Plastic Injection Moulding Dies

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Plastic Injection Moulding Dies
Summer Training Project Report
Submitted in partial fulfillment of the requirements for the degree of
Bachelor of Technology (B.Tech)

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Table of Contents
1 Introduction ................................................................................................................. 6
2 Feasibility Report ........................................................................................................ 7
3 Requirement Specification ........................................................................................ 22
4 Design Specification ................................................................................................. 33
5 Conclusion ................................................................................................................ 51
6 Checklist ................................................................................................................... 53
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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, were 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.
Feasibility Report / ME
FEASIBILITY Report
Plastic Injection Moduling Dies
Page 1-1 of 50
TABLE OF CONTENTS
1.1 Purpose 9
1.2 Scope 9
1.3 Project References 9
1.4 Acronyms and Abbreviations 9
1.5 Points of Contact 10
1.5.1 Information 11
2.1 Organizations Involved 12
2.2 Equipments 12
2.3 Performance Objectives 13
2.4 Assumptions and Constraints 14
2.5 Methodology (Basic Principle Involved) 14
2.6 Recommendation 15
3.1 Description of Design / Fabrication of Proposed System / Model 16
3.2 Time and Resource Costs 17
3.3 Rationale for Recommendations 18
4.0 Description of [Alternative Mechanism / Design of System / Model] 19
Page 1-2 of 50
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1.0 GENERAL INFORMATION
1.1Purpose
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.
1.2Scope
Injection-moulded plastic parts are part and parcel of everyday life. Be they mobile phone casings, beverage crates,
toy figures, gearwheels 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 .
1.3 Project References

Engage polyolefin elastomers have a wide processing temperature window. The following
temperatures should be used as a reference point and can vary±5°C. These temperatures should
be usedas a starting point and can be increased by a maximum of +20°C.Note: From starting
point, the hopper feed throat should be cooled below 50°C to avoid polymer bridging, especially
on Engage®8400/Engage® 8407.Successful injection molding of Engage® requires fast
injection velocities to promote shear thinning throughout the material. Typical polyolefin
equipment should be used.
 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.
1.4 Acronyms and Abbreviations

Acronyms with
Definition Language Category
MOLDING
Acronym in Science, Unit Measure, Chemistry,
AMC Advanced Molding Compound
English Biology, Acronym
Page 1-3 of 50
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

DMC Dough Molding Compound

GMVC Gentle Molding Vision Center

IMM Injection Molding Machine
IMT Injection Molding Technology
1.5 Points of Contact

1.5.1 Information
I’ll take the help from the company.With the help of several machines like
lathe,milling,drilling,shaper etc. or even CNC machine,we used for making the core and cavity
of the sample and these two dies(core and cavity) goes for surface finish.Now,the core and cavity
will fitted together with support plate on their either sides,the complete die will subjected to the
injection moulding machine where the raw granular plastic will suffers through the heater and
the molten plastic will subjected to the middle of the core and cavity through a hole called sprue
bush 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.
Page 1-4 of 50
Page 1-5 of 50
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2.0 MANAGEMENT SUMMARY
2.1Organizations Involved
Omax Auto Ltd.
2.2Equipment
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).
2.3 Performance Objectives (Efficiency)
Page 1-6 of 50
If we use cast iron material for a making of any plastic mold,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.
Page 1-7 of 50
2.4 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.
2.5 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, Qcool, required to cool the
polymer melt is related to the change from the melt temperature, Tm, to the ejection temperature,
Te, the heat capacity of the plastic melt, CP, and its mass, m:
Qcool  CP  m  Tm  Te  [J ]
The energy per square meter of surface area, Q, can also be considered as a function of the wall
thickness, h:
Q  CP    h  Tm  Te  [ J / m 2 ]
The average cooling power per square meter, Pcool, is:

CP  h    Tm  Te 
Pcool  2
[W / m ]
tcooling
The cooling time, tcooling, can be estimated using one-dimensional heat transfer as [5]:
Page 1-8 of 50
h2    T  T 
t cooling  ln   m c 
2  4  Te  Tc 
where is the thermal diffusivity and Tc 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:
tcooling  4  h 2
2.6 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
- 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 polymers.
Page 1-9 of 50
3.0 PROPOSED SYSTEM
3.1 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).
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
Page 6 of 50
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.
3.2 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
Page 6 of 50
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.
3.3 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
Page 6 of 50
4.0 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.
4.0 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 greaterclamping 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
Page 6 of 50
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.
Page 6 of 50
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Requirements Specification
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Table of Contents
1. Revision History 24
1. 2. Approved By 25
2. Introduction 26
2.1 Purpose 26
2.2 Document Conventions 26
2.3 Reading Suggestions 26
2.4 Project Scope 26
2.5 References 27
3. Overall Description 27
3.1 Product Perspective 27
3.2 Assumptions 28
4. Equipment / Component 28
4.1 Give the of names of each Component 28
4.2 Specification of each Component 28
4.3 Material of the Component used 29
4.4 Basic Principle of Working of Component 30
4.5 Material of the Component used 30
5. Other Requirements 30
Appendix A: Glossary 31
Appendix B: Analysis Models 32
Appendix C: Issues List (Optional) 32
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1.Revision History
Version Name Reason For Changes Date
1.0 Initial Revision
Page 6 of 50
2. Approved By
Approvals should be obtained from faculty/ HOD
Faculty comments :
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
_____________________
Faculty name: faculty signature
_____________________________
__________________________
Project coordinator project coordinator signature
_____________________________
__________________________
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Introduction
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.
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)
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
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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.
References
 Bryce, Douglas M. Plastic Injection Molding: Manufacturing Process

Fundamentals. SME, 1996.
 Brydson, J, Plastics Materials, Butterworths 9th Ed (1999).
http://www.mold-mould.com/conventional-injection-molding-
machine-289.html
Overall Description
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.[1] After a product is designed, usually by
an industrial designer or an engineer, molds are made by a moldmaker (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
moldUses 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 andbosses 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.
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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 machineor 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:
Equipment / Component
Give the of 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
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
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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 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.
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 plastication—pressure injection—mold filling and cooling --startup
mould. Closed modules after remove mold parts then go ahead next cycle.
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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.
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Appendix A: 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.
Appendix B: Analysis Models

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Appendix C: Issues List (Optional)

In this list the following pending decisions, information that is needed, conflicts awaiting
resolution are lefted:
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
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Design Specification
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Table of Contents
1. Revision History 35
2. Approved By 36
3. Introduction 37
3.1 Document Outline 38
3.2 Document Description 41
3.2.1 Introduction ............................................................................................................. 41
3.2.2 System Overview .................................................................................................... 42
4. Design Considerations 45
4.1 Assumptions and Dependencies 45
4.2 General Constraints 45
4.3 Goals and Guidelines 45
5. Design and Calculations 47
5.1 Drawing of the each Component being used 47
5.2 Design and Calculation of the Component being used 48
6. Glossary System Architecture 49
7. Bibliography 49
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1. Revision History
Version Name Reason For Changes Date
1.0 Initial Revision
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2. Approved By
Approvals should be obtained from faculty/ HOD
Faculty comments :
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
_____________________
Faculty name: faculty signature
_____________________________
__________________________
Project coordinator project coordinator signature
_____________________________
__________________________
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3. 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
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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).
3.1 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
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.
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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 stared.
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.
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.
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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.
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3.2 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
3.2.1 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
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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 lay man'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..
3.2.2 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
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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, ultra-sonic 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.
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4. Design Considerations
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.
4.1 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, ultra-sonic welding, spin welding, vibration and laser welding.
4.2 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
4.3 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
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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
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5. Design and Calculations
5.1 Drawing of the each Component being used
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5.2 Design and Calculation of the Component being used
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
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6. Glossary System Architecture
1. Granules of plastic powder (note the plastics listed above) are poured or fed into a
hopper which stores it until it is needed.
2. A heater heats up the tube and when it reaches a high temperature a screw thread starts
turning.
3. A motor turns a thread which pushes the granules along the heater section which melts
then into a liquid. The liquid is forced into a mould where it cools into the shape (in this
case a DVD storage unit).
4. The mould then opens and the unit is removed.
7. Bibliography
1. Injection Molding Handbook By Tim A. Osswald, Lih-Sheng Turng, Paul J.
Gramann
2. http://www.cadmodels.biz/3d_cad_design_for_injection_molded_plastics.html
3. http://www.custompartnet.com/wu/InjectionMolding#cost_drivers
4. http://www.vero-software.com/products.php?page_id=1&sub_id=4
5. http://www.efunda.com/designstandards/plastic_design/plastic_intro.cfm
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2 Conclusion
I hereby conclude that we have submitted all the documents related to our project in
the correct format as specified.
We conclude that our project is a simple project for now as it works according to the
user. We have been implementing iterative server, and later on it can be extended to
become concurrent server. It is easier for the programmer to use the code and
understand the functionality.
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3 Bibliography
1. Injection Molding Handbook By Tim A. Osswald, Lih-Sheng Turng, Paul J.
Gramann
6. http://www.cadmodels.biz/3d_cad_design_for_injection_molded_plastics.html
7. http://www.custompartnet.com/wu/InjectionMolding#cost_drivers
8. http://www.vero-software.com/products.php?page_id=1&sub_id=4
9. http://www.efunda.com/designstandards/plastic_design/plastic_intro.cfm
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4 Checklist
1. Is the report properly hard/ spiral bound? Yes / No
2. Is the Cover page in proper format? Yes / No
3. Is the Title page (Inner cover page) in proper format? Yes / No
4. (a) Is the Certificate from the Company in proper format? Yes / No
(b) Has it been signed by the Manager? Yes / No
5. (a) Is the Acknowledgement from the Student in proper format? Yes / No
(b) Has it been signed by the Student?
7. Does the Table of Contents include page numbers? Yes / No
(i). Are the Pages numbered properly? Yes / No
(ii). Are the Figures numbered properly? Yes / No
(iii). Are the Tables numbered properly? Yes / No
(iv). Are the Captions for the Figures and Tables proper? Yes / No
(v). Are the Appendices numbered properly? Yes / No
8. Is the conclusion of the Report based on discussion of the work? Yes / No
9. Are References or Bibliography given in the Report? Yes / No
Have the References been cited inside the text of the Report? Yes / No
Is the citation of References in proper format? Yes / No
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10. A Compact Disk (CD) containing the softcopy of the Final Yes / No
Report (preferably in PDF format) and a Final Project
Presentation in MS power point only has been placed in a
protective jacket securely fastened to the inner back cover of the
Final Report. Write the name and Roll No on the CD.
Declaration by Student
I certify that I have properly verified all the items in the checklist and ensure
that the report is in proper format as specified in the course handout.
Name:
Place:
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1.0 GENERAL INFORMATION

1.3 Project References

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

1.4 Acronyms and Abbreviations

Aligned Short Fiber Sheet Acronym in General, Common Abbreviation,

Acronym in General, Common Abbreviation,

Acronym in General, Common Abbreviation,

Acronym in General, Common Abbreviation,

Acronym in General, Common Abbreviation,

1.5 Points of Contact

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2.0 MANAGEMENT SUMMARY

each square inch of the projected areas.

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

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

2.3 Performance Objectives (Efficiency)

CNC m/c is higher than the different operation of machines.

2.4 Assumptions and Constraints

beneficially utilized in many commercial applications. Determine the assumptions and

2.5 Methodology (Basic Principle involved)

The average cooling power per square meter, Pcool, is:

1. 0.03mm diameter for use with polyethylene and polypropylene

3.0 PROPOSED SYSTEM

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

3.2 Time and Resource Costs

3.3 Rationale for Recommendations

1. Short shot, record 1. Adjust feed to minimum consistent cushion

1. Increase mould temperature

4.0 Alternative Mechanism/ Design