SEKISUI DLJM Molding Pvt. Ltd. Industrial Report(Plastic Injection Molding)

Department of Mechanical & Automobile Engineering

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Summer Training Report

SEKISUI DLJM MOLDING PVT. LTD.

Working On Plastic Injection Molding Machine

Submitted in partial fulfillment of the requirements for the degree of

BACHELOR OF TECHNOLOGY

by

ABHIKANT YADAV

110106004


Sharda University, Greater Noida

June, 2014


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APPROVAL SHEET

Summer training report, entitled: (PLASTIC INJECTION MOLDING)

is approved for award of 12 credits.

Examiners

__________________

__________________

Coordinator

__________________

Head of Department

__________________

Date:


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CERTIFICATE

This is to certify that Mr. / Ms.___________________________ has partially completed /

completed / not completed the Industrial Training in our Organization / Industry during 1st

June, 2014 to 15th July, 2014. He / She was trained in the field of ______________

____________________________________________________ __________. His / Her

overall performance during the period was Excellent / Very Good / Good / Average / Poor.

Manager/Guide


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ACKNOWLEDGEMENT

I would like to place on record my deep sense of gratitude to Mr. V.P. SINGH, HR

DEPARTMENT, SEKISUI DJLM MOLDING Pvt. Ltd., GREATER NOIDA, for his

generous guidance, help and useful suggestions.

I express my sincere gratitude to Mr.U.K.GUPTA, Dept. of Mechanical and Automotive

Engineering, Sharda University, Greater Noida, for his stimulating guidance, continuous

encouragement and supervision throughout the course of present work.

I also wish to extend my thanks to Mr. VINEET KUMAR, etc. and other colleagues for

attending my seminars and for their insightful comments and constructive suggestions to

improve the quality of this research work.

I am extremely thankful to Prof. BHARAT B.GUPTA, Head, Dept. of Mechanical and

Automotive Engineering, Sharda University, Greater Noida, for providing me infrastructural

facilities to work in, without which this work would not have been possible.

Signature of the student


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CONTENTS

ACKNOWLEDGEMENTS i

ABSTRACT ii

LIST OF TABLES iv

LIST OF FIGURES v

ABBREVIATIONS vi

NOTATIONS vii

INTRODUCTION 1

Industry 2

Purpose 2


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Abstract

Injection molded components are consistently designed to minimize the design and

manufacturing information content of the enterprise system. The resulting designs, however,

are extremely complex and frequently exhibit coupling between multiple qualities attributes.

Axiomatic design principles were applied to the injection molding process to add control

parameters that enable the spatial and dynamic decoupling of multiple quality attributes in the

molded part. There are three major benefits of the process redesign effort. First, closed loop

pressure control has enabled tight coupling between the mass and momentum equations. This

tight coupling allows the direct input and controllability of the melt pressure. Second, the use

of multiple melt actuators provides for the decoupling of melt pressures between different

locations in the mold cavity.

Such decoupling can then be used to maintain functional independence of multiple

Qualities attributes. Third, the heat equation has been decoupled from the mass and

momentum equations.


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Introduction

The purpose of the joint venture is to expand business with vehicle manufacturers in India

and be the foremost competitor by using the advantage of Sekisui Chemical and Sekisui

Techno Molding products, technology, and design. JV is focused on to build up a business

base in India centered on Japanese vehicle manufacturers by adding Japanese manufacturers

trust for Sekisui Techno Molding's quality and technology.

The fusion of the products Sekisui Techno Molding has that contribute to lighter weight

(metal substitute products and foam mold products) and its insert molding, and mold design

technology will exploit a technological synergy for market establishment.

From aesthetic to functional, from outer parts exposed to harsh environments to pleasing

interiors, from engine and transmission parts exposed to heat and water, to chrome grilles

enhancing the value of automobile, we make a wide variety of moulded plastic auto parts.

Sekisui DLJM Molding Pvt., Ltd. is a joint venture of Sekisui Chemical Co., Ltd. and Dipty

Lal Judge Mal Pvt. Ltd. and was established in August 2011.The purpose of the joint venture

is to expand business with vehicle manufacturers in India and be the foremost competitor by

using the advantage of Sekisui Chemical and Techno Molding products, technology, and

design. JV is focused on to build up a business base in India centered on Japanese vehicle

manufacturers by adding Japanese manufacturers trust for Techno Molding's quality and

technology. The fusion of the products Techno Molding has that contribute to lighter weight

(metal substitute products and foam mold products) and its insert molding, and mold design

technology will exploit a technological synergy for market establishment.

We have two plants located in Tapukara ( Bhiwadi), Rajasthan & Greater Noida, U.P. with

approx. 650 employee strength.Soon we are going to start a new plant in Chennai, Tamil

Nadu.

Sekisui DLJM turnover for Financial Year April 2013 - March 2014 was approx INR 700

million. Projected turnover Financial Year April 2014 - March 2015 INR 1500 million.


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SEKISUI DLJM is a part of Sekisui Chemical Group founded in 1947. Since its founding, the

Sekisui Chemical Group has delivered a wide range of products and services to enrich

people's lives and the social infrastructure.

In 1947, Established Sekisui Sangyo Co., Ltd. in order to run a general plastic business. But

in a short span of time, changed the company name to Sekisui Chemical Co., Ltd. and opened

the Nara Plant with plastic automatic injection molding tagged to be the first in Japan. 1950s

was the decade of achievement in term of new plants & award winning product

developments. In 1954 SEKISUI became listed on the Tokyo Stock Exchange.

In 1960s SEKISUI group continued its success saga by set up Sekisui Plastics Corporation in

the U.S., the very first plant by a Japanese manufacturer in this part of world.

1970s was the period of honor & new activities. In 1970, exhibited the “Sekisui Heim (Heim

M1)" modular house at the International Good Living Show in Tokyo. SEKISUI Group

started the medical project in the Central Research Laboratory in 1979. SEKISUI Group

awarded the Deming Prize, the highest honor for quality management, including production,

sales and service in November 1979.

In 1980s not only started sales of "Two-U Home", a wooden structured modular house

nationwide but also established SEKISUI AMERICA CORPORATION in the U.S.

1990s was the decade of Figures. In September 1996, The Company’s capital exceeded 100

billion yen and in March 1997 SEKISUI Group celebrated the 50th anniversary of the

company's founding.

In the 2000s SEKISUI Group achieved the first zero emission plants and started the company

division organization. Established & acquired more companies to expend the wings in US &

Europe.

In 2010s The Group rores its success. Established a joint venture company SEKISUI DLJM

MOLDING in India for a vehicle components molding business.

We have number of group of companies 235 and number of employee is 22000.


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Outline of SEKISUI

Name SEKISUI CHEMICAL CO., LTD.

Establishment March 3, 1947

Paid-up Capital 100,000 million yen

President Naofumi Negishi

Number of Employees 23,017 (for the term ended March 2014; on a consolidated basis)

Net Sales 1,110,851 million yen (for the term ended March 2014; on a consolidated basis)

Operating Income 82,541 million yen(for the term ended March 2014; on a consolidated basis)

Ordinary Income 83,310 million yen(for the term ended March 2014; on a consolidated basis)

Net Income 41,190 million yen (for the term ended March 2014; on a consolidated basis)

Corporate

Headquarters

Osaka Head Office

2-4-4 Nishitemma, Kita-ku, Osaka 530-8565 Japan

Tel: +81-6-6365-4122

Tokyo Head Office

2-3-17 Toranomon, Minato-ku, Tokyo 105-8450 Japan

Tel: +81-3-5521-0521


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Our Vision

Through Our Excellent Customer Support for Mutual Growth We Provide New Value to

Customers to Help Them Become the Best.

Quality Policy

SEKISUI DLJM is a customer-centric organization and Quality is the driving force behind

our success. Our ultimate moto is to achieve the highest level of client satisfaction.SEKISUI

DLJM believes in continuous improvement act and actively involved various improvement

activities through TPM and Kaizen that are implemented throughout its plants.

Sekisui DLJM is committed to maintain market leadership and customer confidence by

supplying high quality of products and services, conforming to agreed specifications of

customer, at local competitive price. These shall be achieved by:-

Implementation and continual improvement of effectiveness of Quality Management System.


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Improving customer satisfaction levels by prompt dispatches and reduction of non-

conformities.

Improving productivity by optimum utilization of machines and reducing inventories.

OUR PRINCIPLE

Sekisui Chemical Group’s Principle (“Our Principle”) comprises elements such as our

Company Creed, Mission Statement, Group Vision that expresses an ideal form aimed for by

the Group in the medium to long term, and our concrete Business Strategy (e.g. Medium-term

Management Plan) to realize the Group Vision. Based on Our Principle, it is our aim to create

social values as a unified group.

COMPANY CREED

The “3S Principle” (Service, Speed, Superiority)

Service

We enhance the well-being of the world community through our global business network.

Speed

We surge ever forward into new fields of development with the power and vitality of a

mighty waterfall.

Superiority

We obtain the trust of our customers through superior operational performance and the

highest quality standard.

The “3S Principle”

Our company badge comprises the three S’s of the company’s original name, adopted at the

time of its foundation, “SEKISUISANGYO” enclosed in a hexagonal shape resembling a

tortoise shell (the chemical


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symbol for benzene), symbolizing the Chinese character meaning “water.”

In November 1959, this mark was defined as the “3S Principle”and formally established as

the company creed.

“The difference between people living their lives in accordance with ideals and those simply

going where the currents and eddies of life take them becomes ever more apparent as the long

years of their lives pass. The same is true of business. Only when employees mass under a

common ideal arising from a basic policy of business management can the company

demonstrate its great power as a corporate community.”

It was in the spirit of this intent that the 3S Principle comprising Service, Speed and

Superiority was established as the motto of SEKISUI.

Origin of Company Name

SEKISUI means “pent-up water.” An expression used by Sun Tzu in his classic treatise.

Meaning of “SEKISUI”

“The battle of victor is determined in a fell swoop with tremendous force, just as a full body

of water (pent-up water or “SEKISUI”) let drop into a deep gorge.”

Adoption of this concept into corporate

activities:

The expansion of business activities will inevitably experience problems and challenges. To

overcome such difficulties, it is important both to gain a full understanding of and to analyze

one’s opponent’s circumstances, to consolidate one’s own structure and then to release the

power of pent-up waters to do battle and be victorious.

MISSION STATE MENT

Create social value while fulfilling stakeholder expectations

Sekisui Chemical Group will fulfill the stakeholder expectations of our “Customers,”

“Shareholders,” “Employees,” “Business Partners,” “Local Communities and the

Environment.”

Customers


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Shareholders Employees in

• Satisfy customer needs to the fullest extent

• Provide the best possible services to customers

•Established a culture that encourages employees to set their own goals and take on new

challenges.

•Assure the validity of the performance-based evaluation.

• Contribute to society and the environment with our products.

•Build harmony with local communities as a good corporate citizen.

•Strive for the sustained growth of corporate value.

•Ensure the clear and timely disclosure of information.

• Deepen relationships with business partners and associated companies

•Promote coexistence and co-prosperity through fair transactions.


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GROUP VISION

Sekisui Chemical Group will continue to develop the frontiers of “Creation

of Housing/Social Infrastructure” and “Chemical Solutions, ” utilizing its

prominent technology and quality, thereby contributing to people’s lives

around the world and the global environment.


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The Group Vision contains the intention of the Sekisui Chemical Group. All Group

employees will realize the intention and continue to be a business group that is trusted and

expected.

Prominent technology and quality.We provide quality that satisfies customers, including

technology accumulated over many years in the plastics processing and housing sectors, as

well as "hard" products and "soft" services and solutions.

Creation of Housing / Social Infrastructure

We offer housing and related materials, and infrastructure related to water and the

environment, which

make full use of advanced technology.

Chemical Solutions

We supply chemical products that anticipate the advanced needs of customers in the

industrial fields of

transport equipment, electronics, healthcare, etc.

Development of frontiers

We create new value while exploring and expanding business, in keeping with the

progressive spirit of

development that flows through the Sekisui Chemical Group.

People’s lives around the world

We contribute to improving the quality of people’s lives by responding to global markets and

taking part

in global activities.

Global environment

We seek to create an environment in which people of the next generation can enjoy true

peace of mind

through business that combines ecology and economy.

CORPORATE HISTORY

Mar. 1947 sekisui industry co., ltd. Formed as a general plastics company by former

employees of nippon chisso hiryo k.k. (currently


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Chisso corporation)

Jan. 1948 nara plant (currently nara control center) opened, started the first plastic automatic

injection molding business in japan

Jan. 1948 changed the name to sekisui chemical co., ltd.

Mar. 1953 listed on the osaka securities exchange (currently osaka securities exchange co.,

ltd.)

Jul. 1953 amagasaki plant opened, began manufacture of plastic tape

Sep. 1953 tokyo plant opened, began manufacture of molded plastic products

Apr. 1954 listed on the tokyo stock exchange (currently tokyo stock exchange group, inc.)

Jun. 1956 central research laboratory (currently research & development institute )

established

Aug. 1960 shiga ritto plant opened, began manufacture of pvc pipe and pvc building

materials

Nov. 1960 shiga minakuchi plant opened, began manufacture of polyvinyl butyral and

interlayer film

Jul. 1962 musashi plant opened, began manufacture of plastic tape and pvc tape

Jan. 1964 tokuyama sekisui industry co., ltd. (currently a consolidated subsidiary) established

and began manufacture of pvc resins

Feb. 1971 entered the housing business with the launch of steel frame unit housing “heim”

Oct. 1971 naseki industry co., ltd. (currently kinki sekisui heim industry co., ltd.,

consolidated subsidiary) established and began

Manufacture of unit housing

Mar. 1972 3s (san-es) heim manufacturing co., ltd. (currently tokyo sekisui heim industry co.,

ltd., consolidated subsidiary)

Established and began manufacture of unit housing

May 1977 introduction of a new divisional head office system

Mar. 1982 launch of wooden frame unit housing “two-u home”

Apr. 1982 gunma plant opened, began manufacture of pvc pipe and exterior paneling for unit

construction housing

Dec. 1983 sekisui america corporation (currently a consolidated subsidiary) established

Jul. 1987 applied electronics research center (currently development center, r&d center)

established


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Sep. 1990 housing research & development institute (currently housing technology institute)

established in the housing division (currently

Housing company)

Apr. 1992 kyoto technology center (currently kyoto r&d laboratory) established

Aug. 1997 komatsu kasei co., ltd. (currently vantec co., ltd., consolidated subsidiary)

acquired to strengthen pipe business

Jan. 2000 hinomaru co., ltd. (currently a consolidated subsidiary) acquired to strengthen

operations in the kyushu region

Mar. 2000 seven divisions combined into three: housing division, urban infrastructure &

environmental products division, and high

Performance plastics division; new business headquarters established

Oct. 2000 housing sales system reorganized, with the Tokyo and Kinki regional sales

companies overseeing local regional sales networks

Mar. 2001 New “company” system introduced, renaming the Housing, Urban Infrastructure

& Environmental Products, and High

Performance Plastics Divisions as the Housing Company, Urban Infrastructure &

Environmental Products Company, and High

Performance Plastics Company

Apr. 2002 Head office functions reorganized into 7 departments

Apr. 2003 Chugoku region housing business sales structure reorganized, Sekisui Heim

Chugoku Co., Ltd., (currently Sekisui Heim

Chushikoku Co., Ltd., consolidated subsidiary) established

Apr. 2003 Youngbo Chemical Co., Ltd. (listed on the Korea Exchange, consolidated

subsidiary) acquired, strengthening global

competitiveness

Aug. 2004 Tohoku region housing business sales structure reorganized, Sekisui Heim

Tohoku Co., Ltd. (currently a consolidated

subsidiary) established

Jul. 2005 Kyushu region housing business sales structure reorganized, Sekisui Heim Kyushu

Co., Ltd. (currently a consolidated

subsidiary) established


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Oct. 2006 Daiichi Pure Chemicals Co., Ltd. (currently Sekisui Medical Co., Ltd., a

consolidated subsidiary) acquired to strengthen the

medical business of the High Performance Plastics Company

Jan. 2007 Head office functions reorganized into 6 departments, and CSR department

established

Jul. 2007 Tokyo, Chubu and Kinki region housing business sales structures reorganized,

Tokyo Sekisui Heim Co., Ltd., (currently a

consolidated subsidiary) Sekisui Heim Chubu Co., Ltd. (currently a consolidated subsidiary)

and Sekisui Heim Kinki Co., Ltd.

(currently a consolidated subsidiary) established

Apr. 2008 Introduction of the Executive Officer System

Aug. 2008 Chugoku and Shikoku region housing business sales structures reorganized,

Sekisui Heim Chushikoku Co., Ltd. (currently a

consolidated subsidiary) established Jul. 2009 Polyvinyl alcohol resin business acquired from

group companies of the Celanese Corporation chemical company of the United States, stable

raw material supply structure for the interlayer film for laminated glass business established.

Main Businesses

High Performance Plastics Company

Electronics

LCD fine particles, photosensitive materials, semiconductor materials, industrial tapes and

films, ITO film

Automobiles and Transportation

Interlayer film for laminated glass polyolefin foam, molded resin products for vehicle use

Building and Infrastructure

Functional resins for infrastructure, fire-resistant tapes and sheets, rainwater storage materials

Life Science

Diagnostic pharmaceuticals, testing equipment, pharmaceuticals, drug-discovery support

businesses, sanitary materials

Industry

Adhesives packaging tapes, packaging, agricultural films, plastic containers

More Urban Infrastructure & Environmental Products Company


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Public and private infrastructure (construction)

PVC pipes and fittings, polyethylene pipes and fittings, plastic valves, system piping

Pipeline rehabilitation materials and methods, reinforced plastic composite pipe, fiber-

reinforced foamed urethane (FFU)

Building materials (rain gutters, flooring materials), insulation material, unit baths, water

storage tanks

Design, construction and maintenance management of pipeline and water treatment facilities

Functional materials and others

DC Plate, aircraft sheets, interior and exterior sheet for vehicle use

More Housing Company

Housing business

Sekisui Heim steel frame modular housing, Two-U Home wooden frame modular housing,

apartment, building lots, Overseas business

Refurbishing Business

Sekisui Fami S

Real Estate Business

Circulation of secondhand housing, apartment leasing & management

Residential Services Businesss

Elderly housing with supportive services, interior/exterior decoration

Other Businesses

Manufacture and sales of industrial, agricultural and construction materials, etc.

Products and services not included in the above

Injection molding

Injection molding is a manufacturing process for producing parts by injecting material into a

mold. Injection molding can be performed with a host of materials, including

metals, glasses, elastomers confections, and most commonly thermoplastic

and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and

forced into a mold cavity, where it cools and hardens to the configuration of the cavity. After

a product is designed, usually by an industrial designer or an engineer, molds are made by a

mould maker (or toolmaker) from metal, usually either steel or aluminum, and precision-

machined to form the features of the desired part. Advances in technology now also allow


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for 3D printing of injection molds for certain applications, using photopolymer plastics which

do not melt during the injection process. Injection molding is widely used for manufacturing

a variety of parts, from the smallest components to entire body panels of cars.

Parts to be injection moulded must be very carefully designed to facilitate the moulding

process; the material used for the part, the desired shape and features of the part, the material

of the mould, and the properties of the moulding machine must all be taken into account. The

versatility of injection moulding is facilitated by this breadth of design considerations and

possibilities.

APPLICATIONS

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 modern

method of manufacturing parts; it is ideal for producing high volumes of the same object.

INJECTION MOLDING MACHINE

An Injection molding machine, also known as an injection press, is a machine for

manufacturing plastic products by the injection molding process. It consists of two main

parts, an injection unit and a clamping unit.

OPERATIONS

Injection molding machines can fasten the molds in either a horizontal or vertical position.

The majority of machines are horizontally oriented, but vertical machines are used in some

niche applications such as insert molding, allowing the machine to take advantage of gravity.

Some vertical machines also don't require the mold to be fastened. There are many ways to

fasten the tools to the platens, the most common being manual clamps (both halves are bolted

to the platens); however hydraulic clamps (chocks are used to hold the tool in place) and


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magnetic clamps are also used. The magnetic and hydraulic clamps are used where fast tool

changes are required.

The person designing the mold chooses whether the mold uses a cold runner system or a hot

runner system to carry the plastic from the injection unit to the cavities. A cold runner is a

simple channel carved into the mold. The plastic that fills the cold runner cools as the part

cools and is then ejected with the part as a sprue. A hot runner system is more complicated,

often using cartridge heaters to keep the plastic in the runners hot as the part cools. After the

part is ejected, the plastic remaining in a hot runner is injected into the next part.

FIGURE:- (A 1300 ton injection molding machine with robotic arm)


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Types of injection molding machine

Machines are classified primarily by the type of driving systems they use hydraulic,

mechanical, electric, or hybrid.

Hydraulic

Hydraulic presses have historically been the only option available to molders until Nissei

Plastic Industrial Co., LTD introduced the first all-electric injection molding machine in

1983.

Hydraulic machines, although not nearly as precise, are the predominant type in most of the

world, with the exception of Japan.

Mechanical

Mechanical type machines use the toggle system for building up tonnage on the clamp side of

the machine. Tonnage is required on all machines so that the clamp side of the machine does

not open (i.e. tool half mounted on the platen) due to the injection pressure. If the tool half

opens up it will create flash in the plastic product. Reliability of mechanical type of machines

is more as tonnage built during each cycle is the same as compared to hydraulic machines.

Electric

The electric press, also known as Electric Machine Technology (EMT), reduces operation

costs by cutting energy consumption and also addresses some of the environmental concerns

surrounding the hydraulic press. Electric presses have been shown to be quieter, faster, and

have a higher accuracy, however the machines are more expensive.

Hybrid injection (sometimes referred to as "Servo-Hydraulic") molding machines claim to

take advantage of the best features of both hydraulic and electric systems, but in actuality use

almost the same amount of electricity to operate as a standard hydraulic,


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A robotic arm is often used to remove the molded components; either by side or top entry, but

it is more common for parts to drop out of the mold, through a chute and into a container

Plastic Injection Molding

• Plastic Injection Molding is a manufacturing technique for making parts from

thermoplastic and thermoset materials

• In contrast to the extrusion (which makes continuous parts of constant cross section),

injection molding make discrete parts (with complex and variable cross section)

• Molten plastic is injected at high pressure into a mold, which is the inverse of the

desired shape.

• The mold is made from metal, usually either steel or aluminium

• widely used for manufacturing a variety of parts, from the smallest component to

entire body panels of cars.

• The key to success in injection molding are to have;

– Proper machine for good melting and injecting of the resin

– The proper resin to appropriate part performance

– A good mold for part definition and removal

Proper operation for efficient molding cycle (mold cycle depends on the design of the

mold and manufacturing parameters)

• The most commonly used thermoplastic materials are;

– polystyrene (low-cost, lacking the strength and longevity of other materials)

– ABS or acrylonitrile butadiene styrene (a co-polymer or mixture of

compounds used for everything from Lego parts to electronics housings)

– nylon (chemically resistant, heat-resistant, tough and flexible - used for

combs)

– polypropylene (tough and flexible - used for containers


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– PVC (more common in extrusions as used for pipes, window frames, or as the

insulation on wiring where it is rendered flexible by the inclusion of a high

proportion of plasticizer).

Injection Unit:

Purpose: to liquify the plastic materials and then inject the liquid into mold

– Resin is introduced through hopper

– Some machines can have several hoppers (to fed filler, colorants, other

additives)-Injection molding act as mixer

– However, due to limited size of barrel, mixing capability is poor

From hopper – hole (feed throat)

Barrel made of heavy steel cylinder to withstand the pressure and temperature involved in

melting the resin

2 types of system used in injection molding;

– Reciprocating screw- similar to extruder screw but with unique reciprocating

action

– Ram injector

• Design of screw- similar to an extrusion screw

• 3 sections;

– Feed section- to advance the resin

– Compression section- to melt the resin

– Metering section- to homogenize the resin and pump it forward

• The screw of injection molding machine is shorter than extruder, L/D ratios are 12:1

and 20:1

• Low L/D ratios suggest the mixing is less efficient in the injection molding machine

• The compression ratio (diameter of root at feed zone to the diameter of root at

metering zone) often in the range of 2:1 and 5:1

• Low compression ratio means less mechanical action is added during melting process.


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• Important measure of the size of an injection molding is weight of resin that can be

injected, called shot size

• Typical shot size range from 20g to 20 kg

• Since shot size depends on the density of the plastic, PS has been chosed as the

standard for rating the machine

Reciprocating Screw Injection Molding Machine:

• Resin is melt by mechanical shear and thermal energy from heaters

• The molten resin is conveyed to a space at the end of the screw- collects in a pool

• Here, the mold is closed

• The entire screw move forward and pushes the molten resin out through the end of

barrel

• To ensure the resin does not flow backward, a check valve or nonreturn valve is

attached to the end of screw

• Normally the screw will stay in the forward position, until resin began to harden in the

mold

• Retraction of the screw, create space at the end of the screw

• Cooling of the part in the mold, until it can be removed

While the part is cooling, the screw turns and melts additional resin

• Advantages

– More uniform melting


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– Improved mixing or additives and dispersion throughout the resin

– Lower injection pressure

– Fewer stresses in the part

– Faster total cycle

Ram Injection- Injection Molding Machine:

• In this type of injection molding, the resin is fed from a hopper into the barrel, and

heated through thermal energy from the heaters

• The molten resin is collect in a pool in a barrel celled injection chamber

• The molten resin is then push forward by the action of plunger (ram or piston)

• To five better mixing, the molten resin is pushed past a torpedo/spreader, impart shear

to the melt

Molds:

• Designing and making mold for injection molding is more complicated than making

extrusion die

• Mold Parts – mold is placed in between stationary plate and the moveable plate


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• The connection from the injection unit to the mold is through the nozzle

• The channel that run through the stationary plate of the mold is called the sprue

channel (material that is in the channel is called the sprue)

• The solid sprue is removed from the finished part assembly after the part is ejected

from the mold.

• Resin flow from the sprue through the runner (connecting channel) to the mold

cavities.

Assembly of various mold parts.

• Mold bases can be purchased as entire units, then the cavities are cut from A & B

plates.


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Runners:

• Distribution system for the resin from the sprue to the cavities

• Flow characteristics (viscosity), temperature and other factors are important in

determining the runner diameter and length

• If the diameter of the runner is too small or the length is too long,the resin can freeze

in the runner before the mold is completely full

• If the runner system is too large, excess material would be ejected and too much

regrind created

• If the resins have a high viscosity, larger runners are needed compared to low

viscosity resin

• The optimum flow of the resin through the runner system depends on the shape and

diameter of the channel

• Round channel give the best flow characteristics but difficult to machine

• Machining cost can be reduce by machining one side of the mold plates

• Better shape where the depth of the channel is at least two-thirds the size of the width

and the sides are tapered between 2 to 5º.


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Secondary Runners:

• Secondary runner channel are used for multicavity molds

• The flow into the secondary channel should be streamlined (angle in flow direction)

• The streamlined minimizes shear on the resin

Gates:

• The end of runner and the entry path into the cavity

• The gate shape can also affect the filling of the cavity, dimension and properties of the

parts

• Gate is the most restricted point in injection molding system, i.e. for reinforcement

and filler + polymer systems

Gate Design:

• Small rectangular opening at the end of the runner channel, connect to the edge of

cavity

• Edge gate can be below the parting line if the channel and part are also below the

parting line

• Or it can be symetricaly about the parting line, if the runner channel and part are at

both side of parting line


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Submarine Gate:

• Starts from the edge of the runner, and goes into the cavity edge at an angle

• It narrows to a point as it moves from the runner to the cavity

• The advantage; separation of the parts and the runner is automatic

• Disadvantage; gate cannot be used for some resins because of high shear

Tab Gate:

• By connecting the runner directly into the cavity with no reduction in runner cross-

section

Used for very large parts where a reduction in flow would disturb the resin’s flow pattern and

might result inadequate flow into the cavity

Fan Gate:

• Made by reducing the thickness and not the diameter of the runner channel as it goes

into the cavity

• Used for intermediate size, and when reinforcement in the resin cannot flow through

the edge gate


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Ring Gate:

• Used to make hollow cylinder parts

• The ring gate covers the entire top of the cylinder part so that the resin flow is

downward into the wall of the part

Cavities:

• Are actual molding locations

• Resin enter the cavities through gate, fills the cavities, and cools to form the solid.

The parts are ejected and finished

• Cavities are the heart of the molding process, and must be precisely prepared

• The shape of the cavities determines the shape of the part

Materials & Product Consideration:

• Almost all thermoplastic can be injection molded

• Resin with low melt viscosity is required; so that the flow through runner, gate, cavity

– easily done with minimum injection pressure

• Resin with injection molding grades have low molecular weight and narrow

molecular weight distribution

Shapes:

• Hollow parts can be created by allowing the moveable plate to protrude into the cavity

of the stationary plate

• Threads can be placed on the inside of a part by using a core pin that is inserted into

the cavity where the threads are desired


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• A hollow part with a hole on the side is even more complicated (the core pin is used)

• The core pin slide into position after the mold is closed

• The core pin seals against the surface of the moveable plate, prevent flow of resin into

the area

Infrastructure

In its endeavor to manufacture products at par with global standards, SEKISUI DLJM has equipped all its manufacturing units with modern machines and technology for producing top of the line Plastics Parts. A true customer-centric OEM Parts supplier, SEKISUI DLJM is equipped with necessary resources and manpower to meet exacting demands of its clients. Today, the company has two manufacturing units at Greater Noida and Tapukara. These facilities are certified as per ISO/TS16949 system and also follow continuous improvement concepts like Kaizen in order to exceed previous performanceWe have 32 Injection Molding Machines Ranging from 100 T to 1000 T with Automatic Raw Material Conveying System. We have Centralized Process Control for Machine Parameters, chillers , assy lines all with 100 % power backup. We started a new paint shop from July 2013 which facilitate new design with advanced technology.We also provide there Special pre-treatment line for :Dust free partsBetter surface activation by additional surface conditioning mist spray


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We are soon going to start our new Injection Molding Plant in Chennai which is spread over 15000 sq.mtrs. where 10 Injection Molding Machines ( 200 T to 1000 T) at 1st stage & which have Total Capacity of 40 Injection Molding Machine

Tool Room

Our design section not only develops Injection and Blow moulds in-house but also provides Mould Flow Analysis.We work on Pro-E, VISI CAD/CAM and are equipped to handle any design software. We have been working in tandem with our customers in designing products as per their specifications. Reverse engineering or proto tooling works are undertaken to support customer’s need for changing part design. The design to moulded part turnaround time has been exciting for many of our customers. Our tooling and design activities for local and export markets have earned us a high level of customer satisfaction and trust evolving into strong relationship.Our state of the art in house Tool & Die manufacturing facility comprising of next generation CNC machine and other machines like EDM, Die Spotting, Lathe, Milling Machine, Radial Drilling Machine & Grinders from renowned companies like DMG, Haas, Kirloskar, HMT, Cincinnati Milacron etc.


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Molding Shop

With the prime focus on Quality, Cost and timely delivery, SEKISUI DLJM accomplishes these virtues through its meticulously planned Injection Moulding set-up. The plant has centralized process control for all machine parameters. The Plastic materials processed range from PP, ABS, PC, PC-ABS to PA6, PA66, PA46, including glass-filled or elastomer composite grade Gas assisted injection molding at our facility helps us in maintaining the aesthetic value of critical parts and reducing part weight and cost in otherwise thick sectioned areas.

Paint Shop

The molded parts can be Painted, Plated or Assembled as per customer requirement. Our painting line and flexible assembly lines cater to many thousand units per day. Millions of parts including Chrome Plated Handles, Logos, Bezels and others are custom made at the facility.


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Assembly

The molded and painted sub parts are assembled with other parts to make an assembly as per customer requirement. Our flexible assembly lines cater to many thousand units per day. Millions of parts including plastic parts, Logos, Bezels and others are custom made at the facility.

Test Lab

The company is equipped with reputed brand of test equipment. A modern test lab with latest equipments supports the company’s commitment to quality. Apart from regular quality and performance tests, all critical products are tested on special testing equipments. The company also implements modern analytical techniques and quality planning processes


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Products

The company manufactures premium quality plastic moulded auto parts. We are involved with its customers, right from Product designing stage to Prototyping till the serial production. The components are manufactured as per demands and specifications provided by different companies and are in conformity with international norms and standards.

Two Wheelers Plastic Parts

With vast experience, we are now one of the major Two Wheeler Plastic Parts Manufacturers..


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.

Department of Mechanical & Automobile

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Technology

Possess more than 25 years of experience in Plastic Auto parts manufacturing.

Advanced Technology Input as a JV by Japan’s leading moulding group.

Offer complete solutions in Plastic Processing Technologies i.e. Injection.

Two state-of-the-art manufacturing units & one coming soon.

ISO / TS 16949 : 2009 certified plants .



Technology Input as a JV by Japan’s leading moulding group.


art manufacturing units & one coming soon.


Department of Mechanical & Automobile


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Single window contact point for all our customers available.

A well experienced product development team with deep understanding of the most intricate products.

Various In house Testing facilities and a well equipped tool room with latest CAD software.A True One Stop OEM Solution provider.

Clients of SEKISUI DLJM MOLDING PVT.LTD

HERO HONDAYAMAHAMARUTI SUZUKISUZUKIDONALDSON

Corporate Social Responsibility

CSR: The Foundation of Management

As a Sekisui Group company, Sekisui DLJM Molding considers CSR to refer to contributing to sustainable society through its businesses. We believe that promoting CSR management increases the quality of corporate management.

Three Prominences:

First, we aim to be an environmental leader by contributing sustainable society and lessening the environmental load of its business activities. Second, we pursue quality specified by customers, through maximizing the quality of human resources, products, and systems. Third, we encourage individual prominence and self-realization, providing opportunities for diverse human resources in our workplace.

Three Attitudes of Sincerity:

We aim to continue being a company trusted by society through deploying compliance. Each employee can be proud, not just for his or her own sake but for his or her family and society at large, as they strives to put our management vision into practice. Also, we aim to increase sensitivity to risks by running through PDCA cycle, and to advance CSR management through communication with our stakeholders build on trust.


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Three attitudes and Prominences of sincerity of company:


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Why Us??


Advanced Technology Input as a JV by Japan’s leading moulding group.


Two state-of-the-art manufacturing units & one coming soon.


Single window contact point for all our customers available.

A well experienced product development team with deep understanding of the most intricate products.

Various In house Testing facilities and a well equipped tool room with latest CAD software.A True One Stop OEM Solution provider


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Policy

SEKISUI has basically three main policy. There are given below :

1-Quality Policy.

2-Enviroment Policy.

3-Enviroment Policy.


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ENVIRONMENT

SEDM commitment to General environment. Rainwater harvesting (RWH) and recharging of groundwater is emerging as a sustainable measure to cope with the increasing pressure on scarce freshwater resources. It is imperative that RWH practices have to be promoted globally for a secure water future of our societies and of the planet as a whole. Industry can play a vital role in producing and propagating RWH systems and solutions in this critical and challenging direction. SEKISUI DLJM takes pride in envisioning and enterprising in this direction through its sincere and sustained efforts in contributing with its groundbreaking environment conservation technology called CROSS-WAVE, brought from the pioneers, Sekisui Techno Molding of Japan.


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Conclusion

On the whole, this internship was a useful experience. I have gained new knowledge, skills and met many new people. I achieved several of my learning goals, however for some the conditions did not permit. I got insight into professional practice. I learned the different facets of working within an industrial machines. I experienced that financing, as in many industryis an important factor for the progress of projects.Related to my study I learned more about the injection molding and maintenance of mould and the assembly of parts. There is still a lot to discover and to improve. The methods used at the moment are still not standardized and a consistent method is in development.In injection molding education is an important aspect of the conservation of the parts joining. I have seen that local people can contribute to conservation, for example with their knowledge. Furthermore I experienced that it is of importance that the education is objective and that you have to be aware of the view of other people. Industrial education is not one sided, but it is a way of sharing knowledge, ideas and opinions.The internship was also good to find out what my strengths and weaknesses are. This helped me to define what skills and knowledge I have to improve in the coming time. It would be better that the knowledge level of the language is sufficient to contribute fully to projects. After my master I think that I could start my working career. However I could perform certain tasks in research better if I practice/know more the research methodologies applied in cetacean studies. It would also be better if I can present and express myself more confidently.At last this internship has given me new insights and motivation to pursue of my career.


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Refrences

1. www.google.com

2. www.wikipedia.com

3. www.sekisuidljm.com

4. www.sekisuichemical.com


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SUMMER TRAINING EVALUATION

COURSE:

SEMESTER:

PROJECT TITLE:

STUDENT NAME:

ROLL NUMBER:

S.No. Description Total Marks Mark

Awarded

1. Training Diary with attendance 50

2. Training Report 100

3. Presentation 50

4. Viva

(For self arranged training 25

marks)

100

Total 300

EXAMINERS NAME INITIALS DATE

Internal

External

SEKISUI DLJM Molding Pvt. Ltd. Industrial Report(Plastic Injection Molding)

Engineering

Transcript of SEKISUI DLJM Molding Pvt. Ltd. Industrial Report(Plastic Injection Molding)