, feeding the next shot to the front
screw.This causes the screw to retract as the next shot is prepared. Once the
part is sufficiently cool, the mold opens and the part is ejected.[18]:13
DIFFERENT TYPES OF INJECTION MOLDING
PROCESSES
Die casting
OPERATION
machines also don't require the mold to be fastened. There are many ways to
fasten the tools to the platens, the most common being manual clamps (both
halves are bolted to the platens); however hydraulic clamps (chocks are used
to hold the tool in place) and magnetic clamps are also used. The magnetic
and hydraulic clamps are used where fast tool changes are required.
TYPES OF INJECTION MOLDING MACHINES
HYDRAULIC
molders until Nissei Plastic Industrial Co., LTD introduced the first all-
MECHANICAL
machines so that the clamp side of the machine does not open (i.e. tool half
mounted on the platen) due to the injection pressure. If the tool half opens up
machines is more as tonnage built during each cycle is the same as compared
to hydraulic machines.
ELECTRIC
press. Electric presses have been shown to be quieter, faster, and have a
HYBRID
best features of both hydraulic and electric systems, but in actuality use
side or top entry, but it is more common for parts to drop out of the mold,
1. FUNNEL
2. GEAR BOX
3. A.C MOTOR
5. HEATER
6. POWER HANDLE
7. STAND
8. MOULD
FUNNEL
A funnel is a pipe with a wide mouth, good for feeding, often conical
would occur.
withstand the weight of the substance being transferred, and it should not
react with the substance. For this reason, stainless steel or glass are useful in
transferring diesel, while plastic funnels are useful in the kitchen. Sometimes
adequately clean the funnel afterward (for example, in adding motor oil to a
car). Dropper funnels, also called dropping funnels or tap funnels, have a tap
on a ship. The term funnel is even applied to other seemingly strange objects
A heater is any object that emits heat or causes another body to achieve a
commonly used to generate heating (i.e. warmth). Heaters exists for all
The opposite of a heater (for warmth) is an air cooler (for cold) used
to keep the user cooler than the temperature originally surrounding them.
MOULD
Mold or die are the common terms used to describe the tool used to
Since molds have been expensive to manufacture, they were usually only
mold from is primarily one of economics; in general, steel molds cost more
to construct, but their longer lifespan will offset the higher initial cost over a
higher number of parts made before wearing out. Pre-hardened steel molds
are less wear-resistant and are used for lower volume requirements or larger
Hardened steel molds are heat treated after machining; these are by far the
mold that require fast heat removal or areas that see the most shear heat
POWER REQUIREMENTS
The power required for this process of injection molding depends on
reference guide states that the power requirements depend on "a material's specific gravity,
melting point, thermal conductivity, part size, and molding rate." below is a table from page 243
of the same reference as previously mentioned that best illustrates the characteristics relevant
MOLD DESIGN
plate) and the ejector mold (B plate). Plastic resin enters the mold through a
sprue or gate in the injection mold; the sprue bushing is to seal tightly
against the nozzle of the injection barrel of the molding machine and to
allow molten plastic to flow from the barrel into the mold, also known as the
cavity. The sprue bushing directs the molten plastic to the cavity images
through channels that are machined into the faces of the A and B plates.
These channels allow plastic to run along them, so they are referred to as
runners. The molten plastic flows through the runner and enters one or more
specialized gates and into the cavity geometry to form the desired part.
The amount of resin required to fill the sprue, runner and cavities of a
mold is a shot. Trapped air in the mold can escape through air vents that are
ground into the parting line of the mold; if the trapped air is not allowed to
squeezed into the corners of the cavity, where it prevents filling and can also
cause other defects. The air can even become so compressed that it ignites
To allow for removal of the molded part from the mold, the mold features
must not overhang one another in the direction that the mold opens, unless
parts of the mold are designed to move from between such overhangs when
Sides of the part that appear parallel with the direction of draw (The axis of
the cored position (hole) or insert is parallel to the up and down movement
of the mold as it opens and closes) are typically angled slightly (with draft)
to ease release of the part from the mold. Insufficient draft can cause
deformation or damage. The draft required for mold release is primarily
dependent on the depth of the cavity: the deeper the cavity, the more draft
necessary. Shrinkage must also be taken into account when determining the
draft required.[13]:332 If the skin is too thin, then the molded part will tend to
shrink onto the cores that form while cooling and cling to those cores, or the
part may warp, twist, blister or crack when the cavity is pulled awayA mold
is usually designed so that the molded part reliably remains on the ejector
(B) side of the mold when it opens, and draws the runner and the sprue out
of the (A) side along with the parts. The part then falls freely when ejected
from the (B) side. Tunnel gates, also known as submarine or mold gates, are
located below the parting line or mold surface. An opening is machined into
the surface of the mold on the parting line. The molded part is cut (by the
mold) from the runner system on ejection from the mold. [13]:288 Ejector pins,
also known as knockout pins, are circular pins placed in either half of the
mold (usually the ejector half), which push the finished molded product, or
Easy fabrication.
Smoother operation.
APPLICATIONS
APPLICATIONS
SMALL INDUSTRIES
PLASTIC COMPANY
RUBER FACTORY
MERITS
DISADVANTAGES
COST ESTIMATION
1. MATERIAL COST:
Sl. No. Qty. Amount
PARTS
(Rs)
i. A.C MOTOR 1 800.00
ii. INJECTION MOULDING MACHINE 1 1500.00
iii. HANDLE 1 150.00
iv. STAND 1 2000.00
v. HEATER 1 400.00
vi HEATER CONTROLLER 1 900.00
vii. MOULD 1 500.00
viii GEAR BOX 1 1200.00
ix BELT AND PULLEY 1 500.00
TOTAL 7950.00
CONCLUSION
CONCLUSION
The project work has been completed successfully. The project hardware
functions satisfactorily as per the design. The project work was developed after
reduced the bottle necks and we did not face much difficulty in the final integration
process.
In general the entire development of the project work was educative and we
could gain a lot of experience by way of doing the project practically. We could
life practice of which we have heard through lectures and of which we have
BIBLIOGRAPHY
Bangalore.
PHOTOGRAPHY