Final Project Me

PROJECT REPORT

PROJECT REPORT ON

SINGLE CAVITY HOT TIP MOULD IN

WORKORDER NO.822098N CUSTOMER-LARSEN &TOUBRO LTD. MUMBAI

By

ADTDM-04YOGESH V.NIKAM

ENROLL NO. =2004141

Production Department 1

PROJECT REPORT PROJECT REPORT

(A GOVERNMENT OF INDIA SOCIETY)

P-31, MIDC INDUSTRIAL AREA, CHIKALTHANA,AURANGABAD- 431210.

CERTIFICATE OF APPROVAL OF PROJECT WORK

This is Certify to The Mr. YOGESH VISHNU NIKAM, S/O

Mr.VISHNU NIKAM of ADTDM 2004 BATCH, Enroll no: - 2004141 has

successfully completed his project work in the Production

Department as implant training, a part of there ADVANCE DIPLOMA

IN TOOL & DIE MAKING (4 yrs.) in the partial fulfillment of course for

the award of Advance diploma in tool & die making from INDO

GERMAN TOOL ROOM, Aurangabad during the period of 12TH JAN.

2008 TO 31ST JULY. 2008.

The project has been approved as it satisfies the academic

requirements in respect of project work prescribed for the trainees.

PROD . MANAGER COURSE CO’OR. PROJECT GUIDE By

(T.A.

KARANDE)


PROJECT REPORT

I am very thankful to Mr. H.D.KAPSE (General Manager. Indo-

German Tool Room).

Mr.D.SIVAIAH (Sr. Manager Training) for assigning me does the live

project in the Design Department.

I would like to express my sincere thanks to Mr. T.A.Karande,

Mr. Mahesh kande, Mr.Yogesh Dxit, Mr. Amit Gajbhiye & Mr.

S.M.Shreerame for their expert guidance and valuable time. Also

thanks for the valuable guidelines and help from Mr. Vishal Sabde

and Mr. Kailash Gaikwad.

At last I would like to thank all the members of IGTR and collogues

for their Co-operation.


PROJECT REPORT This project reveals the effort taken during the implant training in

design department between the duration of 12th Jan 2008 to 31st

July 2008.

The project gives a brief introduction about the work accomplished

in design including the explored applications in ProE, Unigraphics &

other design related information.

This project is basically dependent upon different types of Moulds

such as Injection Mould; hot tip Mould & Compression Mould etc. It also

gives a view of design consideration involved in press tool, mould & die-

casting-dies. It gives the idea of the flow of design from the stage of

receive till dispatch of the tool.

Finally this project is an overview of the work in design department.


PROJECT REPORT


SR.NO.

DESCRIPTION

INTRODUCTION

DESIGN CONSIDERATION

PROCESSDESIGN & PROJECT DETAILS

COMPONENT DETAILS

COMPONENT MATERIAL

DETAIL MOULD CAL.& M/C DETAIL

PART DETAIL & ASSEMBLY DETAIL

PART LIST

PROCESS SHEET

JOB CARD

COST ESTIMATION

01

02

03

04

05

06

07

09

08

11

10

50-62

45-49

42-44

40-41

29-39

22-28

20-21

17-19

15-17

14

6-13

PAGE NO.

TOOL INSPECTION REPORT12 63-68

ACHIEVEMENT & CONCLUSION13 69-70

PROJECT REPORT

1 BASICSThe single most important component in the moulding process is the Mould. Some times cost of the mould overtakes machine cost and always plays a vital role in deciding the product cost.

Almost 70% of the plastic products are produced by Injection Moulding method among all the plastics processing techniques available so far. So it is obvious that a large number of Injection moulds are made everywhere. Accordingly a lot of developments in mould making techniques have taken place. Hot Runner Mould is one of such great achievements in mould making field.

1. EVOLUTION OF HOT RUNNER MOULDS

Shaping of plastic materials in an Injection mould, particularly in a multi-cavity one needs a well-laid feeding system. The feeding system carries the plastic melt, under pressure, from the nozzle of the injection moulding machine to the entry point of the mould cavity and the continuity of the pressure helps the melt to reach the extreme end of the impression. The receiving end of the melt is known as Sprue. The Sprue delivers the melt on the main feeding channel known as Runner and further branching of it is known as sub-runners. The narrow bridge between cavity and the runner or sub-runner is known as Gate. In general the combination of sprue, runner and sub-runners is regarded as RUNNER SYSTEM.

In conventional moulding process the runner system is always moulded and ejected along with the moulded article in every cycle. This moulded runner is use less and forcibly produced as waste because of the technological barrier. But elimination of the runner system in the conventional moulding process is not possible. On the other hand the total volume of the runners and sprue exceeds that of the mouldings in case of multi-impression moulds quite often. More volume means more cycle time, more manpower loss and there by


PROJECT REPORTmore wastage. One can argue of reusing the scrap as seconds and mixing to virgin material, but, still the process is uneconomical.

Paying a constructive attention to eliminating moulding and ejection of

the runner system is worth the effort. Evolution of HOT RUNNER

SYSTEM is the right result of such progressive thought. Incorporation

of the Hot Runner System in the conventional mould makes it a HOT

RUNNER MOULD.

The Hot Runner Mould consists of a runner system, which remain hot

and keeps the plastics in molten condition right up to the gate point all

along the production cycle. So the runner system is never moulded

and ejected unlike conventional mould in every cycle. On injection

only the cavities are filled to form the moulding. During ejection

stroke the moulding is degated and ejected out of the mould. Perhaps

this is the reason the hot runner mould is often called as runner less

mould.

1. TYPES OF HOT RUNNER SYSTEM

Hot Runner System gives an opportunity to make either hot runner

mould or semi-hot runner mould. Hot runner moulds eliminate the

entire runner system where the Semi hot runner moulds eliminate a

part of the runner system. choice for fabrication of such types of

moulds is left to user’s economic consideration as well as geometry

and aesthetic of the product.

The classification of Hot Runner Systems is subject to the kind of

heating provision available with it. They are two types in general, i.e.


PROJECT REPORTi. Externally Heated Hot Runner Systems

In this case the melt is heated from out side while passing through the feeding channel. Electrical heaters supply the heat.

ii. Internally Heated Hot Runner Systems

In this case the heater is placed inside the feeding channel and the melt is supplied with heat from inside.

A third variety of system is also available, known as Combination

System. In this type the runner system contains a mixture of both

externally and internally heated hot runner systems.Indirect heating

system.

This kind of heating system is limited to Hot Nozzles only. The indirectly heated nozzles do not have any dedicated heater. It receives the required heat from the manifold to which it is attached. This is why the nozzles for indirect heating should be made from good heat conducting materials like BeCu, Cu or other such alloys. The main advantage of this type is simplification of design. However their temperature can not be controlled directly and independently.

1. HOT RUNNER ELEMENTS

Various elements used in hot runner systems are broadly divided into

two types as per their function. These are Path Elements and

Heating System Elements.

Path Elements consists of the followings

i. Hot Sprue Bushing

ii. ManifoldProduction Department 8

PROJECT REPORTiii. Injection Nozzles

Heating System Elements consists of the followings

i. Heaters

ii. Temperature Sensors

iii. Temperature Controller

Hot Sprue Bushing

The hot sprue bushings are designated to remove the superfluous direct gate on single mouldings. Also this is used to carry plastic melt up to main runner in case of multiple gate design.

Manifold

The heart of the hot runner system is the ‘MANIFOLD’. Manifold is a heated block, which houses the runner system. Distribution of the melt to every gate points takes place in this heated block. Leading standard mould base and components’ manufacturers have standardized various types of manifolds and these are readily available. Apart from this, customized mould bases can be easily manufactured with respect to the runner system design.

Injection Nozzles

Injection nozzle also some times called as Secondary nozzles is a part of the hot runner system which provides as connecting flow path from the manifold block to the cavity entry point. There are a number of possible designs of these nozzles available in the market. Most commonly used are cylindrical in shape and usually incorporate a threaded section


PROJECT REPORTwhich screws into the manifold block. A leak free joint between nozzle and manifold is essential.

Heaters

In practice electrical heaters are normally used for heating. Different types of heaters are engaged to supply heat to different sections of the hot runner system. Catridge heater, Tubular heater, Band heater and Coil heater etc. are most commonly used one.

1. Catridge heatersMost Common method of manifold heating is done with catridge heaters. They are placed inside accurately drilled and reamed holes parallel to the runner. The advantage lies with easy replacement of the heaters. Catridge heaters are commercially available as standard part in various diameters, lengths and wattage.

2. Tabular heaters

3. Band heater

4. Coil heater

Temperature Sensors

The hot runner system remains hot during its entire operation. Temperature sensor is essential to keep track of the temperature of the manifold and other components. Different types of thermocouples are used to sense the temperature and give feed back to the controlling unit.

Temperature Controller

Hot runner moulds are extremely sensitive to temperature variation in nozzle and gate area. Even a change of a few degrees in temperature can interrupt the moulding process. Many times a high volume of rejections result because of temperature variation. Exact temperature control is, there fore, an important precondition for a good and automatically operating hot runner mould. Temperature controllers receive feed back from the heaters with the help of thermocouples and


PROJECT REPORTregulate the temperature of by varying the current supply. In principle each nozzle should be controlled individually for easy and smooth flow of the melt. Dedicated controllers are now available which houses a number of controllers to control multiple zones of the hot runner system.

1. ADVANTAGES AND DISADVANTAGES

2. ADVANTAGES

BENEFITS REASONS

1. Savings in material

No sprue or runner is produced

C

OM

MER

CIA

L

2. Savings in cost for

regrind

3. No investment for

grinder

4. No Investment for

robotized runner picker

5. Savings in storage cost

for scrap

6. Shorter cycle Moulding of the sprue and

runner is eliminated7. Shot size is reduced by

volume

8. Larger shot volume is

available for filling

larger number of

cavities

9. Cooling timeis reduced

10. Smaller opening stroke

than for a three plate

mould


PROJECT REPORT11. Ease of manufacturing Standard parts for hot runner

system are easily available, i.e.

Sprue bushings

Manifolds

Nozzles

Heaters

Thermocouples

12. Less moving parts

compared to three

plate mould

Hot runner system become

integral and remain fixed to the

injection half

1. Simpler Automation of

the moulding process

Omission of the moulding of the

runner.

Abolition of the three plate

mould construction.

2. Increased flow length

for impression

Runner network acts as an

extension to the machine

barrel, thus length of flow is not

accountable.

3. Longer holding

pressure

Ideal positioning of the gate

allows it

4. Less pressure drop Diameter of the sprue and

runner is machined to bigger

size

5. Dimensional

repeatability

Injection is possible right on the

component which improves

more homogenious feeding. 6. Increased mechanical

strength


PROJECT REPORT

DISADVANTAGES

FLAWS REASONS1. More work is

necessary in mould

design

Experienced designers are

required

CO

MM

ER

CIA

L

2. Higher mould cost Incorporation of auxiliary

equipment’s like Nozzles, Heaters,

Temperature sensors,

Temperatures etc.

3. Unit cost goes up

incase of low

production

requirement

4. Costly maintenance Careful handling is essential. Also

repair due to wear & tear and

damage costs more

1. Hazardous Thermal degradation of some

sensitive material. TEC

DESIGN CONSIDERATION

Moulds:-

Material used for the component, its applications.

Shrinkage of the material.

Calculate the weight of the component.

Study the detail of the component.

Type of mould required for the component to be produced.


PROJECT REPORT Machine available for the component.

Injection pressure required.

Type of runner system & gate required.

Type of ejection system weather blade, stripper etc.

Split and side core consideration if the component is having

any groove or notch on its sides.

Cycle time required for the component for complete fill.

Effective cooling in a short duration is necessary.

Cooling channels must be lick proof.

Selection of the material for core & cavity.

Adding of shrinkage to core & cavity dimensions.

Parts in the assembly must not foul with each other in

operation.

The layout of the tool must not be oversized

SINGLE CAVITY HOT TIP MOULD

FOR BOTTOM HOUSING

Component detail


PROJECT REPORT

Customer gives information to the marketing department regarding their requirement. Before starting the design activities following things should be make clear with the customer.

The component related input from the customer may be in the form of

2D Component Drawing

3D Component Model

Existing Sample of Component

The Tool related input from the customer may be in the form of

Type of Mould / Die

No. of Cavities

Production Rate

The Material related input from the customer may be in the form of

Component Material

Shrinkage

Component weight

Die Set Material

Core/Cavity Material

Production Department

1 Customer LARSEN & TOUBRO LTD,MUMBAI

2 Drg. No/Component Name BOTTOM HOUSING(DCL50809)

3 Projected Area(mm²) 90 sq.cm4 Component material POLYCARBONATE PC

943R(LAXAN)5 Material shrinkage 0.6%6 Material co-efficient of friction of

plastics with steel µ 0.5

7 Bulk factor 1.758 Molding temperature 300 0C9 Component weight (single) 33 grms

10 Density of Polycarbonate 1.20 gm/cu.cm

15

DESIGN INPUT

PROJECT REPORTAesthetic & Functional Requirements of Component that should be discussed with the customer are as follows

Type of gate

Location of gate

Parting Line Constraints

Ejection mark constraints

Other inputs required from the customer are as follows

Reference Information

Standard Parts

Side Core Actuation Method

Machine Specification

Tool details…

Hot tip mould preferred when quantity of production is more and time is limited. The quality of the mouldings bring a sense of hot runner moulds as advanced one where the others might be considered as obsolete. We can still go for the obsolete methods with an economic projection towards it. But in the long run HOT RUNNER SYSTEM brings more money.

The two plate Hot tip mould has been designed for single cavity system, provided with Pin point gating for auto degating. The tool with 354mm shut height and gross weight of 180 kg with ejection stroke of 42 mm.

Materials for the plates are taken as M.S./C-45 and for inserts it is ORVAR SUPREME also, based on the property of EN-31 we have selected it for guide pillar and guide bush. the slide is made of o.s material to Resist wear and tear during functionng.

Push back pins has been provided with springs as to assure the self return provision of the ejector assembly. The ejector assembly including ejector plate and ejector back plate has been supported by


PROJECT REPORTtwo ejector supports, it is also provided with two ejector guide pillar screwed with cavity back plate. Component has been feeded by point gate to assure minimum gate mark and self degating.

Sufficient cooling has been provide in tool to optimize cycle mark and to achive sound product. As the core in fixed half required cooling, to assure effective cooling we have provided cooling channel right from the bottom plate, the concept of cooling is not quite popular, provision of cooling has also been provided in moving half cavity insert.Every aspects and considerations of designing and manufacturing also has been taken in the tool to fulfill the requirement of the customer and fit to economy of the organization.

Component details…


PROJECT REPORT

Component details…


PROJECT REPORT

Material – Polycarbonate (PC)

Shrinkage – 0.6%

Density - 1.2 gm/cm3

Type of Polymer – Amorphous Thermoplastic

Injection Moulding Processing Conditions

Drying: Suggested drying conditions are 80-90 C (176-195 F) for a minimum for two hours. The material moisture content should be less than 0.1%.

Melt Temperature: 290-300 C Aim -300 C

Mould Temperature: 25-80 C (77-176 F). Mould temperature controls the gloss temperature; lower mould temperature produce lower gloss levels.

Material Injection Pressure: 50-100MPa

Injection Speed: Moderate-High

Project details…Production Department 19

PROJECT REPORT

Mould details

1 Moulding machine

SP80

2 Weight of feed system

0 grms.(approx.)

3 Total shot weight 33 grms.

4 Locating ring Dia 120f8 mm

5 Sprue bush Radius /Dia

R12/dia 5 mm

6 Minimum ejection stroke reqd. 42 mm

7 Type of ejection PIN & SLEEVE EJECTION.

8 Minimum day light

354 mm.

9 Total height 354 mm.

10 Overall mould size(HxLxW)

346x270x354

11 Total weight of mould 290 kg.

12 Weight of injection side 110 kg.

13 Weight of Ejection side 180 kg.

1.Weight Calculations :-


PROJECT REPORT

Weight of Component = Volume X Density

= 27.5 X 1.2

= 33 grams

NO FEED SYSTEM DUE TO HOT TIP MOULD

(C) Shot Weight Required

Shot Weight = 33 grams

2. SHOT CAPACITY:-

The screw type machine is normally rated in terms of “Swept Volume”

of the injection cylinder (Cu. Cms).

Machine Available is SP 80. For SP 80 Swept Volume is 49 cm3

Shot capacity (g) = Swept Vol. (Cm3) x p x C

p = Density of plastic at normal temperature (g/cm3)

C = 0.93 for amorphous materials.

Shot capacity (g) = 49 X 1.2 X 0.93

= 54.68 grams

3. PLASTICISING CAPACITY:

Plasticizing rate of material B (g/hr) = plasticizing rate of

material A (g/hr) x QA/QB


PROJECT REPORTA = Polystyrene

B = ABS (Material actually to be used)

Q = Thermal capacity of the material (cal/g) (Heat content)

QA = 239.4 KJ/Kg

QB = 302.4 KJ/Kg

Machine Available is SP 80, Plasticizing rate = 4.7 g/S

Plasticizing rate of material B (g/hr) = 4.7 X (3600/1000) X

(239.4/302.4)

PB= 13.395 Kg/hr

4. Locking Force Calculations:-

The clamping force required to keep the mould closed during injection must exceed the force given by the product of the opening pressure in the cavity and the total projected area of all impressions


PROJECT REPORTand runners. Lower clamping values can be used with screw presses owing to the lower injection pressures possible with these machines.

Thin sections need a high injection pressure to fill and therefore require more clamping force. Easy flowing materials like high melt index polyethylene and polystyrene fill more readily and hence require a lower clamping force. In the case of screw injection 2/3 to 1/2 times of injection Pressure should be taken for Clamping purposes. Max. Injection pressure may be obtained from press manufacture’s data sheet.

(A) Projected Area of the component = 9000 mm

(E) Total Projected Area =9000 mm

(F) Clamping Force = {Total Projected Area

X 1/2 Injection pressure}

= 1250 X 0.5 X 900

= 40 KN

(G) Locking Force = 1.2 X clamping force

(20% safety)

= 48 KN

Determination of number of Cavities:

The number of cavities in injection moulds is determined in most cases by the machine performance, but some times by the moulding shape or the mould locking pressure.


PROJECT REPORTDetermined by Shot Capacity:

(Based on 85% of rated shot capacity)

Ns = No. of cavities based on shot capacity

W = Rated shot capacity for particular polymer (g)

m = Moulding weight per cavity(g)

Ns = 0.85 X 54.68 / 33

= 1.4 Approx.2

Determined by plasticizing capacity:

(Based on 85% of rated plasticizing capacity)

Np = No. of cavities based on plasticizing capacity.

P = Rated plasticizing capacity for particular polymer (g/hr)

Tc = Over all cycle time (Sec.) = 4 seconds

Np = (0.85P X Tc) / 3600m

Np = (0.85 X 13.39 X 1000 X 13)/ (3600 X 33)

= 1.2 Approx. 2

Determined by clamping capacity:


PROJECT REPORTNc = No. of cavities based on clamping capacity

C = Rated clamping capacity (KN)

Pc = Clamping pressure in KN.

Am = Projected area of moulding (Sq. Cm.) including runners.

FOR FIRST COMPONENT

Nc = 300 X 1000 / (90 X 40000)

= 0.8 Approx

2. MIN. WALL THICKNESS

t = 3 C. P. d4 E.Y.

t = Min. wall thickness (cm)

y = Max. Deflection of Side Wall = 0.003cm

Pc= Max. Cavity Pressure = 900 bar

d = Total Depth of Cavity Wall = 3.6 cm

E=Modulus of Elasticity = 2.1 X107 N/cm2

c = constant

Ratio of the length of Cavity wall to the depth of Cavity wall (L/d)

Value of C

1.0 0.044

1.5 0.084

2.0 0.111

3.0 0.134


PROJECT REPORT

4.0 0.140

5.0 0.142

Ratio of length/depth=21/10.56 = 1.98

So value of c=0.111 from table

= 3 0.111 X 900 X 10 5 X (3.6) 4 2.1x107 x 0.003 x104

= 0.5 cm

= 5.00 mm

SPLIT CALCULATION:-


PROJECT REPORT

M = (L x Sin Ø)-(c/cos Ø)

Where:

M = split movement in mm = 15.5 mm

Ø = angle of finger cam = 18º

L =working length of finger cam=?

C = clearance = 0.5

We have to find L

15.5 = (L x sin18º)-(0.5/cos18º)

=28 mm

So working length of finger cam taken as 30 mm

Project details…


PROJECT REPORT

Machine Selection

Machine selection for making any plastic moulding should be based principally on max. shot capacity, max. die opening and die size, max. & min. die height, clamping force and operating stroke, length of shot stroke, tie bar distance, over-all size and cost.

The thumb rule for selection of plastic moulding machine is to use the smallest machine that will do the job. This will ensure fundamental economy of operation, since the larger the machine, the slower its cycle. Clamping force is not necessary the deciding factor in the selection of a plastic moulding machine. Die dimensions must be considered. The machine adequate tonnage for casting a part may have insufficient platen area or tie-rod spacing for the die, or the opening stroke may not be sufficient for removal of component.

Machine available for this case is SP 80.

Machine Specifications for SP 80

INJECTION UNIT


PROJECT REPORT

CLOSING UNIT

Part details…


1 Injection pressure 1800 bar2 Stroke volume 49m cu.cm 3 Max. Injection weight 98gms.4 Injection rate 100cc/s5 Plastering rate 4.7gm/s6 Screw L/D ratio 187 Screw diameter 25mm8 Screw stroke 100mm9 Screw speed (max.) 250rpm.

11 Locating ring diameter 120 mm

12 Nozzle type Round nozzle

11 No. of heating zones 4

12 Closing force 400 KN.13 Mould opening stroke 450 mm.14 Min. mould height 100mm.15 Max. daylight 470mm.16 Distance between Tie Bar

(h x v)395 x 395 mm.

17 Size of mould plate (h x v) 400 x 400 mm.18 Ejection force 24KN.19 Ejector stroke 65mm

29

PROJECT REPORT

Part details…


CAVITY INSERTCAVITY INSERT

PROJECT REPORT

Assembly details…

ASSEMBLY DETAILS


CORE INSERTCORE INSERT

PROJECT REPORT

Assembly details…


ASSEMBLY OF TOOLASSEMBLY OF TOOL

PROJECT REPORT

Assembly details…


MOVING HALF OF TOOLMOVING HALF OF TOOL

PROJECT REPORT

Hot tip details


FIXED HALF OF TOOLFIXED HALF OF TOOL

PROJECT REPORT


HOT TIP HOT TIP

PROJECT REPORT


HOT TIP WITH SECTIONHOT TIP WITH SECTION

PROJECT REPORT

Assembly details…

Production Department 372D ASSEMBLY DRAWING2D ASSEMBLY DRAWING

PROJECT REPORT

WORK ORDER NO. 822098N

MATERIAL PR. NO. P.O. NO. COST

INSERTS O.S R-180 R-151 485/kg

MOULD BASE STD R-221 R-214 65,000 /-


PROJECT REPORT

Part list…

PROCESS PLANNING


PROJECT REPORT As work piece quantities and costs in press work are usually high, considerable

economy can be affected by choosing an appropriate sequence of operations and

the right type of tooling. The process plan should take into account the total cost:

material, tooling, labour (time). Process planning generally includes the following

considerations.

Quantity required – total and annual,

Work piece – shape and size,

Work piece – dimensional tolerances,

Work piece – material limitations,

Equipment available for manufacture.

In every tool, the process planning done a vital role and it is

followed by above mentioned points. To manufacture the parts of the tool, it is

necessary to follow the proper methodology of manufacturing, so that one can get

accurate dimensional stability for that particular part within appropriate time.

In Die casting dies also all the parts of the tool are

manufactured by considering all above mentioned sequence and choosing of

machining sequence. Below mentioned sheet expresses all the view of machining

sequence of the tool. Similarly all the parts of the tool are manufactured by the

same followed suit.

MANUFACTURING PROCESSES PLANNING FOR EACH PART


PROJECT REPORT All the features of the part with dimensions & their references with respect to

the assembly.

The part is studies and the plans for sequence of process like conventional,

non-conventional & CNC machining, heat treatment in process & stage

inspection etc.

Special requirements for the tooling, electrode, and CAD/CAM support for the

programs required for the Core & Cavity inserts that are to be machined on

the CNC machines etc. are planned in advance to meet the process flow & to

maintain the delivery schedule.

Stage drawings of each parts coming & going out from process are made for

the convenience of the machine operator showing the references, tolerance

analysis, manufacturing allowances using the ordinate dimensioning and

inspection methodology.

A continuous follow up for the machine availability is made for the

completion of the job in the planned time period to maintain the delivery

date.

The above information is applied for all processes related to the part

indicating earliest start & finish date of each process with respect to material

planning, date of availability of special tooling, electrode, CAD/CAM data,

monthly priority list etc.The start & finish date can be taken from the job

cards the earliest finish date of assembly can be analyzed for the first trial

and is communicated to all the interface departments about planning and

their support

JOB CARDProduction Department 41

PROJECT REPORT

WORK ORDER NO.

822098 PART MATERIAL O.S

PART NO. 01 PART MATERIAL SIZE 61.80X181.5X147.5

PART NAME MAIN CORE INS PART QTY 61

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN

01 BLOCK MILLING VF2 16/6 16/6 XX

02 S/G NEW KENT

17/6 17/6 XX

03 SPOTTING & DRILLING

V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT 510 7/8 8/8 XX

XX

XX

B. REWORK DETAILS


PLAN BY

DATE

42

PROJECT REPORT

WORK ORDER NO.


PART NO. 62 PART MATERIAL SIZE

PART NAME CAVITY INSERT PART QTY 01

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN


02 S/G NEW KENT

17/6 17/6 XX


V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX


10 WIRE CUT 510 7/8 8/8 XX

XX

XX

B. REWORK DETAILS

WORK 822098 PART MATERIAL OS


PLAN BY

DATE

43

PROJECT REPORTORDER NO.PART NO. 63 PART MATERIAL SIZE

PART NAME LOCAL CORE-1 PART QTY 01

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN


02 S/G NEW KENT

17/6 17/6 XX


V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX


10 WIRE CUT XX

XX

XX

B. REWORK DETAILS


PLAN BY

DATE

44

PROJECT REPORTWORK ORDER NO.


PART NO. 64 PART MATERIAL SIZE

PART NAME LOCAL CORE2 PART QTY 01

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN


02 S/G NEW KENT

17/6 17/6 XX


V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX


10 WIRE CUT XX

XX

XX

B. REWORK DETAILS

WORK ORDER NO.



PLAN BY

DATE

45

PROJECT REPORTPART NO. 65 PART MATERIAL SIZE

PART NAME SIDE CORE PART QTY 01

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN


02 S/G NEW KENT

17/6 17/6 XX


V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX


10 WIRE CUT XX

11 EDM XX

XX

B. REWORK DETAILS

WORK ORDER NO.

822098 PART MATERIAL OHNS


PLAN BY

DATE

46

PROJECT REPORTPART NO. 01 PART MATERIAL SIZE

PART NAME GUIDE RAIL PART QTY 02

DATE FINISH SIZE

A. PROCESS FLOW

SR.NO.

PROCESS DESCRIPTION

M/C START DATE

COMP.DATE

QTYACC. REJ.

COMP.BY

SIGN


02 S/G NEW KENT

17/6 17/6 XX


V33 20/6 20/6 XX

04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX


10 WIRE CUT XX

XX

XX

B. REWORK DETAILS

PART MATERIAL DETAIL


PLAN BY

DATE

47

PROJECT REPORT

MATERIAL C% Mn% Si% S% P% Cr% Ni% Mo%

M.S. 0.25 0.6-

0.9

0.1-

0.35

0.055 0.55 0.2-

0.35

EN-8 0.35-

0.45

0.6-

1.0

0.05-

0.35

0.06 0.06

EN-31 0.9-

1.2

0.3-

0.75

0.1-

0.35

0.05 0.05 1.0-

1.6

OHNS 0.85-

0.95

1.0-

1.5

0.2-

0.4

0.3-

0.6

0.3

O.S 0.39 0.4 1.0 5.2 1.4

HEAT TREATMENT DETAIL

Heat Treatment of steel may be defined as an operation or combination

of operations involving the heating and cooling the steel in solid state;


PROJECT REPORTso as to modify its properties and to make it suitable for a particular

uses.

Purposes of Heat Treatment –

The heat treatment is done for following purposes

1) To improve machinability.

2) To produce a hard surface on a ductile interior.

3) To refine grain size.

4) To relieve internal stress or eliminate the effect of cold working.

5) To increase mechanical properties.

6) To increase the resistance to wear, heat & corrosion.

7) To improve magnetic & electric properties.

8) To change chemical composition.

9) To increase cutting properties of steel.

10) To remove gases.

Hardening

It is a method of steel heating, 40 - 500C above the upper critical

temperature for hypo eutectoid steel or 40 - 500 above lower critical

temperature for hyper eutectoid steel, soaking for a specified time. The

hardness obtained by hardening process depends upon following –

1) Carbon content

2) Quenching rate

3) Work size

Quenching

Mark tempering – it is a process in which a steel is heated at the

hardening temperature soaked for a specified time & quenched in


PROJECT REPORTisothermal bath having temperature 1800 to 3000C, kept just above the

martensite start line. The material is held there for a time just before

the nose of the bainite line. Afterwards it is cooled in air. The end

product it martensite.

Objective

1) Less distortions or warping

2) Less change in volume

3) Less change of quenching cracks & internal stresses

H.T. FOR

ORVAR SUPREME -

Hardening temperature - 1020 to 1050 deg. cel.

Quenching medium - air

Hardness after quenching - 46 to 52 HRC

Tempering temperature - 250 to 550 deg. Cel.

Hardness after tempering - 54 HRC

H.T. FOR

O.H.N.S -

Hardening temperature - 790 to 815 deg. cel.

Quenching medium - oil

Hardness after quenching - 63 to 65 HRC

Tempering temperature - 150 to 425 deg. Cel.

Hardness after tempering - 50 HRC

Cost estimation…


PROJECT REPORT


PROJECT REPORT

Cost estimation…

Costing of tool

Involves Designing cost of the tool.

Material cost.

Pre machining cost.

Precision machining cost.

Heat treatment cost.

Fitting & assembly ,bench work cost.

Inspection & trail cost.


PROJECT REPORT

Cost estimation…

1) Designing cost The amount and cost of time spent in designing a product are

estimated either on the basis of similar jobs previously

manufactured or on the basis of good judgment of designer. For

new and complicated product the job estimator must consult the

designer.

It is always preferable that standard rates per hour be used to

calculate the cost of designer’s time, and actual rates which are

usually paid on a monthly or any other basis.

It required, 60hours - 2D designing 20 hours - 3D modeling

As, 2D designing cost = 300 per hours 3D modeling cost = 500 per hours

2D designing cost 60 x 300 = 18000 /- 3D designing cost 20 x 500 = 10000/- ---------------- 28000/-

TOTAL DESIGNING COST = 28,000 /-


PROJECT REPORT

Cost estimation…

2) Material costs.

For estimating the material cost of the product, following steps

are followed.

Find out the volume of the material.

Multiply it with density of the material.

The drawings of the product to be manufactured are broken up

into smaller simpler parts and their volumes are calculated by

applying the formulae.

Volume of square or rectangular cube = L x B x H. Where, L = length of piece, B = breadth of piece, H = height of piece.

Volume of cylinder = 2π RH.Where, π = constant i.e. 3.14 or 22/7, R = radius of piece, H = height of piece.

Volume of pyramid =( L x B x H)/3Where, L = length of piece, B = breadth of piece,

H = height of piece.

Density of steel = 7.86 gm/cm³


PROJECT REPORT

Cost estimation…

3) Pre machining cost Unit costs (in hours)

Th e tool requires, Lathe = 20 hours Milling = 60 hours Surface grinding = 48 hours Cylindrical grinding = 18 hours

Lathe operation cost = 0 x 290 = 0 Milling operation cost = 60 x 290 = 1740Surface grinding = 48 x 290 = 1392Cylindrical grinding = 0 x 290 = 0 --------------------- 3,132 /-

TOTAL PRE MACHINING COST = 3,132 /-

Cost estimation…Production Department

Lathe 290/-Milling 290/-Surface grinding 290/-Cylindrical grinding 290/-

55

PROJECT REPORT

4) Precision machining cost

Unit costs (in hours)

The tool requires,

Lathe = 00 hours Milling = 18 hours Wire cut = 30 hours EDM = 40 hours Lathe operation cost = 00 x 575 = 0000 Milling operation cost = 22 x1000 = 22,000Jig boring = 00 x 575 = 0000Wire cut = 30 x 750 = 22500EDM = 40 x 600 = 24000 ----------------- 68,500/-

TOTAL PRECISION MACHINING COST = 66,500/-

Cost estimation…


CNC Lathe 575/-CNC Milling 1000/-CNC Wire cut 750/-CNC EDM 575/-

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PROJECT REPORT

5) Heat treatment cost


The tool requires, Conventional = 60 hours. Vacuum = 20 hours.

Conventional treatment cost = 60 x 80 = 4800 /- Vacuum = 20 x 300= 6000/-

TOTAL HEAT TREATMENT COST = 10,800/-

6) Fitting / assembly cost


Fitting / assembly cost = 140 /-

The tool requires, Fitting / assembly time = 24 hours.

Fitting / assembly cost = 24 x 140 = 3,360/-.

TOTAL FITTING / ASSEMBLY COST = 3,360/-

Cost estimation…


Conventional 80/-vacuum 300/-

57

PROJECT REPORT

6) Inspection cost


Conventional = 200/- CMM = 1000/-

The tool requires, Conventional = 18 hours CMM = 06 hours

Conventional Inspection cost = 25 x 200 = 5,000 /-CMM Inspection cost = 08 x 1000 = 8,000/-

TOTAL INSPECTION COST = 13,000/-

Cost estimation…


PROJECT REPORT

TOTAL COST OF TOOL

TOTAL DESIGNING COST = 28,000 /-

TOTAL MATERIAL COST = 22,500 /-

STANDARD MOULD BASE = 65,000 /-

TOTAL PRE MACHINING COST = 3,132 /-

TOTAL PRECISION MACHINING COST = 68,500/-

TOTAL HEAT TREATMENT COST = 10,800/-

TOTAL FITTING / ASSEMBLY COST = 3,600/-

TOTAL INSPECTION COST = 13,000/-

STANDARD PARTS COST = 25,000 /-

PACKING CHARGES = 4% OF NET VALUE.

SALES TAX = 12.5% AS APPLICABLE

EXCISE DUTY = 15% AS APPLICABL

MARGIN = 15 % of NET VALUE

---------------------- 3, 27,000 /-

TOTAL COST OF TOOL = 3, 27,000 /-TOTAL COST OF TOOL = 3, 27,000 /-

Trail report…


PROJECT REPORT

INSPECTION

Due to the great advancement, the continuous improvements in

the production methods and increasing quality demands, the Industrial


PROJECT REPORTInspection does not mean fulfilling of the specifications lay down by the

manufacturer. Rather the Inspection in real sense is concerned with the

checking of a product at various stages of manufacturing, right from the

raw material form to the finished products in the hands of the end

customer. That is what called as the CUSTOMER SATISFACTION.

Thus, the Inspection led to the development of the precise

Inspection instruments which helps to change over from the traditional

lesser accurate machines to better design and more precise machines.

It also led to the improvements in metallurgy and raw material

manufacturing due to high demand of accuracy and precision.

Ultimately it leads to the QUALITY IMPROVEMENT.

After manufacturing of all the parts they are transferred to Quality

Control department to check the accuracy of profile also it’s positioning

from the reference. Various geometrical features such as

perpendicularity, parallelism, circularity, run out, and etc if required.

Inspection of all the parts are carried out by trained personal and precisely working machines and it is followed by below mentioned path

FITTING & ASSEMBLY

ASSEMBLY - PROCESS PLANNING


PROJECT REPORT First of all the assembly & sub-assembly is to be studied the

process is planned considering the functional requirement along

with fitment of mating parts showing indications & directions.

The detail record is maintained of each part required for the

assembly right from the material received to the final inspection

report.

The details of the process of each part can be obtained from the

job cards. While the dimensions with tolerances can be known

from the inspection reports.

The details of part reaching the assembly can be obtained from

the bar chart made before starting the actual manufacturing.

ASSEMBLY – PROCESS

While assembly of all parts and sub units first of all check the

following things.


PROJECT REPORT Study the drawing.

Check the component thoroughly.

Collect and analyze the mating parts and its dimensions.

Check the deburring if not then deburr it.

Before final assembly, check the fault occurring between mating

parts.

The Pre-machining & assembly is done in the Assembly &

Fitting section. Then centre drilling done on the plates, on NC machine.

Then drilling operation, for cooling holes, tapping holes are performed

on the bench drilling machines. Then those holes get tapped. Then after

the manufacturing of all the parts, actual assembly gets starts. All

standard parts available like Allen screw, etc which is required during

assembly are collected.

After manufacturing of Core and Cavity inserts are

transferred to Quality Control department to check the accuracy of

profile also it’s positioning from the reference. Various geometrical

features such as perpendicularity, parallelism, circularity, run out, and

etc. if required. For assembly of tool various points which are to be

considered are as following.

Check all parts of standard die set and plate thickness for

further calculation.


PROJECT REPORT Check all the standard parts which are being used in this tool.

All the inserts are maintained as per drawing for easy fitment.

Check the all alignments and fitments of all matting parts.

Identification marks are marked on each part to avoid further

confusion after disassembly.

Trail report…

INJECTION MOLDING DEPARTMENT

COMPONENT TRAIL REPORT Date: -

Work order no:-822098N Trail no:-


TOOL INSPECTION REPORT

PROJECT REPORT

Mould description: - DESIGN OF SINGLE CAVITY HOT TIP MOULD FOR BOTTOM HOUSING

Component description :- Ref:-Component no:- Customer name: - L &T Mumbai

Material: - Inj.moulding machine:-SP80No. of shots:-Shot weight:- Component weight :-

REMARKS / OBSERVATIONS:-

Observation on component

1} 2}3)

Observation on mould functioning

1} 2)3)4}

PARAMETERS:-

ACHIEVEMENT


Clamping pressure :- Injection Time :- Holding Time :- Cooling Time & Refilling Time:- Total Cycle Time :-

65

PROJECT REPORT The project was a medium for me to enhance my knowledge in the field of

tool & Die Making. It helped me lot in better understanding of the concepts of

Injection Mould manufacturing.

During the project I had to communicate with various departments and

authorities to solve the problems and difficulties around in between. It has

helped to improve my abilities to work as a team.

A Hot tip mould for Bottom housing was required to be completed in a

specific period of time for which I had to work to the best of my abilities to

complete the Hot tip mould.

In the project work I was given an opportunity to study the HOT TIP Mould

right from manufacturing to dispatch as per planned time period, which

stretched our limits to achieve the goal.

It was a nice opportunity for me to learn about such a tool, thus enhancing

my knowledge.

CONCLUSION


PROJECT REPORTA complete mould designer must have a through

knowledge of the principles of the mould making as the design of the

various parts of the mold depends on the technique adopted for its

manufacturer. Case studies of the various moulds of same kind have

been conducted prior to the design process. Proper evaluation of the

previous designs were performed and created something even better

instead of simply keeping to what was done previously. The various

demands of the customer were considered while designing of the

tool. The final mould design is prepared after the part design has

been specified and all requirements affecting the design of mould

have been clarified. The outcome is a near perfect design and the

trail made on the mould just about confirms it.


Final Project Me

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