An Industrial Mini Project Report

On

PLASTIC INJECTION MOULDING DIES

Submitted in partial fulfilment of the requirements

For the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By

A SAI DHANCHANDER (15R01A0364)

Under the guidance of

Mr. G. VENKAT RAMANA ​M.E​,
Assistant Professor Dept. of Mechanical Engineering

CMR INSTITUTE OF TECHNOLOGY

(Approved by AICTE and Affiliated to JNTU, Hyderabad)
Kandlakoya, Medchal Road, RR Dist.​,​ Hyderabad.

2015-2019
 CMR INSTITUTE OF TECHNOLOGY
(Approved by AICTE and Affiliated to JNTU, Hyderabad)
Kandlakoya, Medchal Road, RR Dist.​,​ Hyderabad.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the project report entitled “​PLASTIC INJECTION MOULDING DIES​” is
the bonafide work carried out and submitted by ​A SAI DHANCHANDER ​bearing
H.T.NO:15R01A0364 ​to the Department of Mechanical Engineering, CMR Institute of
Technology Hyderabad, In partial fulfilment for the award of ​Bachelor of Technology
(MECHANICAL ENGINEERING) ​during the academic year 2018-2019.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr. G. Venkat Ramana ​M.E, Dr. B. Sridhar Babu ​ ​ ​M.Tech, Ph.D.

Assistant Professor Professor & Head of
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering, CMRIT,
CMRIT,

Date: Examiners: 1.

Place: 2.
 ​ACKNOWLEDGMENT

The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mention of people who made it possible, whose constant guidance and
encouragement crowned our efforts with success. It is a pleasant aspect that I have now the
opportunity to express my guidance for all of them.

I thank Mr. ​Ch. Gopal Reddy​, Secretary, CMR Institute of Technology, for his help to undergo
project work as part of university curriculum.

I am extremely grateful to ​Dr. M. Janga Reddy​,Director, M.Tech. Ph.D., M.I.S.T.E, CMR

Institute of Technology for his advice to pursue the Post-Graduation.

I am extremely grateful to principal ​Dr. B. Satyanarayana​, B. Tech., M. Tech., Ph.D, CMR

Institute of Technology

My sincere thanks to ​Dr. B. Sridhar Babu, M. Tech, Ph.D. Professor & Head in Mechanical
Department for encouraging me to complete the project within the stipulated period.

My sincere thanks to Dr. T. Vishnu Vardhan, ​M.Tech, Ph.D, professor and Dean(IIIC) of
Mechanical Department for providing consistent guidance and support throughout the project.

We would like express our sincere thank to ​Mr. G. Venkat Ramana, ​M.E, Asst.Professor of
Mechanical Department for giving us chance to the project.

We are deeply thankful to Mr​S.VenuGopal Rao​,M.Tech(Ph.D),Associative Professor,

Department of Mechanical Engineering for providing us an opportunity with their consistent
guidance and support throughout the project period.

We would like to thank our internal project mates and department professors for their full-fledged
guidance and giving me courage to carry out the project.
 ABSTRACT

Injection Moulding (IM) is considered to be one of the most prominent processes for mass
production of plastic products. One of the biggest challenges, facing injection molders today, is to
determine the proper settings for the IM process variables. Selecting the proper settings for an IM
process is crucial because the behavior of the polymeric material during shaping is highly
influenced by the process variables. Consequently, the process variables govern the quality of the
parts produced. The difficulty of optimizing an IM process is that the performance measures
usually show conflicting behavior.

Injection Moulding (IM) is considered to be one of the most prominent processes for mass
production of plastic products. One of the biggest challenges, facing injection molders today, is to
determine the proper settings for the IM process variables. Selecting the proper settings for an IM
process is crucial because the behavior of the polymeric material during shaping is highly
influenced by the process variables. Consequently, the process variables govern the quality of the
parts produced. The difficulty of optimizing an IM process is that the performance measures
usually show conflicting behavior.

In this project we focus on gaining an improved understanding of modern methods of Injection

moulding dies by using CNC, lathes and other machines. And acquired primary industry skills that
provides opportunity in preparing the material to specified dimensions.

For each component, detailed engineering drawing was created that helped to shape and
construct all the operations and procedures that must be undertaken and controlled to attain
accuracy. The main relevant factors that has been examined are CNC Programming, consumer’s
selection. The extent to which these factors can influence the molding process.
 INDEX

​CONTENT PAGE NO
CHAPTER 1. INTRODUCTION
1.1 Purpose 1

1.2 Scope

1.3 Points of Contact 1

1.4 Management​ Summary 1

​1.4.1 Organizations Involved 1

​1.4.2 Equipment

1.5 Performance Objectives (Efficiency)

1.6 Assumptions and Constraints 12

1.​7 Methodology (Basic Principle Involved) 14

1.8 ​R​ecommendation 15
CHAPTER 2. PROPOSED SYSTEM 16

2.1 Description of Design / Fabrication of the Proposed System / Model 16

2.2 Time and Resource Costs 17

2.3 Alternative Mechanism/ Design 18

​2.3.1 Description of [Alternative Mechanism / Design] 19

CHAPTER 3. REQUIREMENTS SPECIFICATIONS

3.1​ Purpose

3.2​ Document Conventions

3.3 Project Scope 21

3.4 Product Perspective 22

3.5 Assumptions

3.6 Equipment/ Component 22

​3.6.1 Names of each Component 23

 ​3.6.2 Specification of each Component 24

3.7 Basic Principle of Working of Componen​t

​3.7.1 Glossary

3.7.2 Issues list 24

CHAPTER 4. DESIGN SPECIFICATIONS

4.1 Introduction

4.2 Document Outline 28

4.3 Document Description 30

​4.3.1 Introduction 30
​4.3.2 System Overview 32

CHAPTER 5. DESIGN CONSIDERATIONS

5.1 Introduction

5.2 Assumptions and Dependencies 34

5.3 General Constraints 34

5.4 Goals and Guidelines

5.5 Design and Calculations 35

​5.5.1 Drawing of the each Component being used 36

​5.5.2 Design and Calculation of the Component being used

CHAPTER 6. CONCLUSION

CHAPTER 7. REFERENCES 37
 LIST OF FIGURES

FIGURE NAME PAGE NO

1) 1.1: INJECTION MOLDING MACHINE SETUP

2) 2.1: EACH PART OF INJECTION MOLDING SETUP

3) 2.2: CUTAWAY VIEW OF INJECTION MOLDING PROCESS

4) 2.3: MOLDED AND FINAL PART

5) 4.1: INJECTION MOLDING MACHINE SETUP

6) 4.2: OUTLINE OF INJECTION MOLDING

7) 4.3: MOLDING PART SETUP

8) 4.4: SPRUE

9) 4.5: CNC INJECTION MOLDING MACHINE (VICTOR)

10) 5.1: CLAMPING UNIT SETUP

11) 5.2: MOLDING UNIT SETUP

12) 5.3: 3D VIEW OF THE INJECTION MOLDING SETUP

13) 5.4: RAW PLASTIC INJECTED IN TO THE MOLDING MACHINE

​LIST OF TABLES

TABLE NAME PAGE NO

1) 1.1 ACRONYMS AND ABBREVIATIONS

2) 2.1 RATIONALE FOR RECOMMENDATIONS

3) 3.1 SPECIFICATIONS FOR INJECTION MOLDING

 CHAPTER 1. INTRODUCTION

The Project has tried to highlight the need of Training & Development mechanism which helps
successful organization to build on their success and to generate and meet the desire of feedback.
The organization is its viability, and hence its efficiency, there is continuous environmental
pressure for efficiency and if the organization does not respond to this pressure it may find itself
rapidly losing whatever share of the market it has. Employee training, therefore, imparts specific
skills and knowledge to employee in order that they contribute the organization’s efficiency and be
able to cope with the pressure of changing environment.
Employee training tries to improve skills, or add to the existing level of knowledge so that the
employee is letter equipped to his present job, or to prepare him for a higher position with
increased responsibilities.
The effective functioning of any organization requires that employees learn to perform their jobs at
satisfactory level of proficiency, So much that the organizations need to provide opportunities for
the continuous development of employees not only in their present jobs, but also to develop their
capabilities for other jobs for which they later be considered.

Training is the act of increasing the knowledge and skill of an employee for doing a particular job.
Training will provide for an output in this decision. The positive benefits of Training are:
● Training helps employees to learn their jobs and attain desired levels of performance
especially thus contributing better utilization of employees, machines and materials.

● Training helps to reduce the cost of raw materials and products –reducing losses due to
waste, poor quality products and damage to machinery –which would result if an untrained
employee, where to learn on his own.

● Finally, training aids in the development of individual skills, better methods, new
equipment and new work relationship. Such a process would also facilitate technological
change by updating the versatility of employees.

1.1 Purpose
Plastic has become the 'all-purpose' material. From packaging, plastic plants, domestic items,
containers, pipes to automobile parts, the plastic industry has come a long way from its small
beginnings about a hundred years ago. Some of the processes involved in plastic technology are
compression, moulding, lamination, fabrication etc. Injection moulding and blow moulding are the
commonly used processes.
1.2 Scope
Injection-moulded plastic parts are part and parcel of everyday life. Be they mobile phone casings,
beverage crates, toy figures, gear wheels for adjustment mechanisms, bumpers on cars, drinking
cups, CDs and DVDs, or syringe bodies in medical technology, injection mouldings are
encountered everywhere in all sizes, ranging from a few micrograms to several kilograms. Uniting
several components in a single injection moulding, integrating as many functions as possible in a
single component, and converting production methods comprising several steps into a single-stage
process – these are the chief innovation goals in the injection moulding sector​.

​Fig 1.1: Injection molding machine setup

 Table 1.1: Acronyms and Abbreviations

Acronyms with
Definition Language Category
MOLDING
Acronym in Science, Unit Measure, Chemistry,
AMC Advanced Molding Compound
English Biology, Acronym
Aligned Short Fiber Sheet Acronym in General, Common Abbreviation,
ASSMC
Molding Compound English Slang, Acronym
Acronym in Science, Unit Measure, Chemistry,
AMC Alkyd Molding Compound
English Biology, Acronym

Acronym in General, Common Abbreviation,

BMC Bulk Molding Compound
English Slang, Acronym
Bulk Molding Compounds Acronym in General, Common Abbreviation,
BMCI
Incorporated English Slang, Acronym

Acronym in General, Common Abbreviation,

DMC Dough Molding Compound
English Slang, Acronym

Acronym in General, Common Abbreviation,

GMVC Gentle Molding Vision Center
English Slang, Acronym

Acronym in General, Common Abbreviation,

IMM Injection Molding Machine
English Slang, Acronym
Acronym in General, Common Abbreviation,
IMT Injection Molding Technology
English Slang, Acronym

1.3 Points of Contact

With the guidance and supervision of project manager we used to work on several machines like
lathe,milling,drilling,shaper etc and CNC machine, we used to make the core and cavity of the
sample and these two dies(core and cavity) goes for surface finish. Now,the core and cavity will be
fitted together with support plate on their either sides,the complete die will subjected to the
injection moulding machine on a mold core and the clamping opened the die eject the product and
finally the product will thermalised and sintered to form the finalized product.
1.4 Management Summary

1.4.1 Organizations Involved

Ghonemy Construction company, AIESEC in Egypt worked for Sustainable Cities and

Communities.

1.4.2 Equipment
Injection molding machines consist of a material hopper, an injection 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 6000 tons, with the higher figures used in comparatively few

manufacturing operations. 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 2 to 8 tons for each

square inch of the projected areas.

Molds are built through two main methods: standard machining and ​EDM​. Standard ​machining​,

in its conventional form, has historically been the method of building injection molds. With

technological development, ​CNC​ ​machining​ became the predominant means of making more

complex molds with more accurate mold details in less time than traditional methods.

General Machines which are used in the company are:lathe,milling,shaper,slotting,drilling

and CNC(sanco sdm 2214) and CNC(cosmos cmo 1060).

1.5 Performance Objectives (Efficiency)

We use cast iron material for a making of any plastic mould; we generally use CNC machines for

making the core and cavity of any component. Other than if we uses different operation in different

machines like lathe,drilling,milling,boring etc.,it takes more time than the CNC machine, which

will reduced in time and processing speed, and increases productivity and staff .On the other hand

the CNC m/c will takes less time and higher processing speed and totally control over automated

decision making. The CNC m/c reduces staff.So,the efficiency of the CNC m/c is higher than the

different operation of machines.

The performance of conventional molding processes are governed by these physics, with

significant trade-offs required in the design of the part geometry, molding process, and polymeric

materials. For instance, a light product may require thin walls. However, the filling of such a

thin-walled product may require very high injection pressures and a lower viscosity resin.

1.6 Assumptions and Constraints

Plastics injection molding is perceived by many as a mature technology. However, many

performance constraints in plastics injection molding still exist that prevent the development and

manufacture of higher performance products at lower cost. A primary issue is not whether these

performance constraints can be overcome, but rather which performance constraints should be

overcome. With respect to control of the melt temperature in plastics injection molding, this paper

has provided analytical, experimental, and economic proof of feasibility. This analysis provides

convincing argument that control of melt temperature should be overcome and beneficially utilized

in many commercial applications. Determine the assumptions and constraints, such as operational

life of the proposed system; period of time for comparison of system alternatives; input, output,
and processing requirements; financial constraints; changing hardware, software, and operating

environment; and availability of information and resources.

1.7 Methodology (Basic Principle Involved)

The method used for the making any plastic object by injection molding process are:
First. The plastic matter should filled to the IMM from the top and the matter will heated in the
m/c which is filled to the tool and after the product will ejected through the tool .the cooling
process will be:
Cooling: Once the plastic melt at the gate solidifies, no additional material can be forced into the
cavity and the pressure decays. The amount of energy to be removed, Q​cool​, required to cool the
polymer melt is related to the change from the melt temperature, T​m​, to the ejection temperature,
T​e​, the heat capacity of the plastic melt, C​P​, and its mass, m:

The energy per square meter of surface area, Q, can also be considered as a function of the wall
thickness, h:

The average cooling power per square meter, P​cool​, is:

The cooling time, t​cooling​, can be estimated using one-dimensional heat transfer as [5]:

where  is the thermal diffusivity and T​c is the mold coolant temperature. It should be noted that
for many materials and processing conditions, molders have found the following approximation of
eq. (6) useful where h is measured in mm:
1.8 Recommendation
- Verify the temperature of the mold cavities using a temperature probe.
- Confirm the melt temperature using a temperature probe moved about in a volume of melt, shot
onto an insulator (a glove, cardboard, etc.)
- Set the initial cooling time and set a zero hold time and/or pressure
- Inject incomplete parts by gradually increasing the shot volume using an average to high
injection speed.
- When the mold is almost filled (90 to 95%), set the initial hold pressure and gradually increase
the hold time.
- In this way, the end of the filling is done under constant pressure and part over-packing is
avoided.
- Adjust the hold phase parameters to obtain a constant part weight and the required dimensional
stability.
- The cooling time depends on the part geometry.
- Gradually adjust the cooling time until the optimal cycle time is obtained.

The variety of plugs offered fit a wide spectrum of polymer needs. Vent diameter should be chosen
to correspond to these needs. Examples are listed below.

1. 0.03mm diameter for use with polyethylene and polypropylene

2. 0.05mm diameter used in Nylon, ABS and polycarbonate.
3. 0.10mm diameter vents for highly viscous polymer
 CHAPTER 2. PROPOSED SYSTEM

2.1 Description of Design / Fabrication of the Proposed System / Model

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​ 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
is squeezed into the corners of the cavity, where it prevents filling and causes other defects as well.
The air can become so compressed that it ignites and burns the surrounding plastic material. 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 the mold opens (utilizing components called Lifters).

​Fig 2.1: Each part of Injection moulding setup

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. If the skin is too thin, then the molded part will
tend to shrink onto the cores that form them while cooling, and cling to those cores or part may
warp, twist, blister or crack when the cavity is pulled away. The 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.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 runner system out of a mold.

Fig 2.2 Cutaway view of the injection molding process

2.2 Time and Resource Costs

The cost of manufacturing molds depends on a very large set of factors ranging from number of
cavities, size of the parts (and therefore the mold), complexity of the pieces, expected tool
longevity, surface finishes and many others. The initial cost is great, however the piece part cost is
low, so with greater quantities the overall price decreases.
The tooling cost has two main components - the mold base and the machining of the cavities. The
cost of the mold base is primarily controlled by the size of the part's envelope. A larger part
requires a larger, more expensive, mold base. The cost of machining the cavities is affected by
nearly every aspect of the part's geometry. The primary cost driver is the size of the cavity that
must be machined, measured by the projected area of the cavity (equal to the projected area of the
part and projected holes) and its depth. Any other elements that will require additional machining
time will add to the cost, including the feature count, parting
surface, side-cores, lifters, unscrewing devices, tolerance, and surface roughness.
Table 2.1: Rationale for Recommendations
FAULT RECOMMENDATION
1. Short shot, record 1. Adjust feed to minimum consistent cushion
groove effect 2. Increase injection pressure
3. Increase injection speed
4. Increase back pressure
5. Increase barrel temperatures
6. Increase mould temperature, particularly for
very
thin large area parts
7. Check non-return valve
8. Improve venting
9. Enlarge gates, sprue diameters and runners

1. Increase mould temperature

2. Weld line 2. Increase injection speed
3. Increase melt temperature
4. Increase hold on pressure
5. Check venting
6. Relocate gate to change flow pattern
 2.3 Alternative Mechanism/ Design

A program begins with a need - either an improvement on something already in existence, or a

unique way of fulfilling a need. The initial idea may start as a sketch or as a model. The next step
is to put the idea into a workable form and to determine how it will be manufactured and the cost
to manufacture it.

With competitive pressures demanding maximum efficiency from every facet of a company's
operations, designers and engineers are faced with the increasingly difficult task of developing a
product which not only meets the functional requirements of the application, but a product which
can be produced in the most cost effective manner. Add to this challenge the ever-increasing
number of government regulations, new materials, and improved manufacturing processes, and the
task of designing even a "simple" pan is no longer simple. The path becomes more complicated.

2​.​3.1​ Description of [Alternative Mechanism / Design]

The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes,
and consists of the following four stages:

1. Clamping - Prior to the injection of the material into the mold, the two halves of the mold must
first be securely closed by the clamping unit. Each half of the mold is attached to the injection
molding machine and one half is allowed to slide. The hydraulically powered clamping unit
pushes the mold halves together and exerts sufficient force to keep the mold securely closed
while the material is injected. The time required to close and clamp the mold is dependent
upon the machine - larger machines (those with greater clamping forces) will require more
time. This time can be estimated from the dry cycle time of the machine.
2. Injection - The raw plastic material, usually in the form of pellets, is fed into the injection
molding machine, and advanced towards the mold by the injection unit. During this process,
the material is melted by heat and pressure. The molten plastic is then injected into the mold
very quickly and the buildup of pressure packs and holds the material. The amount of material
that is injected is referred to as the shot. The injection time is difficult to calculate accurately
due to the complex and changing flow of the molten plastic into the mold. However, the
injection time can be estimated by the shot volume, injection pressure, and injection power.
3. Cooling - The molten plastic that is inside the mold begins to cool as soon as it makes contact
with the interior mold surfaces. As the plastic cools, it will solidify into the shape of the
desired part. However, during cooling some shrinkage of the part may occur. The packing of
material in the injection stage allows additional material to flow into the mold and reduce the
amount of visible shrinkage. The mold can not be opened until the required cooling time has
elapsed. The cooling time can be estimated from several thermodynamic properties of the
plastic and the maximum wall thickness of the part.
4. Ejection - After sufficient time has passed, the cooled part may be ejected from the mold by
the ejection system, which is attached to the rear half of the mold. When the mold is opened, a
mechanism is used to push the part out of the mold. Force must be applied to eject the part
because during cooling the part shrinks and adheres to the mold. In order to facilitate the
ejection of the part, a mold release agent can be sprayed onto the surfaces of the mold cavity
prior to injection of the material. The time that is required to open the mold and eject the part
can be estimated from the dry cycle time of the machine and should include time for the part to
fall free of the mold. Once the part is ejected, the mold can be clamped shut for the next shot to
be injected.
After the injection molding cycle, some post processing is typically required. During cooling, the
material in the channels of the mold will solidify attached to the part. This excess material, along
with any flash that has occurred, must be trimmed from the part, typically by using cutters. For
some types of material, such as thermoplastics, the scrap material that results from this trimming
can be recycled by being placed into a plastic grinder, also called regrind machines or granulators,
which regrinds the scrap material into pellets. Due to some degradation of the material properties,
the regrind must be mixed with raw material in the proper regrind ratio to be reused in the injection
molding process.

Fig 2.3: Molded and final part

 CHAPTER 3. REQUIREMENTS SPECIFICATIONS

3.1 Purpose
Injection molding is the most commonly used manufacturing process for the fabrication of plastic
parts. A wide variety of products are manufactured using injection molding, which vary greatly in
their size, complexity, and application. The injection molding process requires the use of an
injection molding machine, raw plastic material, and a mold.

3.2 Document Conventions

In this process, the plastic granules or pellets are poured into a machine hopper and fed into the
chamber of the heating cylinder. A plunger then compresses the material, forcing it through
progressively hotter zones of the heating cylinder in order to accelerate the heating of the center of
the plastic mass. The torpedo may also be heated so that the plastic is heated from the inside as
well as from the outside.

The material flows from the heating cylinder through a nozzle into the mold. The nozzle is the seal
between the cylinder and the mold. It is used to prevent leaking of the material caused by the
pressure used. The mold is held shut by the clamp end of the machine. For polystyrene, two to
three tons of pressure on the clamp end of the machine is generally used for each inch of projected
area of the part and runner system. The conventional plunger machine is the only type of machine
that can produce a mottle-colored part.

Reading Suggestions

KPa x 0.145 = psi

MPa x 145 = psi
°C x 1.8 + 32 = °F
Liters/min x 0.2642 = Gal/min
Inches x 25.4 = mm
Flow rate = ((# of cavities) x (volume per cavity))/(injection time)

3.3 Project Scope

Injection molding is the most commonly used manufacturing process for the fabrication of plastic
parts. A wide variety of products are manufactured using injection molding, which vary greatly in
their size, complexity, and application. The injection molding process requires the use of an
injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection
molding machine and then injected into the mold, where it cools and solidifies into the final
part.injection molding is used to create many things such as wire spools, ​packaging​, bottle caps,
automotive dashboards, pocket combs, some musical instruments (and parts of them), one-piece
chairs and small tables, storage containers, mechanical parts (including gears), and most other
plastic products available today.

3.4 Product Perspective

▪ Plastic injection molding​ is a ​manufacturing​ process for producing parts from

both ​thermoplastic​ and ​thermosetting​ ​plastic​ materials. Material is fed into a heated barrel,
mixed, and forced into a mold cavity where it cools and hardens to the configuration of the
mold cavity. After a product is designed, usually by an ​industrial designer​ or an ​engineer​,
molds are made by a ​mold maker​ (or toolmaker) from metal, usually either ​steel​ or ​aluminum​,
and precision-machined to form the features of the desired part. Injection molding is widely
used for manufacturing a variety of parts, from the smallest component to entire ​body
panels​ of ​cars​ .It utilizes a ram or screw-type plunger to force molten plastic material into a
mold cavity. It produces a solid or open-ended shape that has conformed to the contour of the
mold. Uses thermoplastic or thermoset materials. It produces a ​parting line​, ​sprue​, and gate
marks. Ejector pin marks are usually present Injection molding is used to produce thin-walled
plastic parts for a wide variety of applications, one of the most common being plastic
housings. Plastic housing is a thin-walled enclosure, often requiring many ribs and bosses on
the interior. These housings are used in a variety of products including household appliances,
consumer electronics, power tools, and as automotive dashboards. Other common thin-walled
products include different types of open containers, such as buckets. Injection molding is also
used to produce several everyday items such as toothbrushes or small plastic toys. Many
medical devices, including valves and syringes, are manufactured using injection molding as
well.

3.5 Assumptions

Optimal process settings are critical to influencing the cost, quality, and productivity of plastic
injection molding. The main trouble in injection molding is to have a box of good plastics parts
contaminated with scrap. For that reason process optimization studies have to be done and process
monitoring has to take place. First article inspection of internal and external geometry including
imperfections such as ​porosity​ can be completed using ​Industrial CT Scanning​, a 3D x-ray
technology. For external geometry verification only a ​Coordinate-measuring machine or ​white
light scanner​ can be used.
To have a constant filling rate in the cavity, the switch over from injection phase to the holding
phase can be made based on cavity pressure level.
Having a stable production window, the following issues are worth investigating:
3.6 Equipment / Component

3.6.1 Names of each Component

1.Support Plate
2.Ejector Box
3.Ejector Plate
4.Ejector Retaining plate
5.Mold Core
6.Mold Cavity
7.Sprue Bush
8.Locating ring

3.6.2 Specification of each Component

Injection molding machines are typically characterized by the tonnage of the clamp force they
provide. The required clamp force is determined by the projected area of the parts in the mold and
the pressure with which the material is injected. Therefore, a larger part will require a larger
clamping force. Also, certain materials that require high injection pressures may require higher
tonnage machines. The size of the part must also comply with other machine specifications, such
as shot capacity, clamp stroke, minimum mold thickness,and platen size.
Injection molded parts can vary greatly in size and therefore require these measures to cover a very
large range. As a result, injection molding machines are designed to each accommodate a small
range of this larger spectrum of values. Sample specifications are shown below for three different
models (Babyplast, Powerline, and Maxima) of injection molding machine that are manufactured
by Cincinnati Milacron.

​Table 3.1: Specifications for Injection molding

Babyplast Powerline Maxima
Clamp force (ton) 6.6 330 4400
Shot capacity (oz.) 0.13 - 0.50 8 - 34 413 – 1054
Clamp stroke (in.) 4.33 23.6 133.8
Min. mold thickness (in.) 1.18 7.9 31.5
Platen size (in.) 2.95 x 2.95 40.55 x 40.55 122.0 x 106.3
Material of the Component used

There are many types of materials that may be used in the injection molding process. Most
polymers may be used, including all thermoplastics, some thermosets, and some elastomers. When
these materials are used in the injection molding process, their raw form is usually small pellets or
a fine powder. Also, colorants may be added in the process to control the color of the final part.
The selection of a material for creating injection molded parts is not solely based upon the desired
characteristics of the final part. While each material has different properties that will affect the
strength and function of the final part, these properties also dictate the parameters used in
processing these materials. Each material requires a different set of processing parameters in the
injection molding process, including the injection temperature, injection pressure, mold
temperature, ejection temperature, and cycle time.

3.7 Basic Principle of Working of Component

The working principle of​ injection molding machine ​is similar to injection syringe, it using screw
thrust injection the plasticized plastic into die cavity, after formalization take out products.
Injection molding​ is a cyclical process, every cycle mainly include: rated material feeding-- melt
and plastination—pressure injection—mold filling and cooling --startup mould. Closed modules
after remove mold parts then go ahead next cycle.
The injection molding are basic requirements of the plasticizing, injection and molding.
Plasticizing is achieve and guarantee the quality of molding products, in order to meet
requirements of molding, injection must have enough pressure and speed. At the same time,
injection pressure high, consequently produce high pressure in die cavity, so must have enough
clamping force. Thus it can be seen, injection equipment and clamping equipment key parts in
injection ​molding machine​.

Material of the Component used

The main tool of injection molding is made up cast iron or copper or HSS.

Other Requirements

Other Requirement for injection molding process is the making the mold of tool of the machine by
general operation like lathe,milling,drilling,shaper or it can be done in the CNC machine.
3.7.1 Glossary

Acceptable runner/cavity ratio: runner systems designed for high pressure drops to minimize
material usage and increase frictional heating in the runner.
Additive: A substance compounded into a resin to enhance or improve certain characteristics.
Adhesive Assembly: The process of joining two or more plastic parts by means of an adhesive.
Aging: The process of, or the results of, exposure of plastics to natural or artificial environmental
conditions for a prolonged period of time.
Backing Plate: A plate used as a support for the mold cavity block, guide pins, bushings, etc.
Balanced Runner: A runner system designed to place all cavities at the same distance from the
sprue.
Barrel: The section of a molding machine that contains the feed screw, also the section where resin
heating and mixing occurs.
Binder: A resin or other material used to hold particles together. The binder is the continuous
phase in a reinforced plastic, which provides mechanical strength or ensures uniform consistency,
solidification, or adhesion to a surface coating. Typical binder materials include resin, glue, gum
and casein.
Clamping Plate: A plate fitted to a mold and used to fasten the mold to a platen.
Clamping Pressure: The pressure applied to the mold to keep it closed during the molding cycle.
Core: A protrusion, or set of matching protrusions, in a plastics forming mold which forms the
inner surfaces of the molded articles.
Cavity: A depression, or a set of matching depressions, in a plastics-forming mold which forms the
outer surfaces of the molded articles.

3.7.2 Issues List

In this list the following pending decisions, information that is needed, conflicts awaiting resolution are
lifted:

1.making of core and cavity

2.process in the CNC machine
3.parts of Injection molding machine
4.concept of the resins of the making component
 CHAPTER 4. DESIGN SPECIFICATIONS

4.1 Introduction

Tool design & manufacturing capabilities of the group are a key to its ability to provide full
system solutions. The group has collaborations with Sumitomo Wiring Systems, Japan and Center
Tooling, Australia for tool design & manufacturing.

The tool rooms specialize in high precision, multi cavity, small, medium and large size tools
capable of running on injection molding machines upto 3200 tonnes.

Tool manufacturing is done on state-of-the-art CNC machines. In-house proving & tryout facilities
on injection molding machines are in tandem with tool manufacturing facilities.

The complete range of services from tool design to tool manufacturing and injection molding
under one roof make the group a Total Tooling Solutions provider.
A successful application of an engineering thermoplastic requires more than identifying a specific
product or grade. Three areas – design, product, process – are all interrelated and the appropriate
rules in each area must be followed to ensure a successful application. In most cases, the process
must be determined before a specific resin grade can be selected. During this review, designers
also need to consider whether the process is capable of meeting the design requirements such as
size, shape, detail and tolerance.
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​ 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.
Molds are built through two main methods: standard machining and ​EDM​. Standard ​machining​, in
its conventional form, has historically been the method of building injection molds. With
technological development, ​CNC​ ​machining​ became the predominant means of making more
complex molds with more accurate mold details in less time than traditional methods.
The ​electrical discharge machining (EDM)​ or ​spark erosion​ process has become widely used in
mold making. As well as allowing the formation of shapes that are difficult to machine, the process
allows pre-hardened molds to be shaped so that no heat treatment is required. Changes to a
hardened mold by conventional drilling and milling normally require annealing to soften the mold,
followed by heat treatment to harden it again. EDM is a simple process in which a shaped
electrode, usually made of copper or graphite, is very slowly lowered onto the mold surface (over a
period of many hours), which is immersed in paraffin oil (kerosene).

4.2 Document Outline

1. What is injection molding ?
Injection molding is a method to obtain molded products by injecting plastic materials
molten by heat into a mold, and then cooling and solidifying them.
The method is suitable for the mass production of products with complicated shapes,
and takes a large part in the area of plastic processing.
The process of injection molding is divided into 6 major steps as shown below.

1. Clamping
2. Injection
3. Dwelling
4. Cooling
5. Mold opening
6. Removal of
products

​Fig 4.1: Injection Molding machine Setup

The process is proceeded as shown above and products can be made successively by
repeating the cycle.

​2. Injection molding machine

Injection molding machine is divided into 2 units i.e. a clamping unit and an injection
unit.
The functions of the clamping unit are opening and closing a die, and the ejection of
products. There are 2 types of clamping methods, namely the toggle type shown in the
figure below and the straight-hydraulic type in which a mold is directly opened and closed
with a hydraulic cylinder.
The functions of the injection unit are to melt plastic by heat and then to inject molten
plastic into a ​mold​.
The screw is rotated to melt plastic introduced from the hopper and to accumulate
molten plastic in front of the screw ( to be called metering ) . After the required amount of
molten plastic is accumulated, injection process is started.
While molten plastic is flowing in a mold, the machine controls the moving speed of
the screw, or injection speed. On the other hand, it controls dwell pressure after molten
plastic fills out cavities.
 The position of change from speed control to pressure control is set at the point where
either screw position or injection pressure reaches a certain fixed value.

Fig 4.2: Outline of Injection Molding

3. Mold
A mold is a hollow metal block into which molten plastic is injected to from a certain
fixed shape. Although they are not illustrated in the figure shown below, actually there are
many holes drilled in the block for temperature control by means of hot water, oil or
heaters.
Molten plastic flows into a mold through a sprue and fills cavities by way of runners
and gates. Then, the mold is opened after cooling process and the ejector rod of the
injection molding machine pushes the ejector plate of the mold to further eject moldings.

Fig 4.3: Molding part setup

4. Molding
A molding consists of a sprue to introduce molten resin, a runner to lead it to cavities,
and products. Since obtaining only one product by one shot is very inefficient, a mold is
 usually designed to have multiple cavities connected with a runner so that many products
can be made by one shot.
If the length of the runner to each cavity is different in this case, the cavities may not
be filled simultaneously, so that dimensions, appearances or properties of the moldings
are often different cavity by cavity. Therefore the runner is usually designed so as to have
the same length from the sprue to each cavity.

​Fig 4.4: Sprue

4.3 Document Description

▪ Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity
▪ Produces a solid or open-ended shape that has conformed to the contour of the mold
▪ Uses thermoplastic or thermoset materials
▪ Produces a ​parting line​, ​sprue​, and gate marks
▪ Ejector pin marks are usually present

4.3.1 Introduction

Purpose:
The purpose of the injection molding is used to produce thin-walled plastic parts for a wide variety
of applications, one of the most common being plastic housings. Plastic housing is a
thin-walled enclosure, often requiring many ribs and bosses on the interior. These housings
are used in a variety of products including household appliances, consumer electronics,
power tools, and as automotive dashboards. Other common thin-walled products include
different types of open containers, such as buckets. Injection molding is also used to produce
 several everyday items such as toothbrushes or small plastic toys. Many medical devices,
including valves and syringes, are manufactured using injection molding as well.
Scope:
Injection molding is used to create many things such as wire spools, ​packaging​, bottle caps,
automotive dashboards, pocket combs, some musical instruments (and parts of them),
one-piece chairs and small tables, storage containers, mechanical parts (including gears), and
most other plastic products available today. Injection molding is the most common method
of part manufacturing. It is ideal for producing high volumes of the same object.​[5]​ Some
advantages of injection molding are high production rates, repeatable high tolerances, the
ability to use a wide range of materials, low labor cost, minimal scrap losses, and little need
to finish parts after molding. Some disadvantages of this process are expensive equipment
investment, potentially high running costs, and the need to design moldable parts.
Summary:

There is no mystery in injection moulding of plastics. Each and every phenomenon has its
scientific reasons. Since injection moulding involves Polymers, Mould and Machinery, it is
necessary to understand all of them; their role and their limitations. We explore in this book
–Cavity pressure profile, pvT diagram, Shear thinning of plastics, Flow mechanism- simultaneous
flow and freeze of melt with skin formation and fountain flow.

We also appreciated the root cause of most of the quality problems lie with three balancing tricks
in the process.

● Flow balance in part,

● Heat balance in mould,
● Uniform freezing in mould.
● Moulding process in this book is not discussed in layman's point of view but it is discussed
in terms of physics of plastic melt, which is best described by pvT characteristic, shear
thinning characteristic and orientation characteristic of melt.
● This book provides technical perspective to the process that is relevant to understand CAE
technologies. You can develop skills to visualise the happenings inside the Screw-Barrel
and inside the Mould. This knowledge can help you to understand the root causes of all the
quality related problems.
● Very vital information are provided with figures and tables about Screw Design, Machines,
Support Equipment, Service lines, Injection Moulding Process, Quality related Problems,
Mould, Hot Runners, Mechanical failures in Moulds, Energy efficiency, Testing of
Machines, Robot, Multi-component Moulding, Gas assisted Moulding, Thermoset
Moulding, CAE, CAD, CAM Technology. A chapter on Myths and Truth clarifies the most
misunderstood aspects in the industry..
4.3.2 System Overview
Injection molding of plastics is one of the most cost effective processes for manufacture of parts in
volume. While mold costs can be significant, amortization over many parts can make the overall
cost of injection molding highly competitive with other manufacturing processes. The wide range
of available polymers multiplied by the huge array of specific blends offer a tremendous range of
physical, thermal, electrical, and chemical properties. Engineering plastics, classified by
mechanical properties such as stiffness, toughness, and low creep, increasingly replace metals on a
cost and performance evaluation.

Designing for injection molded plastics requires planning. Too often parts will be presented to a
molder or tool designer late in the product development process only to be confronted with
feasibility issues. If that happens the developer faces decisions to rework part designs or to face
higher tooling and part costs. Leaving design for manufacturing and assembly (DMFA)
considerations until late in the development program is a common mistake the misses out on
optimization and disrupts the transition to manufacturing.

Planning begins in preliminary design. Some will argue that consideration for manufacturing early
in the program will inhibit creativity; the reality is that it does not if perspectives are kept in
balance. In fact design committee often err in committing to a design that later reveals feasibility
and cost issues. While designers and engineers need to be free to brainstorm potential solutions,
taking time to evaluate for manufacturing options is vital to assume a successful program.

Design concept modeling is a vital step in preliminary product design. Form and function can be
evaluated in blocked-out quick CAD studies. Drawings produced from 3D CAD model studies can
help evaluate the size, cost, and architecture of a proposed design. Multiple preliminary model
studies are a good use of time because many factors can be evaluated after a few hours of work.
Such studies can include component packaging, part break out, and overall size and weight.
Concept parts can be submitted for preliminary price quotations. DMFA (design for manufacturing
and assembly) has become a hot buzz word in product development the truth is that consumer
products manufacturers have been doing DMFA for decades as a means of competitive survival.

Injection molding is particularly advantageous for assemblies wherein components can be mounted
using ribs and bosses inside the shell of the parts allowing to easy assembly most commonly using
screws, push nuts, snap latches, or heat staking. Components are commonly captured between two
shells. Consideration for assembly procedure in part design is critical to reducing cost and boosting
assembly line yields. In many industries, cost competitiveness is key factor in market success.
Secondary assembly operations can include sonic insertion of threaded fasteners and plastic
welding operations such as thermal welding, ultrasonic welding, spin welding, vibration and laser
welding.

Consumer product industries were the first to focus on aesthetics for competitive advantage
wherein one product would out-sell another primarily because of form and function. The field of
Industrial Design sprung up wherein artistic individuals entered into product design realm bring
their drawing, rendering, model sculpting skills and aesthetic sensibilities into the product
development process. Early pioneer Raymond Loewy in the 1930s came from the fashion industry
and proved to be a fastidious designer with great attention of detail and construction. Solid
modeling CAD systems offer powerful 3D (three dimension) surface modeling capabilities that
can satisfy high expectations for appearance in the field of Industrial Design. Surface modeling
provides the tools to capture complex surface geometries for seamless data transfer to machine
tooling operations for injection molding. CAD data is captured electronically and interpreted by
CAM (computer-aided-machine) operations. CAM software programs define specific cutter tool
paths for efficient and accurate cutting of mold cores and cavities. CAD/CAM processes can
capture virtually any surface configuration that a designer envisions. CAM data is used for CNC
(computer-numerical-control), EDM (electro-discharge-machining or spark erosion) and wire
EDM cutting methods.

​Fig 4.5: CNC injection molding machine (Victor)

 CHAPTER 5. DESIGN CONSIDERATIONS

5.1 Introduction
Injection molding is used to create many things such as wire spools, ​packaging​, bottle caps,
automotive dashboards, pocket combs, some musical instruments (and parts of them), one-piece
chairs and small tables, storage containers, mechanical parts (including gears), and most other
plastic products available today. Injection molding is the most common method of part
manufacturing. It is ideal for producing high volumes of the same object.​[5]​ Some advantages of
injection molding are high production rates, repeatable high tolerances, the ability to use a wide
range of materials, low labor cost, minimal scrap losses, and little need to finish parts after
molding. Some disadvantages of this process are expensive equipment investment, potentially high
running costs, and the need to design moldable parts.

5.2 Assumptions and Dependencies

Injection molding is particularly advantageous for assemblies wherein components can be mounted
using ribs and bosses inside the shell of the parts allowing to easy assembly most commonly using
screws, push nuts, snap latches, or heat staking. Components are commonly captured between two
shells. Consideration for assembly procedure in part design is critical to reducing cost and boosting
assembly line yields. In many industries, cost competitiveness is key factor in market success.
Secondary assembly operations can include sonic insertion of threaded fasteners and plastic
welding operations such as thermal welding, ultrasonic welding, spin welding, vibration and laser
welding.

5.3 General Constraints

To insure a quality final product, it is necessary to start out with quality components. Injection
molded parts can be molded to a high quality standard by focusing on these areas of plastic
technology:

1)Correct Part Design

2)Accurate Selection of Material

3) Processing Plastic Processing

5.4 Goals and Guidelines
1 Use uniform wall thicknesses throughout the part. This will minimize sinking,
warping, residual stresses, and improve mold fill and cycle times.

▪ Wall Section Considerations

▪ Voids and Shrinkage
▪ Warpage

2 Use generous radius at all corners. The inside corner radius should be a minimum of
one material thickness.

▪ Radius Limitations

3 Use the least thickness compliant with the process, material, or product design
requirements. Using the least wall thickness for the process ensures rapid cooling,
short cycle times, and minimum shot weight. All these result in the least possible part
cost.

4 Design parts to facilitate easy withdrawal from the mold by providing draft (taper) in
the direction of mold opening or closing.

▪ Draft and Texture

5 Use ribs or gussets to improve part stiffness in bending. This avoids the use of thick
section to achieve the same, thereby saving on part weight, material costs, and cycle
time costs.

▪ Rib Design
5.5 Design and Calculations

5.5.1 Drawing of the each Component being used

​Fig 5.1: Clamping unit setup

Fig 5.2: Molding unit assembly

​Fig 5.3: 3D view of the Injection Molding setup

5.5.2 Design and Calculation of the Component being used

Fig 5.4: Raw plastic injected in to the molding machine

Injection molding machines are typically characterized by the tonnage of the clamp force they
provide. The required clamp force is determined by the projected area of the parts in the mold and
the pressure with which the material is injected. Therefore, a larger part will require a larger
clamping force. Also, certain materials that require high injection pressures may require higher
tonnage machines. The size of the part must also comply with other machine specifications, such
as shot capacity, clamp stroke, minimum mold thickness, and platen size.

Injection molded parts can vary greatly in size and therefore require these measures to cover a very
large range. As a result, injection molding machines are designed to each accommodate a small
range of this larger spectrum of values. Sample specifications are shown below for three different
models (Babyplast, Powerline, and Maxima) of injection molding machine that are manufactured
by Cincinnati Milacron.

Babyplast Powerline Maxima

Clamp force (ton) 6.6 330 4400
Shot capacity (oz.) 0.13 - 0.50 8 - 34 413 - 1054
Clamp stroke (in.) 4.33 23.6 133.8
Min. mold
1.18 7.9 31.5
thickness (in.)
Platen size (in.) 2.95 x 2.95 40.55 x 40.55 122.0 x 106.3
 CHAPTER 6. CONCLUSION
​ his project was done under the Sustainable cities and communities the main aim was to use the
T
modern methods in order to save the environment and use the already present materials and recycle
them in order to save the environment.
I​ n this project many machines like lathe machine, drilling, CNC, etc.. has been used. And the
calculations for the required amounts of material required for optimal production with low cost has
been studied. And also how the Plastic injection moulding process works and how it is modernized
to improve the efficiency of the plant.
 ​CHAPTER 7. REFERENCES

Bryce, Douglas M. Plastic Injection Molding: Manufacturing Process Fundamentals. SME, 1996.

Brydson, J, Plastics Materials, Butterworths 9th Ed (1999).

Callister, William D, Materials Science and Engineering: An Introduction, John Wiley and Sons

HI *Whelan, Tony. Polymer Technology Dictionary Springer, 1994.

Injection Molding Handbook By Tim A. Osswald, Lih-Sheng Turng, Paul J. Gramann

http://www.cadmodels.biz/3d_cad_design_for_injection_molded_plastics.html

http://www.custompartnet.com/wu/InjectionMolding#cost_drivers

http://www.vero-software.com/products.php?page_id=1&sub_id=4

http://www.efunda.com/designstandards/plastic_design/plastic_intro.cfm