International Journal of Advanced Engineering Research and Science (IJAERS)

[Vol-1, Issue-3, Aug- !1"#

ISS$% 3"&-'"&(
Design and Fabrication of Plastic Injection Molding Tool for
Pump Gaskets
Haribabu Kummara
1
, Dr. G. Harinath Gowd
2
1
PG Student, Department of Mechanical Engineering,Madanapalle n!titute of "echnolog# $ Science,
Madanapalle. %ndhra Prade!h., &D%
2
Profe!!or, Department of Mechanical Engineering ,Madanapalle n!titute of "echnolog# $ Science,
Madanapalle. %ndhra Prade!h., &D%
Abstract This Project gives the information about to
design and fabrication of Injection Molding tool or die
for Production of pump gaskets by using Plastic material.
For Increasing the Production rate, designing and
manufacturing the multi cavity die and also Using PP
polypropylene! to overcome the e"isting plastic material
dra#backs. The injection molding tool$die contains the
core plate, cavity plate, top and bottom supported plates,
channels or runners, sprue, vents, ejector and its pins and
horn pins, etc. The gaskets are used to prevent leakages
by provide a tight fitting joint bet#een t#o surfaces. The
%reek #ord of &Plastic' meaning is &able to be shaped and
molded'( in so many different plastic materials I am using
polypropylene material for production of plastic gaskets
components. For optimi)ation Process, The selected t#o
bolt oval gasket component is making #ith injection
molding process by controlling parameters of plastic
injection molding machine.
KeywordsInjection molding, injection molding tool,
polypropylene, Surface grinding machine.
I. INTRD!"TIN
"he in'ection Molding tool(die contain! the core de!igned
plate, ca)it# de!igned plate, top and bottom !upported
plate!, channel! or runner!, !prue, )ent!, e'ector and it!
pin!, horn pin!, etc. n fabrication proce!!, the
con!idering )ariable! are "emperature, "ime, Speed,
Pre!!ure and !tro*e. "he ga!*et! are u!ed to pro)ide a
tight fitting 'oint between two !urface! to pre)ent
lea*age!. n General the ga!*et! contain! the Propertie!
li*e +onformit#, ,e!i!tance, mpermeabilit#, ,e!i!tance
to chemical attac*, ,e!i!tance to operating condition!,
Pro)i!ion of aperture!, !hrin*age, reu!abilit# and co!t.
"he Gree* word of -Pla!tic. meaning i! -able to be !haped
and molded./ in !o man# different pla!tic material! u!ing
pol#prop#lene material for production of pla!tic ga!*et!
component! and anal#0ing the production rate and
production co!t. 1or optimi0ation Proce!!, "he !elected 2
bolt o)al ga!*et component i! ma*ing with in'ection
molding proce!! b# controlling parameter! of pla!tic
in'ection molding machine.
II. G#$%&T
"he ga!*et! are u!ed to pro)ide a tight fitting 'oint
between two !urface! to pre)ent lea*age!, for e2ample
'oint between c#linder head and bloc*, between cran*ca!e
water pump! etc. %nd a)oid problem! li*e Production
brea*age!, energ#.
"he !elected Ga!*et de!ign with dimen!ion! i! !hown in
figure 1.
1ig. 13 Ga!*et with dimention!
III. IN'&"TIN M(DING T(
n'ection mold tool al!o *nown a! die or mold. "he die!
are two t#pe!, fi!t one i! !ingle ca)it# die and !econd one
i! multi ca)it# die. 1or increa!ing the production rate with
minimi0ing the co!t purpo!e, implemented multi ca)it#
in'ection mold. "ool de!igned depend! on finali0ed part
de!ign dimen!ion!.
1or tool de!igning purpo!e u!ed !oftware are Solid wor*!,
%uto+%D
).* D&$IGN F M!(TI"#+IT, DI&-
n'ection mold tool i! a multi ca)it# die that mean! more
than one part in a ca)it#. t contain! core plate, ca)it#
plate, !pacer, bottom plate, e'ector plate, e'ector bac*
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
plate, !prue bu!h, etc. "ool or die de!igned ba!ed on DME
and Ha!co e'ector !tander!.
3.1.1 D&$IGN F "R& P(#T&:
+ore de!igned three ga!*et part!, air went, guide pillar
hole!, cooling !#!tem, and e'ector pin hole!. "wo e'ector
pin hole! pro)ided for e)er# part of ga!*et mean! totall#
4 e'ector pin hole pro)ided in core plate.

1ig 23 +ore Plate
).*.. D&$IGN F "#+IT, P(#T&3
"here i! no de!ign in +a)it# plate becau!e of the total part
de!ign happen! in core plate it!elf. %lmo!t all die!
contain! ca)it# plate and top !upported plate, but in thi!
pro'ect, we are pro)iding a thic* ca)it# plate without
pro)iding top !upported plate
1ig 53 +a)it# plate
).*.) D&$IGN F $P#"&R$-
1ig 63 Spacer
).*./ D&$IGN F 0TTM P(#T&-
1ig 73 8ottom plate
).*. 1 D&$IGN F &'&"TR P(#T&-
1ig 43 E'ector 1ront plate
).*.2 D&$IGN F &'&"TR 0#"% P(#T&-
1ig 93 E'ector 8ac* Plate
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
I+. T( M#N!F#"T!RING PR"&$$
Some of !e:uential !tep! ha)ing to manufacturing the
multi ca)it# die/ the na)igating !tep! are ,aw material
!election, Premachining, +&+ Milling, Heat "reatment,
Surface Grinding, +&+ Milling, Spar*ing, ;ire EDM
Proce!!, Poli!hing, and %!!embl#.
*. Ra3 Material
Selected Mild !teel <MS= raw material ba!ed on the DME
and H%S+> de!igned !tandard! to de!ign and
manufacturing the tool. n below table contain! raw
material !i0e! of component! of in'ection tool.
Material
Purpo!e
Height
<mm=
;idth
<mm=
"hic*ne!!
<mm=
+ore Plate 27? 24? 6?
+a)it# plate 27? 24? @?
Spacer 27? 77 77
E'ector Plate! 27? 17? 17
E'ector 8ac*
plate
27? 17? 17
8ottom Plate 27? 24? 5?
"able 13 ,aw material !i0e! of tool component!
.. Pre mac4ining- n thi! proce!! decided the metal !i0e!
and bloc* !i0e! for maintaining the tool !tandard!.
). "N" Milling for Roug4 $urface- Here metal !hape i!
obtained b# remo)ing the unwanted material from the
;or* Piece in the form of chip!.
/. 5eat Treatment- Heat treatment proce!! i! u!ed for
hardening the material for better machining.
1. $urface Grinding- Surface grinding di)ided into two
t#pe! one i! c#lindrical grinding <+G= and !econd one i!
!:uare grinding. 8# u!ing thi! proce!! we will fini!h
e'ector pin! and bu!he!, etc.
2. "N" Milling- %fter grinding once again +&+ milling
operation done for !mooth !urface fini!h of the metal.
Here upto ?.1 micron metal cutting !haping proce!!
happen!.
6. 7ire &DM Process- t i! u!ed for accurac# in mold
component to part de!ign in core plate and al!o machining
the e'ector hole!.
8. Polis4ing- t i! manual proce!! to remo)e the wa!te
particle! on metal !urface!.
9. #ssembl:- %fter fini!hing all the machining proce!!
the a!!embl# of tool loo* li*e! the below image
/.* T( R DI& "MPN&NT$-
"he tool contain! core, ca)it#, e'ector, e'ector bac* plate,
bottom plate and !pacer, return pin!, !prue bu!h, e'ector
pin!, bu!he! etc
/.*.* "R& P(#T&-
n in'ection mold tool core plate i! u!ed to attach the
entire product de!ign and al!o attached e'ector pin!,
leader bu!h and return pin!.
1ig. @3 +ore plate
/.*.. "#+IT, P(#T&-
Generall# in ca)it# plate i! u!ed to hold the ca)it# !ide of
the product. 8ut here in thi! pro'ect the !elected part
contain! flat !urface and thinner becau!e of thi! nothing i!
de!igned about part related in ca)it# plate, 'u!t u!ed a!
!upport plate.
1ig. A3 +a)it# Plate
/.*.) &'&"TR-
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
t i! u!ed to hold the e'ector pin! !prue, pu!h bac* pin!
and !upport pillar!
1ig. 1?3 E'ector 1ront Plate
/.*./ &'&"TR 0#"% P(#T&-
E'ector bac* plate pu!he! the return pin! and e'ector pin!,
fi2ed in the plate. 1ig no % i! the e'ector bac* plate.
1ig.113 E'ector bac* plate
/.*.1 0TTM P(#T&-
t i! u!ed to hold or handle the remaining mold part! li*e
return pin! with bu!he!...
1ig.123 8ottom plate
/.*.2 $P#"&R-
Spacer bloc* i! placed between bottom plate and the core
!upported plate to gi)e! !pace for e'ection proce!!.
1ig3 Spacer
/.*.6 $PR!& 0!$5-
Through Sprue hole molten metal enters
into the die.
1ig.153 Sprue 8u!h
/.*.9 #$$&M0(&D T( ;R< M!(D-
"ool component! a!!embled b# u!ing guide pillar!, return
pin!, e'ector pin!, e'ector bac* plate return pin!, bu!he!,
bolt! and with locating ring.
1ig.163 "ool +omponent!
1ig.173 %!!embled Die
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
+. PRD!"T ;R< P#RT
M#N!F#"T!RING-
Product manufacturing i! nothing but pla!tic part
manufacturing b# u!ing in'ection molding proce!!. Pla!tic
i! a good engineering material for mo!t product!. %ll
pla!tic! material! are pol#mer!, the!e pol#mer! are
di)ided into two t#pe! in that fir!t one i! "hermopla!tic!
and the !econd one i! "hermo!et!. "hermopla!tic material
melt! when heated and reformed again and again.
"hermo!et! harden when the# are heated, later it will lo!e
their propertie!. B!ing "hermopla!tic t#pe material for
product manufacturing, becau!e the!e t#pe material! are
softer, fle=ible and it contain! low melting point
temperature.
1.* PRP&RTI&$ F P(#$TI" M#T&RI#($-
n the below table mentioned !hort term propertie! of
!ome important pla!tic material!
Material
Densit:
kg>m)
Fle=ural
modulus
GN>m.
?
elongation
at break
%8S 1?6? 2.2 @
PC+ 15?? ?.??9 5??
P"1E 21?? ?.7 2??
PEEK 15?? 5.@ 6
Epo2# 12?? 5.? 5
&#lon 44 116? 2.@ 4?
Pol#thene A2? ?.2 6??
Pol#imide 162? 2.7 @
Pol#prop#lene A?7 1.7 17?
Pol#carbonate 117? 2.@ 1??
"able 23 General propertie! of pla!tic material
>n den!it#(weight ba!i!, ha)e !elected the PP
<Pol#prop#lene= material for part production.
1.. PRP&RTI&$ F PP M#T&RI#(
n Pol#prop#lene material, identified !ome of the
!ati!factor# propertie! for production or molding. n thi!
den!it#, percentage elongation at brea*, !hrin*age
percentage there are the con!idering propertie! to ta*e for
the production.
Material Pol:prop:lene
Den!it# <*g(m5= A?7
;all "hic*ne!! <in= ?.?27 D ?.17?
Ma2. >perating "emp <E+= 1??
"hermal conducti)it# <w(m(*= ?.2?
"en!ile Strength<M&(m2= 55
1le2ural modulu! <G&(m2= 1.7
F elongation at brea* 17?
mpact Strength <ftGlb(in= ?.6 D 1.2
Melting point "emp<E+= 197
F of Shrin*age 1.7
"able 53 PP Material propertie!
1.) $T#ND#RD IN'&"TIN "("(& TIM&-
Mold +lo!e 3 1G2 !ec
n'ection 3 2G7 !ec
Pac* and Hold 3 @G1? !ec
Part +ooling 3 1?G2? !ec
Screw return 3 2G7 !ec
Mold open 3 1 !ec
E'ection 3 1 !ec
"he total in'ection c#cle time3 27 D 66 !ec
"hi! time change! depend! on product comple2it#
1./ PRD!"TIN PR"&$$-
%fter loading the tool into in'ection molding machine the
material pellet! are melted and in'ected into the mold.
Bnder the pre!!ure, the molten material i! forced in to
mold through !prue. "he mold i! held under pre!!ure until
the material cool! and harden!. >nce the material
harden!, the mold i! opened and the part i! remo)ed. %nd
the proce!! can be repeated. "he !tandard in'ection c#cle
time i! 27 to 66 !ec, thi! time will )ar# depend! on part
de!ign.
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
1ig.143 PP Material Pillet!
1ig.193 Production Proce!! c#cle
Part de!igned according original dimen!ion! with
including !hrin*age percentage of PP material that i!
1.7F, with re!pect to part thic*ne!!, length and width
1ig.1@3 "ool loading into machine
"hat, "he 1inal dimention! of the core de!ign dimention!
are original dimention! with include! 1.7 F of part !i0e!
1ig.1A3 "hree ca)it# tool with material filling
1ig.2?3 +ombination of multiple part! and !ingle part
n figure number 2?, i! the final fabrication product of
ga!*et application, in thi! fir!t one referring e2pected
fabrication re!ult for multiple ca)it# part! and another one
i! !ingle part of ga!*et. "otal output product weight i!
1A.1 gram!, in total weight !ingle part den!it# i! 4 gram!
remaining ?.1 gram! i! related to wa!te material.
Process parameters $pecified #ctual
"emperature
<=
HoneG1 2??G21? 2?7
HoneG2 1@?G2?? 1A?
HoneG5 19?G1A? 1@?
HoneG6 14?G1@? 19?
n'ection
parameter!
n'. Pre!!ure A?G11? 1??
n'. Speed ?@G11 A
,efill
Parameter
,efill !peed 9?GA? @?
+#cle time
n'ection time ?5G?4 7
+ooling time 1?G2? 17
"otal time 2@ 2@
,aw
material
PP G +P M 575?
"able63 1abrication proce!! parameter!
+I. PTIMI@#TIN
n thi! pro'ect optimi0ation proce!! can di)ided into three
wa#!. 1ir!t one i! Proce!! >ptimi0ation and !econd one i!
Production rate final proce!! i! +o!t optimi0ation
2.* PR"&$$ PTIMI@#TIN-
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
% change happen! in machining proce!! of core and
ca)it# plate. "otal part de!ign machining core plate it!elf
there no de!ign ca)it# plate it i! u!ed doe !upported plate
for pac* and holding proce!!.
2.. PRD!"TIN R#T&-
1or increa!ing the production rate, manufacturing
multiple part die for producing multiple part! per c#cle.
2.) "$T PTIMI@#TIN-
"he important co!t effecting parameter! are in'ection
molding c#cle time, metal and material co!t, tooling co!t
and production co!t.

1or co!t optimi0ation !elected !ome factor! the!e factor!
are3
2.).*. TT#( M#N!F#"T!RING "$T
"M+ I M J " J P
"M+ I "otal Manufacturing +o!t
M I Material
" I "ooling
P I Proce!!ing
2.).. M#T&RI#( "$T P&R P#RT
cM I M(:
I <co!t(weight 2 weight= ( number of part!
cM I cw <wp J ww=
I cw <wp J wp=
cM I cw wp <1J=
5ereA
M I "otal material! co!t! <raw=
K I production :uantit#
cM I Lco!t(weightM Lweight(no of part!M
cM I <co!t(weight= <weight(part=
cM I co!t(part
cw I material co!t per unit weight, and
wp I weight of fini!hed part
ww I weight of wa!ted material, !crap
I ratio of wa!ted material weight
( fini!hed weight
I ww ( wp
2.).) T(ING "$T P&R P#RT
+" I "(:
" I "otal co!t of mold!, fi2ture! per c#cle
K I &umber of part! per run
2.)./ PR"&$$ING "$T P&R P#RT
+P I +t .t
;here,
+t I co!t per hour, <machine rate J labor=
t I c#cle time <hour! per part=
2.).1 TT#( "$T P&R P#RT
+o!t per part,
+ I +M J +" J +P <>,=
+ I cw wp <1J= J "(: J +t t
+o!t e!timation calculation! done b# u!ing co!t effecting
parameter! and co!t optimi0ation factor!
+II. R&$!(T$
,e!ult! entered in the following table format, form thi!
ea!# to e!timate co!t difference! in between !ingle ca)it#
and multi ca)it# production proce!!
#lternatiBe
Part Per
":cle
Part Per
":cle
Multiple Per
":cle
Mfg.
Proce!!
n'ection
molding
n'ection
molding
n'ection
molding
Material
PC+
<1le2=
PP PP
Part ;eight @.5 4 4
%lpha ?.?1 ?.?1 ?.?1
Material
+o!t <*g=
A? A? A?
"ooling +o!t 52??? 52??? 57???
Production
:uantit#
7???? 7???? 17????
+#cle "ime 27 27 2@
Machine
,ate
6?? 6?? 6??
Per Part
+o!t
7 7 1.@7
&ote3 Material co!t information gathered from mar*et
"able 7- Manufacturing co!t anal#!i!
n table, for multi ca)it# column production :uantit# i!
17???? for 7???? c#cle! <5 part! per c#cle=.
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International Journal of Advanced Engineering Research and Science (IJAERS)
[Vol-1, Issue-3, Aug- !1"#
ISS$% 3"&-'"&(
+III. "N"(!$IN
"hi! re!earch paper gi)e! effecti)e information about
de!ign, manufacturing and optimi0ation proce!! of
in'ection mold tool and multi ca)it# part production.
1or an effecti)e part de!ign u!e! %uto+%D and in'ection
mold tool de!igned in BG !oftware.
Multi ca)it# die manufacturing purpo!e u!ed +&+
milling machine, !urface grinding machine, ;ire EDM
profile mea!uring machine.
8ecau!e of no comple2 profile !hape of part de!ign,
Entire multi ca)it# part de!ign done in core plate it!elf not
in ca)it# plate, it i! u!ed a! atop plate a! well a! ca)it#
!upported plate. "hi! machining proce!! come! under
optimi0ation of tool de!ign.
Maintain the :ualit# of tool u!e! profile mea!uring
machine and al!o u!ed to a)oiding the macro le)el
difference! in edge le)el.
1or part production u!e! PP material, to o)ercome the
e2i!ting material drawbac*!
"he minimum production c#cle time i! 27!ec/ thi!
duration i! almo!t all !ame for !ingle ca)it# and two
ca)it# part production. %! per e2perimental re!ult! for
three ca)it# production proce!! c#cle time i! 2@ !ec.
n'ection time i! cau!e! for thi! )ariation of time between
!ingle and three ca)it# part manufacturing.
E2perimental production c#cle time cau!e! for co!t
minimi0ation, thi! ha! !hown in re!ult! table.
"he following effecti)e conclu!ion! are deri)ed from the
pro'ect re!ult!3
1. ncrea!ing the production rate b# de)eloping the multi
part die.
2. Machining co!t reduced b# pro)iding effecti)e tool
de!ign
5. 8ecau!e of thi! multi part production c#cle time i!
cau!e to reduce the manufacturing co!t.
R&F&R&N"&$
L1M Shige#u*i haru#ama Nnternational Oournal of Pre!!ure
Ce!!el! and Piping, nfluence of Surface roughne!! on lea*age
of new metal Ga!*etP
L2M -S.Sel)ara'. NDe!ign and 1abrication of an n'ection
Moulding "ool for +am 8u!h with 8affle +ooling +hannel and
Submarine GateP
L5M -Oagannatha ,ao M 8., -Dr. ,amni. , N%nal#!i! of Pla!tic
1low in "wo Plate Multi +a)it# n'ection mould for Pla!tic
+omponent for Pump SealP
L6M -QiG:iG;ang., -OaeG g#u Kim., -OungG il Song.,P>ptimi0ation
of pla!tic n'ection Moulding Proce!!e! Parameter! for
manufacturing a bra*e boo!ter )al)e bod#P.
L7M Shige#u*i Haru#ama a, Didi* &urhadi#anto b,c,R, Moch
%gu! +hoiron d, Ken Kamini!hi, Nnfluence of !urface
roughne!! on lea*age of new metal ga!*etP
L4M Sampath.%, Hemanth.,, N+>&+EP"B%S DESG& >1
&OE+">& M>SD ">>S 1>, "HE +H%, H%&D ,ES"
+>MP>&E&"P.
Page | 45