GTTI PDTD 2019-2020

GEDEE TECHNICAL TRAINING

INSTITUTE
MECHATRONICS DEPARTMENT
PDTD
PROJECT PROPOSAL

WATER PURIFIER
FILTER HOUSING CAP
Submitted by:
P.M.SURESH KANNA
P.SENTHIL KUMAR
S.GOPAL KRISHNA
S.SHANMUGASUNDHARAM

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PREFACE

PREFACE

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This is the report of the project work done by us as the part

of fulfillment of the course.
POST DIPLOMA IN TOOL DESIGN
(2019 – 2021)
AT
GEDEE TECHNICAL TRAINING INSTITUTE
COIMBATORE-18

During the period of the project work, we studied the

overall design concepts and process of Injection moulds and Press
tools. We developed the design in CREO PARAMETRIC and
AutoCAD-2020.This has helped to great extend in simulation and
determining the ideal of mould design.

GROUP MEMBERS

SURESH KANNA.P.M PD1902

SENTHIL KUMAR.P PD1903
GOPAL KRISHNA.S PD1906
SHANMUGASUNDHARAM.S PD1911

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ACKNOWLEDGEMENT

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ACKNOWLEDGEMENT

We would like to express our gratitude to our Mr.Sivakumar.K, Manager

(Trg) and Mr. Senthil kumar, Superintendent (TRG) for the facilities provided to
us.

We would like to express our heartiest gratitude to our Training Officer

Mr.M.Sagith (project coordinator) who helped us to achieve our goal.

Our sincere thanks to all GTTI staff members and our friends for their
unrelenting support and co-operation.

We sincere thanks to our beloved parents for all the support provided to us,

We are deeply grateful to the almighty lord for leading us throughout the
project.

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CONTENTS

CONTENTS
 SYNOPSIS PAGES

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I. ABSTRACT - 10
II. OBJECTIVES - 11
III. INTRODUCTION TO INJECTION MOULD - 12

1. PLANNING AND SCHEDULING

1.1 INTRODUCTION TO PLANNING - 17
1.1.2 PLANNING PROCESS - 17
1.1.3 MAIN CHARACTERISTICS - 18
1.1.4 TYPES OF PLANNING - 18
1.1.5 FLOW DIAGRAM - 19
1.1.6 DESIGN AND PROCESS PLANNING MASSAGE - 19
1.1.7 PROCESSING OF DESIGN TOOL MANUFACTURER - 20
1.2 DESIGN PROCEDURE - 21
1.3 PROCESS PLAN CHART - 22

2. COMPONENT REVIEW
2.1 PROJECT INTRODUCTION - 24
2.2 MATERIAL DATA - 25
2.2.1 SUGGESTED SIZES FOR PRODUCT DESIGN - 25
2.2.2 MECHANICAL PROPERTIES - 25
2.2.3 THERMAL PROPERTIES - 25
2.2.4 PROCESSING PARAMETERS - 26
2.3 COMPONENT ANALYSIS - 27
2.3.1 INJECTION PRESSURE - 28
2.3.2 FILL TIME - 28
2.3.3 SINK MARK - 29
2.3.4 AIR TRAPS AND WELD LINE - 30
2.4 CALCULATION - 31
2.4.1 WEIGHT - 32
2.4.2 SHOT WEIGHT - 32
2.4.3 CAVITY PRESSURE - 32
2.4.4 PROJECTED AREA - 32
2.4.5 CLAMPING FORCE - 32
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2.4.6 PARTING SUFACE AREA - 32

2.4.7 INSERT SIZE - 33
2.4.8 INSERT WALL THICKNESS - 33
2.4.9 CAVITY WALL THICKNESS - 33
2.4.10 CORE BACK PLATE THICKNESS - 33
2.4.11 COOLING TIME - 34
2.4.12 DIAMETER OF COOLING - 34
2.4.13 WATER QUANTITY - 34
2.4.14 LENGTH OF COOLING - 35
2.4.15EJECTION FORCE - 36
2.4.16 SPLIT MOVEMENT - 36
2.4.17 FINGER CAM WORKING LENGTH - 36
2.4.18 LIFTER LENGTH - 36
2.5 MACHINE SELECTION - 37
2.6 DESIGN DATA - 38
2.7 TOOLING REQUIREMENT - 39
2.7.1 GENERAL CONSIDERATIONS - 39
2.7.2 PARTING SURFACE - 39
2.7.3 SHOT CAPACITY - 39
2.7.4 FEED SYSTEM - 40
2.7.5 HOT SPRUE - 40
2.7.6 COOLING SYSTEM - 40
2.7.7 EJECTION SYSTEM - 41
2.7.8 SPLIT - 41
2.7.9 LIFTERS - 41
2.7.10 MOULD ALIGNMENT - 42
2.7.11 TYPES OF FITS USED IN MOULD - 42
2.7.12 MANUFACTURING PROCESS USED - 42

3. SELECTION OF MATERIAL
3.1 INTRODUCTION TO MATERIAL - 43
3.1.1 PLAIN CARBON STEEL - 43

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3.1.2 ALLOY STEEL - 43

3.1.3 TOOL STEEL - 43
3.1.4 MAIN FACTORS FOR STEEL CHARACTERISTICS - 43
3.2 LIST OF MATERIAL - 44
3.3 HEAT TREATMENT & SURFACE TREATMENT - 44
3.3.1 INTRODUCTION - 44
3.3.2 ANNEALING - 44
3.3.3 NORMALIZING - 45
3.3.4 SURFACE HARDENING - 45
3.3.5 HARDENING - 45
3.3.6 SURFACE FINISH - 45
3.3.6.1 DRAW STONE - 45
3.3.6.2 SAND BLAST - 45
3.3.6.3 TEXTURED FINISH - 46
3.3.6.4 MIRROR FINISH - 46
3.4 ESTIMATION AND COSTING
3.5.1 ESTIMATION - 47
3.5.2 COSTING - 47

 CONCLUSION - 48

 BIBLIOGRAPHY

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SYNOPSIS

ABSTRACT

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Tool engineering is one of the important aspects of production

engineering which enable industries to produce standard plastic and metal
items economically. Stamped and moulded components have found
unlimited market in industries like automobile, electrical and electronics
etc. Design of engineering products is made with the intention of ultimately
manufacturing economically.

Plastics are now well established material along with metal and
ceramics. The weight, simplified assembly, durability, easy manufacturing
and such as steels, aluminum, woods, etc.

Even though design is a specialized phase in engineering field, in

tool & die engineering it is divided into two wings as product design and
tool & dies design. A designer must incorporate ideas related with lines like
manufacturing and production shop, quality control etc. with the evolution
of new technologies like CAD, CAM. And mould analysis the designers
can implement their ideas apart from conventional procedure.

OBJECTIVES

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 To involve in the activity of the project undertaken and to learn various

aspects of Tool Design.

 To get proficient in Mould Design.

 To get enough knowledge in Product Design as well as Mould

Design.

 To get practical exposure and understand the do’s and don’ts to be

followed in design.

 To promote our design for practicability and simplicity

 To check for the manufacturing feasibility and understand the benefits

of standardization.

 To incorporate notification and justify the design principles as clearly

as possible.

 To analyze our drawings and make the required changes after viewing
from the shop floor perspective.

 To get the design approved.

INTRODUCTION TO INJECTION MOULD

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 Injection molding process consists of melting a thermoplastic material to a

predetermined shot size then injecting into a cavity space of the mould. Where it is
formed. Once formed, the part is ejected from the mold.

 Automobile parts & Industrial parts, home applications, etc, by injecting

molten thermoplastic material in to a closed mould which is relatively cool.

 This training course covers plastic material injection process, mold design
technology, thermoplastic materials, and the different injection molding process.

ADVANTAGES OF INJECTION MOULDING PROCESS:

 Parts can be produced at high production rates.

 Large volume production is possible.

 Relatively low labour cost per unit is obtainable.

 Process is highly susceptible to automation.

 Parts require little or no finishing.

 Many different surfaces, colours, and finishes are available.

 Good decoration is possible.

INJECTION MOLDING MACHINE:

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FIG: 01 – Injection Moulding Machine

 The injection molding machine's injection unit includes the hopper, barrel,
screw, non-return assembly, nozzle and clamping unit includes the clamping system,
machine ejectors, moveable platen, stationary platen, and tie bar.

 The fig.01 here represents a microprocessor controlled injection molding

machine. The machine controls include the control panel and the computer.

Limitations of Injection Moulding:

 Intense industry competition often results in low profit margins.

 Mould costs are high.

 Moulding machinery and auxiliary equipment costs are high.

 Lack of knowledge about the fundamentals of the process causes problems.

 Lack of knowledge about the long term properties of the materials may result
in long-term failures.

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HISTORY OF INJECTION MOULDING M/C

 In 1946, American inventor James Watson Hendry built the first screw injection
molding machine, which allowed much more precise control over the speed of injection
and the quality of articles produced.

 This machine also allowed the material to be mixed before injection, so that
additives, recycled plastic and filler are added to virgin material is mixed before being
injected. Today screw injection machines account for the vast majority of all injection
machines.

 In the 1970s, Hendry went on to develop the first gas-assisted injection molding
process, which permitted the production of complex, hollow articles that cooled
quickly. This greatly improved design flexibility as well as the strength and finish of
manufactured parts while reducing production time, cost, weight and waste.

 The plastic injection molding industry has evolved over the years from producing
combs and buttons to producing a vast array of products for many industries including
automotive, medical, aerospace, consumer products, toys, plumbing, packaging, and
construction.

OLD INJ. M/C NEW INJ. M/C

FIG - 02 FIG – 03

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INJECTION MOULD
Type of Injection Moulding Machine:
 Hand injection machine.
 Horizontal injection moulding machine.
 Vertical injection moulding machine.
 Universal injection moulding machine.
 Multi color injection moulding machine.
 Special purpose injection moulding machine.

The Injection Process:

 Plasticizes the material by reciprocating Screw.
 Injects the molten material to a closed mould
-Via a channel system of gates and runners..
 Hold the pressure for some time.
 Cools the Mould and Part.
 Refills the material for the next cycle.
 Mould open.
 Ejects the moulded Product.
 Closes the Mould for further cycle.

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PLANNING
AND
SCHEDULING

1.0 PLANNING AND SCHEDULING

1.1 INTRODUCTION:

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 Planning also called forethought is the process of thinking about and

organizing the activities required to achieve a desired goal.

 Planning involves the creation and maintenance of a plan. As such, planning is

a fundamental property of intelligent behavior. This thought process is essential to the
creation and refinement of a plan, or integration of it with other plans; that is, it
combines of developments with the preparation of scenarios of how to react to them.

 An important, albeit often ignored aspect of planning, is the relationship it

holds with forecasting. Forecasting can be described as predicting what the future will
look like, whereas planning predicts what the future should look like .The counterpart
to planning is spontaneous order.

1.1.2 PLANNING PROCESS:

Example of planning process framework,

Patrick Montana and Bruce Charnov outline a three-step result-oriented process
for planning,
 Choosing a destination
 Evaluating alternative routes, and
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 Deciding the specific course of your plan.

In organizations, planning is a management process, concerned with defining
goals for company's future direction and determining on the missions and resources to
achieve those targets. To meet the goals, managers may develop plans such as a
business plan or a marketing plan. Planning always has a purpose. The purpose may
be achievement of certain goals or targets.

1.1.3 MAIN CHARACTER IS TICS OF PLANNING IN

ORGANIZATIONS ARE:
Planning increases the efficiency of an organization. It reduces the risks
involved in modern business activities. It facilitates paring the available time and
resources. The concept of planning is to identify what the organization wants to do by
using the four questions which are,
"Where are we today in terms of our business or strategy planning?
Where are we going?
Where do we want to go?
How are we going to get there?
1.1.4 TYPES OF PLANNING:
Automated planning and scheduling Financial planning
Architectural planning Succession planning
Business plan Strategic planning
Comprehensive planning Marketing plan
Contingency planning Network resource planning
Economic planning Operational planning
Enterprise architecture planning Regional planning
Environmental planning Site planning
Event planning and production Spatial planning

1.1.5 FLOW DIAGRAM IN MOULD-BASE DESIGN

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FIG - 04

1.1.6 DESIGN AND PROCESS PLANNING MASSAGE EXCHANGE

FOR INTERGRATION

FIG - 05

1.1.7 PROCESSING OF DESIGN TOOL MANUFACTURER

SL.NO FUNCTION DEPARTMENT
Job order taken by the marketing department.
Product
1. And product development decides the
development
component with the customers.

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Component finalized and approved from Product

2.
customer with seal. development
Job order and number released to design Product
3.
department. development
Design head distributes the component and gets
4. Design
the concept drawing from Designers.
Designers makes concept and assembly
5. drawing and gets its approval from Design
Sr. Designers.
Detailed drawing are made, checked and
6. Design
released to planning dept.
Planning department will create the schedule for
7. the tool decides outsourcing vendors with bill of Planning
material.
Planning compiles with the design and sends
8. the design to the pre tooling department, for the Planning
material requisition form.
Purchase department, makes order and delivers
9. Purchase
time and quality.
Manufacturing Dept. head plane and distribute
10. Manufacturing
the work to the supervision.
Supervisions get the work done by the machine
11. Manufacturing
operator and supply the part to the assembly.
QAD assures that the tolerances are maintained
12. QAD
and confirm it to assembly.
Assembly department makes last minute
13. Assembly
correction.
Trails are taken by the assembly and production Assembly Dept.
14. department. To make the rectification of the and Production
tools and then sends the tool for dispatch. Dept.

1.2 DESIGN PROCEDURE (ISO FORMAT)

IWO Receivable (Internal Work Order)

↓
Input Verification
↓
CFT
↓
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Design Time Plan

↓
Concept Drawing
↓
Drawing Review
↓
Initial Bill of Material (Core & Cavity)
↓
Mould Base Release
↓
Mould Base Soft Copy to Logistics
↓
3D Splitting
↓
Update assembly Drawing using in 3D split
↓
Insert Detailing
↓-
Design Verification
↓
Design Validation
↓
2D Softcopy to Tool Room
↓
3D Models to CAM
↓
Arrange the Files
↓
2D Hard copy Release

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Component

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2.1 PROJECT INTRODUCTION

CUSTOMER

: GTTI

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COMPONENT : WATER PURIFIER FILTER HOUSING CAP

MATERIAL : POLYPROPYLENE

VOLUME : 202174 mm3

2.2 MATERIAL DATA

Material POLYPROPYLENE
Color White
Shrinkage 1-2%
Density 0.92 g/cm3
Structure Crystalline
Resistance to moisture, electricity,
Advantages
fatigue

2.2.1 SUGGESTED SIZES FOR PRODUCT DESIGN (PP):

Wall thickness 0.63mm – 3.81mm

2.2.2 MECHANICAL PROPERTIES:

Injection pressure 700 - 1400 kg/cm²
Impact strength 7.07 – 54.40 kg/cm
Tensile strength 3.37- 4.39(kg/cm2) x102
Compressive strength 3.52-7.75(kg/cm2) x102
Rockwell hardness R65 - 110

2.2.3 THERMAL PROPERTIES:

Specific heat 0.3 - 0.4g/°C
Coefficient of thermal expansion 8.0 – 10cm/(cm°C)
Thermal conductivity 0.17 – 0.23W/mK
Density 1.060 g/cc
Deflection temperature 95 kg/cm2

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2.2.4 PROCESSING PARAMETERS:

Material (PP) VALUE/SPECIFIED

Mould temperature 40 -80°C
Melt. temperature 220 - 280°C
Max. temperature 280°C
Drying temperature 82 - 88°C
Nozzle Temperature 220 - 280°C
Barrel Temperature 170- 270°C
Ling speed Medium to high
Purge material HDPE, PMMA, PS.
Physical Tough
Melting point 110°C
HDT 99-107
Service temperature 86°C
L/d ratio 24:1
Compression ratio 2.3.0:1
Temperature 190-250°C

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Component
ANALYSIS

2.3 COMPONENT ANALYSIS

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2.3.1 INJECTION PRESSURE ANALYSIS:

The injection pressure analysis result shows the regions where the injection
pressure drops. It also gives information about the drop in pressure and required
pressure to be increased .To fill the cavity with in the cycle time.

2.3.2 FILL TIME ANALYSIS:

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This result shows the flow path of plastic though the part. Each color shown.
Represents the parts of the mould which were being filled at the same time.
The primary use of fill time result is to determine if all flow paths fill at
the Same time (balanced flow paths).The fill time result can also be used to
understand how weld lines and air taps form.

2.3.3 SINK MARK:

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The sink mark result displays the probability of a region in the component.
Causes: Excessive shrinkage, incomplete filling, air trapped and piece ejected too hot.
Remedy: It can reduce by increase melt temperature, increase cooling time and air vent.

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2.3.4 AIR TRAPS and WELD LINE:

The air traps and weld line result displays region in the component.

Defects Causes Remedies

Proper gate position and
Air Traps Improper air vent, gate location
increase vents
Multiple gates, due to flow Improve venting, Increase
Weld line
around cores, and jetting. injection pressure

AIR TRAPS WELD LINE

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Calculation

2.4 PROJECT CALCULATION

MATERIAL = POLYPROPYLENE
DENSITY = 0.92 g/cc
VOLUME = 229.35 cm3 = 229350 mm3
WEIGHT = Volume (cm3) x Density (g/cc) x No. of cavity
= 229.35x 0.92 x 1
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= 211.00 gm

SHOT WEIGHT = Component Weight (gm) x 1.2 (Feed System (gm))

= 211 x 1.2
= 253.20 gm
CAVITY PRESSURE = 2 x Injection Pressure (kg/cm2)
3
= 2 x 1200
3
= 800 kg/cm2

PROJECTED AREA = Area that includes the maximum Perimeter of the

Component as per the Pull Direction
= 604.26 cm2(from Creo)

CLAMPING FORCE = Projected Area (cm2) x Cavity Pressure (kg/cm2)

= 604.26 x 800
= 483408 kg
= 483.408 ton (for single Cavity)

PARTING SURFACE = Clamping Force (ton)

AREA 0.4
= 483.408
0.4
= 1208.52 cm2
= 120852 mm2
TOTAL AREA = Parting Surface Area (mm2) + Projected Area (mm2)
= 120852 + 60426
= 181278 mm2

INSERT SIZE: r2 = 181278

π
r = 240.213 mm (for single Cavity)
INSERT WALL THICKNESS:
T = 6W Where,
B W = Moment of resistance
L = Length of component (cm)
B = Width of component (cm)
σ = Tensile strength of steel (1100 N/mm2)

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W = L x Cavity Pressure
8 x Tensile Strength (σ)
= 11.268 x 800
8 x 1100
= 0.724 cm

T = 6 x 0.724
6.425
T = 8mm

CORE BACK PLATE THICKNESS:

b = Clamping Force (W) x 6 x M
8xLxS
Where,
W = Clamping force (kgf)
M = Distance between the heel block (cm)
L = Length of the core back plate (cm)
S = Permissible working stress (840Kg/cm2)
= 483408 x 6 x 11.6
8 x 4.6 x 840
b = 35 mm

COOLING TIME:
T = PA x t2
k (TC - Tm) 8

T = Cooling time
P = Density of plastic
TC = Melt temperature
Tm = Mould temperature
A = Heat content of plastic material (cal/g)
(Specific Heat x Temperature)

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t = Wall thickness
k = Thermal conductivity of plastic (6 x 10-4 Cal/Sec)
= 1.06 x 54 x (3)2
6 x 10-4 (225-90) x 8
T = 14.72 sec
DIAMETER OF COOLING CHANNEL:
Where,
Q = AxV
Q = Flow Rate (43005.96g/hr)
A = Q V = Velocity of water (2.5 m/s)
V A = Area of cross section (mm2)

πd2 = Q
4 V

D2 = 4Q
πv
D = 43005.96 x 2.5 x 4
3600 x π
D = 10.0mm

WATER QUANTITY REQUIRED FOR COOLING:

Minimum Cycle Time
TC = m x 3600
P x 1000
= 704.82 x 3600
43 x 1000
TC = 59 sec

Amount of Material = M x 3600 Where,

To be molded in an hour TC M = Shot weight (gm)
= 704.82 x 3600 TC = Cycle Time (sec)
59
= 43005.96 g/hr.
Heat content to be removed
From the mould = 43005.96 x Specific Heat x (Melt Temp – Mold Temp)
= 43005.96 x 0.4 (225-90)

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= 2322321.84 cal / hr
In this only 50% of heat energy is removed by circulating water, so
= 2322321.84
2
= 1161160.92 cal/hr
Quantity for Water Required/ Hr (Q)
= 1161160.92
2
= 580580.46 gms/hr
Q = 580.58 lit/hr
Velocity of Water Passed= 1.5 TO 2 Meter / sec
= 200 mm/sec

LENGTH OF COOLING CHANNEL:

L = H1 x Z
k (TMelt - TMold) 2A
Where,
H1 = Specific Heat x Component Weight x (TMelt-TMould)
L = Total length of the cooling
H1 = Heat transferred per sec (H/3600 cal/sec)
Z = Distance of the cooling channel from molding
K = Thermal conductivity of mold material
Tmelt = Temp of cylinder or material (cal/sec°c)
Tmold = Temp of mold
A = Area of cross section of cooling channel (cm²)
= 3322321.84 x 1
3600 x 0.0868 x (225-90) 2x5
L = 446mm.

EJECTION FORCE:
P = St.E.A.CF/d (d/2T - d/4T x μ)
Where,
P = Ejection force required
E = Modulus of elasticity (GN/m2)
A = Total area contact between molding and mould faces
in time of draw (m)
CF = Coefficient of friction between plastic and steel
d = Diameter of circle of circumference equal to length
or perimeter of mould surrounding male core (m)
T = Thickness (m)
μ = Poisson ratio of plastic (0.4 - 0.5)

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S = Thermal construction of plastic across diameter (d)
S = coefficient of Thermal expansion x temperature between
softening point and Ejection temperature x d (m)
= 8 x 10‾5 x 60 x 610
S = 2.928
E = 2.3 X 103 N/mm²
A = 79300 mm²
C.F = 0.5
P = 2.928 x 2.3x 103 x 79300 x 0.5
610 (610/2 x 3) – (610/4 x 3) x 0.4
= 267018960
610 (915-457.5) x 0.4
= 2392 N
P = 23.92 Kg

SPLIT MOVEMENT:
M = (L Sin θ) - (C / Cosθ)
Where:
M = Split Movement
θ = Angle of Finger Cam
L = Working Length of Finger Cam
M = [86 x Sin15º - 0.5 X Cos15º]
M = 60.0 mm

FINGER CAM WORKING LENGTH:

L = (M / Sin θ) - (2C / Sin2 θ)
= (21/ Sin15º) + (2 x 0.5/Sin15º)
L = 210mm

2.5 SELECTED MACHINE DATA

Name of the injection moulding m/c DELTA 200 F02
Shot capacity 468 gm
Screw diameter 50 mm
Min. / Max. mould thickness 300/710 mm

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Max. Opening daylight 1210 mm

Locating ring 100 mm
Rate of injection 246 cc/sec.
Max. Ejector stroke 130 mm
Ejector system Hydraulic
M/c. Ejector coupling thread size M16
Platen size (h x v) 805 x 842 mm
Platen thread size T slots
Distance between tie bars 560 x 560 mm
Core pulling No

2.6 DESIGN DATA

Mould Type Two plate injection mould
No. of cavity 01
Type of gate Sprue Gate
Type of ejection Sleeve ejection
Type of feed system Hot sprue with cold runner
Split Core/Cavity Side Cavity

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Hot Sprue HASCO Standard

Mould base DME Standard
Heat treatment Yes
Mould Polishing Yes
Insulation sheet Yes
Standard items Misumi Standard
Mould size 496 x446 mm
Shut height 578 mm
Ejection stroke 80 mm
Temperature control Water Cooling

2.7 TOOLING REQUIREMENT

2.7.1 GENERAL COSIDERATIONS:
According to the shape of the component, BALANCE MOLD the rate of
production and customer requirement, a two cavity injection mould along with
lifters are decided.
A standard mould base is preferred (DME) as it is advantageous for the mould
maker to purchase a complete set of basic mould parts at reasonable cost, rather than
to be actively engaged on this relatively unimportant aspect of mould manufacture.

2.7.2 PARTING SURFACE:

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The parting surfaces of a mould are those surfaces adjacent to the cavity wall
where core and cavity surfaces touch when the mould is closed for injection. If there
are openings inside the part, the core and cavity surface should touch at opening area.

The shape of the parting surfaces depends fully on the shape of the component.
The main consideration is “can the part be pulled out of the cavity or core”. A parting
surface must be so selected that the mouldinglkkk can be ejected easily from the
mould without any damage. As per our component profile, we make Profiled Parting
Surface.

A profiled parting surface is particularly decided considering the shape of

component. Thus the parting surface is profiled as it lies on a plane parting line.

2.7.3 SHOT CAPACITY:

The maximum weight of material that can be delivered from injection moulding
machine to the mold is called “Shot Capacity”.
Generally the shot capacity of machine is given in the term of polystyrene, because
its latent heat almost zero. The screw type machine is normally rated in volume of the
injection cylinder.
Shot capacity of the sp 130m/c = 180gm

2.7.4 FEED SYSTEM

The flow way in the injection mould to connect the nozzle and the
impression is termed as feed system. It consists of sprue, runner and gate.
As per component “Modified trapezoid runner and Fan gate” is finalized for the
moulding considering the following reason;
 Easy flow of material is possible with this runner.
 The filling of the impression can be controlled relatively independently of the gate
seal time.
 The gate dimensions can be easily modified.
h1 = N.T Where,
 Land L=0.5 - 2MM N = Constant
h2 = W x H1 T = Wall Thick (mm)
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 Thin wider parts

As per the component, the flow way is very long for filling the cavity. For that
we use hot sprue to avoid pressure drop and reduce the defects in the parts.

2.7.5 HOT SPRUE:

• The term “hot-runner moulds” refers to any injection moulding process, in which,
it is not required to remove the sprue and runners between each successive cycle.
• The purpose of the hot runner system is to distribute the hot plastic coming out
from the machine nozzle to all gates of the mould at the same time and pressure.
• Better finish on the component and thin wall section can be easily filled.
• Improves part consistency and quality and reduce cycle time.

2.7.6 COOLING SYSTEM;

Mould shapes the hot plastic material into shape of impression. The heat is
transferred from material to the mould and moulded material solidifies slowly. For quick
solidifying and to reduce the cycle time, cooling medium like water is passed to mould.
Approximately 70% of heat is transferred to core, 20% to cavity and
remaining 10% is carried by part while ejection and cooled in atmosphere. Where,
d = Diameter of waterline = 6mm to 16mm d D

D = Depth of waterline = d to 2d P

P = Pitch = 3d to 5d

2.7.7 EJECTION SYSTEM:

By law the thermo plastic materials solidifies, it also tries to occupy
minimum space. All thermoplastic material contracts as they solidify, which means
that the part will shrink towards the core.
Its makes difficult to eject the part out of core. We should provide some
means of ejection from the core. For that different types of ejection mechanism are
used to remove the part from the core. As per the component, so many undercuts are
there. For that we used split cavities and lifters.

2.7.8 SPLIT:

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• A moulding which has a recess or projection which prevents the normal in line
ejection of the component is termed as an undercut moulding.
• Cavities made of different moving blocks are known as splits.
• The splits are positioned in guides on a flat mould plate are actuated by
mechanical or hydraulic system and those are held together by locking heels which
project on the other mould half.
• As this component has an External undercut in the vertical wall of core, it is not
possible to mould using a conventional core (in line to the axis). Hence a side cavity
is provided. The actuation of side core is done by slider and wedge.

2.7.9 LIFTERS:
• An Internal undercut is the internal protrusion or recess formed in the
molding by using matching core or cavity. It can be successfully moulded in the
conventional mould by incorporating the undercut form on a form pin or lifter.
• The actuation of lifter is done by the action of ejection system. Stopper pins
are provided to control the forward movement of the ejector assembly.
• walls. The inclination angle from 8° to15° will typically yield the best results.
• As this component have an open side parallel to the parting surface
which is not possible to mould using a conventional core(in line to the
axis)hence lifters are provided. It can be used for components which incorporate
internal undercut on one or more

2.7.10 MOULD ALIGNMENT:

To achieve the proper alignment of the moulding process, four guide
pillars and bushes are provided (DME-standards). The ejector assembly is further
aligned by the pillar and bushes itself.

2.7.11 TYPES OF FITS USED IN MOULD:

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TYPES
OF DESCRIPTION
FITS
H7 e7 Pillar & Top plate (clearance Fit)
H7 k6 Pillar & Cavity plate (Tight Fit)
H7 p6 Guide Bush & Core plate (Tight Fit)
H7 g6 Guide Pillar & Bush (Sliding Fit)
Ejector pin & core insert (Sliding
H7 g6
Fit)
Core & Cavity with Plates (Tight
H7 m6
Fit)
H7 g6 Locating ring & Top plate

2.7.12 MANUFACTURING PROCESS USED:

GRADE
MANUFACTURING PROCESS USE
OF HOLES
H5 Fine boring Fine grinding Honing (ID)
H6 Fine boring Honing Hand reaming
H7 Internal grinding Broaching Reaming
H8 Boring Machine reaming
H9 Boring Reaming
Not for diameter Used for
H10 Drill holes
fits milled widths
Coarse drilling
H11 Not used in fits Punching
Drawn recesses

SELECTION OF MATERIAL
3.1 INTRODUCTION TO MATERIAL:
3.1.1 Plain carbon steel:
These steels contain no alloying elements. These steels will harden. But
will exhibit no improved alloying characteristics.
3.1.2 Alloy Steel:
These steels attain hardness and display some improved performance
characteristics, because of the additional alloys contained in their formula.

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3.1.3 Tool Steel:

These steels attain hardness and display improved performance
characteristics such as wear, toughness and strength. The AISI have assigned them a
different title designation that no longer contains four or more numbers. This sets
them apart as a Tool Steel.
3.1.4 MAIN FACTORS FOR STEEL CHARACTERISTICS:
 Carbon is the main Factor for hardening agent in steel.
 Manganese Contributes to strength and also hardness.
 Phosphorus increase a steel’s machinability and resistance to corrosion.
 Molybdenum gives corrosion resistance and makes it less brittle at a high
hardness.
 Chromium provides corrosion resistance and increase hardenability.
 Vanadium gives steel a fine-grained structure and increases its toughness.

Property Grade Characteristics

Water-hardening W
O Oil-hardening
Air-hardening; medium
A
Cold-working alloy
High carbon; high
D
chromium
Shock resisting S  
T Tungsten base
High speed
M Molybdenum base
H1–H19: chromium base
H20–H39: tungsten base
Hot-working H
H40–H59: molybdenum
base
Plastic mold P  
L Low alloy
Special purpose
F Carbon tungsten

3.2 LIST OF MATERIAL STANDARDS FOR MOLDS

Hardness
Mould elements Material standards
(HRC)
Cores, cavities, P20, H13,
48-52
inserts, pins, Orvar supreme
Mould Plates
1020,1040,C45 40-42
Holders
Guide Pillar & P5, P6, En32, 59-61
Bush En353, En36 (Case

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Harden)
Guide Rail A2, D2, O1 52-55
Slider A2, D2, O1 49-51
Angle Lifter H13,P20, M4,D2 45-55
Wear plates A2, D2, O1 52-55
A2,D2,
Wedge Blocks 52-55
M4
58-62
Sleeve Ejector H13, D2, O1
(nitrided)
59-61
En32, En 353,
Rest Button (Case
En34/36
Harden)
Locator ring 1020 Nil
Finger cam M4 58-62

3.3 HEAT TREATMENT & SURFACE TREATMENT:

3.3.1 Introduction:
The purpose of heat treating a finished tool is to obtain suitable mechanical
properties. To improve properties as hardness, toughness and strength. But there are
some problems associated with heat treatment.
Problems like distortion and dimension changes have to be solved. The safest way
of avoiding distortion is to use pre hardened steels such as P20, H13, Orvar supreme,
etc. Steel for which no additional heat treatment is required.
3.3.2 Annealing:
In this process, steel is heated to a suitable temperature depending upon its
carbon content. And is held at that temperature for sufficient time and then slowly
cooled to room temperature. For soften the plates, improve machinability and ductility.

3.3.3 Normalizing:
It is done to produce a fine grain for uniformity of structure and for improved
mechanical properties. In this process, the steel is heated to the required temperature
depending upon its carbon content and held at that temperature and then cooled freely
in air.
3.3.4 Surface hardening:
It is processes harden only the exterior of the steel part, creating a hard, wear
resistant skin (the "case") but preserving a tough and ductile interior. It gives the

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surface good wear characteristics but leaves the core tough. E.g. case hardening and
nitriding.
3.3.5 Hardening:
It is the process used to increase the hardness of a metal. The hardness of a
metal is directly proportional to the uniaxial “yield stress” at the location of the
imposed strain. A harder metal will have a higher resistance to plastic deformation
than a less hard metal.
3.3.6 Surface Finish:
Proper finishing of the mould is important for the release and appearance of the
part. The finish of the moulding part largely depends on the finish of the core and
cavity. This also speeds up the moulding cycle. It is achieved by the “Polishing
process”. There are four types of surface finish are most used,
 Draw stone
 Sand blast or Matte finish
 Textured finish and
 Mirror finish
3.3.6.1 Draw stone:

The finish should be vertical, from bottom of the cavity or core to the parting
surface, to aid in the ease of ejection is called draw stone. This is the most basic of all
finishes and it is strictly for release.
3.3.6.2 Sand-blast or glass-bead:
This produces a matte (not shiny) finish, creating non-slippery, non-reflective
surfaces.

3.3.6.3 Textured finish:

This is done to create a specific appearance, such as wood grain, leather or pebbly
textures.
3.3.6.4 Mirror finish:
It is called diamond finish. High brilliance and reflect ability for optical and
automobile lamp reflectors

STANDARD SPECIFICATION OF FINISH (PLASTICS)

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STANDARD SPECIFICATION OF FINISH (STEEL)

Ra: Roughness average, Arithmetical means of the sums of all profile values.
Ry: Total height of the roughness profile, highest peak and depth of lowest valley length.
Rz: Maximum height of roughness profile, mean value of the from five sampling length

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3.5 ESTIMATION AND COSTING

3.5.1 ESTIMATION:
It is the calculation of the cost of a product before it is actually manufactured.

3.5.2 COSTING:
It is the determination of the actual cost of the product after it has been manufactured.

ESTIMATION TABLE
SL.NO. DESCRIPTION COST(Rs.)

01 Raw Material cost 3,76,618

02 Manufacturing cost 1,27,681

03 Standard item cost RS/- 1,83,200

04 Trail cost RS/- 8000

05 polishing cost/- 20,000

06 Sub Total cost (A) 623499

07 Design cost 15% of raw mat. Cost (B) 56,493

08 profit15% of sub total Cost (C) 92,235

Tool cost (A+B+C)Rs/- 8,73,516

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CONCLUSION:
We feel great pleasure and satisfaction in involving in our injection
Mould project. The most important accept of these project was that, they Were
designed to industrial standards. This project has been on opportunity to enhance
our knowledge and designing capabilities.

We ultimately attained our goal of designing injection mould with the

required standard and talking into account of various manufacturing factors. This
project not only enhanced our designing skills but also updated our awareness in
different fields.

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PHOTOGRAPHY

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CAVITY

CORE

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BIBLIOGRAPHY
BOOKS AND OTHERS:
Injection mould design - R.G.W PYE (4th Edition)

Standard Mould base - DME Catalogue

Standard Elements - “MISUMI, DME” Catalogue

Machine Selection / specification - G – Plast Machines Catalogue

Hot Sprue Details - “HASCO” Catalogue

WEBSITES:
www.wikipedia.com
www.alibaba.com
www.designersguide.com
www.engineersedge.com
www.3dsystems.com
www.efunda.com

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