Design Guidelines Injection Moulding
Transcript of Design Guidelines Injection Moulding
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PRESENTATION
BY
MR ANSHUMAN KUMAR AGGARWAL
DIRECTOR
INDIAN DIECASTING INDUSTRIES, ALIGARH
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INDIAN DIECASTING
I N D U S T R I E S
ISO:9001
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Journey of: Indian Diecasting Industries
Founded by Shri Pramoad Kumar Aggarwal ji with self made pneumatic hot chamber diecasting machine
Added Aluminium Diecasting and developed more than 1000 parts for Automotive OEMs, MNCs
1965 2013
Manufactures 1 Million parts consuming 20-25 MT Zn and 40-60 Tons Al every month.
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About: Indian Diecasting Industries
1. We are a knowledge based and environment friendly company
2. We are not a bulk producers. 3. We manufacture premium quality diecast parts in
complex shapes and designs with minimal porosity, hardware surface finish and wall thickness less than 1mm within close limits in areas of angularity, perpendicularity, concentricity, center distances, parallelism, run outs and eccentricity.
4. Presently ISO:9001 certified, going for TS:16949
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Industries Served By: Indian Diecasting Industries
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Customers: Indian Diecasting Industries We are Tier-1 / Tier-2 Suppliers to following OEMs / MNCs:
Automotive (Tier-2 Suppliers to): •TVS •New Holland •Hero Honda •Fiem •Mahindra & Mahindra •Varroc •Pricol •Mitsubishi •Lombardini •Continental •Autolek •Tafe •Veethree
•Home Appliances: •Videocon •Whirlpool
•Electric Switch-Gear: •Schneider Electric •Havells •Legrand •Indo Asian •Standard Electricals •Anchor
•Home Appliances: •Videocon
•Bathroom Fittings: •Roca •Misc-Small
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Infrastructure: Indian Diecasting Industries
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Images of Few Critical Zinc Diecast Parts Developed By:
Indian Diecasting Industries
10 Sliders 186 Dimensions All within tolerance
External Threads with 6g Go/NoGo Bore Dia within 0.018MM As Cast
Dia 0.9MM 10 MM Deep As Cast
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Images of Few Critical Al Diecast Parts Developed By:
Indian Diecasting Industries
Max Thickness 0.5 MM Weight 0.9 Grams
Hyper Eutectic Al Alloy (B390) having Si>18% For Exports to Automotive OEM
First shot success rates DME Mould Base Used Made on DMG-VMC
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Images of Few Critical Dies Developed By:
Indian Diecasting Industries
With Chiller
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Sharing of Learning & Improvements By
Indian Diecasting Industries, Aligarh Through United Nations Common Fund for Commodities (UN CFC) project
Managed By
The International Zinc Association( IZA)
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Team Indian Diecasting Industries
is thankful to
Mr Joseph Annets
(World’s most renowned Zinc Diecasting Expert)
For sharing his hard earned experience in suggesting improvements and answering
hundreds of our questions.
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Visits of Mr Josef Annets to: Indian Diecasting Industries
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Diamond Handle: Problem of Micro Porosity at Parting Line
Diamond Handle-Casting
Parting Line
Diamond Handle-After Parting Line Grinding
Problem of Micro Porosity observed after grinding or buffing
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54 mm2
Gate Area 80 mm2
Main Runner Start Area 176 mm2
Sprue End Area
Main Runner End Area 60 mm2 Sprue Start Area
176 mm2
Nozzle Area Dia 8=50 mm2
Diamond Handle: Root Cause Analysis of Problem
Section Area (mm2)
Nozzle –Dia 8mm 50
Sprue upper 176
Sprue base 176
Main runner start 81
Main runner end 60
Gate 54
Are
a S
hould
decre
ase fro
m N
ozzle
to G
ate
But
its n
ot
happenin
g h
ere
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Diamond Handle: Root Cause Analysis of Problem
During running there was big variations of temperature at different areas of die
Moving Insert (Deg Celcius) 130 to 145
Fix Insert (Deg Celcius) 170 to 197
Sliding Cores (Deg Celcius) 255 to 260
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Diamond Handle: Changes Made in Die
Change in Nozzle Design
Earlier After Modification
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Diamond Handle: Changes Made in Die
Change in Sprue Design
Earlier After Modification
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Diamond Handle: Changes Made in Die
Change in Nozzle Fitment in Fix Half of Die
Earlier After Modification
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Diamond Handle: Changes Made in Die
Change in Diffuser design
Earlier After Modification
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Diamond Handle Evaluating Modifications
Section Area (mm2)
Before
Area (mm2)
After
Nozzle Dia 8 = 50 Dia 11 = 95
Sprue upper 176 83
Sprue base 176 83
Main runner start 81 81
Main runner end 60 60
Gate 54 54
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54 mm2 54 mm2
Gate Area 81 mm2 81 mm2
Runner Start Area
176 mm2 83 mm2
Sprue End Area
Runner End Area 60 mm2 60 mm2
Sprue Start Area 176 mm2 83 mm2
Nozzle Area 50 mm2 95 mm2
EARLIER DESIGN DESIGN AFTER MODIFICATION
Diamond Handle: Evaluating Modifications
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Diamond Handle: Evaluating Modifications
Variations in temperature at different areas of die was controlled as below
Earlier After Modification
How?
Moving Insert (Deg Celcius)
130 to 145 150 to 170 Focused 1 spray nozzle
Fix Insert (Deg Celcius)
170 to 197 160 to 175 Focused 1 spray nozzle
Sliding Cores (Deg Celcius)
255 to 260 170 to 185 Focused 1 spray nozzle
on each slider
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Other Benefits After Modifications: Improvement in Yield
Re Introduction to Yield:
Shot Wt: 200 Gms Part Wt: 100 Gms
Casting Yield = 100/200 = 50%
= +
Runner / Overflow / Sprue Wt: 100 Gms
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Part Name: Handle Diamond Monthly Production: 40,000 Pcs
Earlier
After Modification Shot Weight=Part Wt (168) + Runner/Overflow Wt (137)
= 305 Gms Shot Weight=Part Wt (168) + Runner/Overflow Wt (80)
= 248 Gms
Yield: (168/305)X100=55% Yield: (168/248)X100=68%
Material Requirement: 0.168Kg/Pc X 40,000Pcs=6,720Kg Material Requirement: 0.168Kg/Pc X
40,000Pcs=6,720Kg Melting Lot (Kg) Casting (Kg) Recycle (Kg) Melting Lot (Kg) Casting (Kg) Recycle (Kg)
6,720.000 3,696.000 3,024.000 6,720.000 4,569.600 2,150.400
3,024.000 1,663.200 1,360.800 2,150.400 1,462.272 688.128
1,360.800 748.440 612.360 688.128 467.927 220.201
612.360 336.798 275.562 220.201 149.737 70.464
275.562 151.559 124.003 70.464 47.916 22.549
124.003 68.202 55.801 22.549 15.333 7.216
55.801 30.691 25.111 7.216 4.907 2.309
25.111 13.811 11.300 2.309 1.570 0.739
11.300 6.215 5.085 0.739 0.502 0.236
5.085 2.797 2.288
2.288 1.259 1.030
1.030 0.566 0.463
0.463 0.255 0.209
12,217.803 6,719.791 5,498.011 9,882.005 6,719.764 3,162.242
Total Melting 12,218 Kg Total Melting 9,882 Kg
Total Casting 6,720 Kg Total Casting 6,720 Kg
Other Benefits After Modifications: Improvement in Yield
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SAVINGS-AFTER IMPROVING YIELD SAVING IN FUEL
Total Melting (Earlier @ 55% Yield) 12,218 Kg
Total Melting (After Improving Yield to 68%) 9,882 Kg
Less Melting Done 2,336 Kg
Average LPG Consumption in Zinc Melting/Holding Crucible 3 Kg/Hr
Melting Crucible / Pot Capacity 180 Kg
Time required to melt 180 Kg 1.5 Hrs
LPG Required to melt 2335.798 Kg Zinc 58.4 Kg
LPG Rate 80 Rs/Kg
LPG Savings 4672 Rs
SAVING IN BURNING LOSS Less Melting Done 2,336 Kg
Average Burning Loss 5%
Zinc Alloy Rate (May'2013) 140 Rs/Kg
Material Saving by doing lesser melting 116.8 Kg
Amount saved by doing lesser melting 16352 Rs
Other Benefits After Modifications: Improvement in Yield
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• 19% saving in material recycling.
• 19% saving of LPG Gas.
• Reduction in material handling
• 1% material saving due to reduced burning losses
• Contribution to Environment by saving Fuel & Material
CONCLUSION
Other Benefits After Modifications: Improvement in Yield
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Diamond Handle: Further Proposed Improvements
Shot Wt: 230Gms Part Wt: 168 Gms Runner/Sprue Wt: 62 Gms
Casting Yield = 168/230 = 73%
Will get increased further from existing 68% to 73%
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Improvements in Runner Design-Mounting Plate (2nd Die)
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Development of New Part: Ring Result-High Quality finish from 1st Shot
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Development of New Part: Heat Sink Result-High Quality finish from 1st Shot
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THANK YOU
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Any Question?