INDUSTRIAL TRAINING

A TRAINING REPORT

Submitted to

GURU NANAK DEV CO-ED. POLYTECHNIC

By

Vikash

B.T.E. ROLL NO:-315578

of

POLYMER TECHNOLOGY

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GURU NANAK DEV CO-ED POLYTECHNIC

SECTOR -15 ROHINI, DELHI-110085

Board Of Technical Education

Muni Maya ram Marg, Pitampura Delhi

Certificate

This is to certify that the project report titled training on injection molding machine by Mr.

vikah being submitted to the Guru Nanak Dev Co-Ed Polytechnic New Delhi affiliated to

Board Of Technical Education Muni Maya Ram Marg,Pitampura Delhi for the award of

the diploma in polymer technology is a project work carried out by him under my supervision

and guidance. I am satisfied that the project work has reached the standard fulfill the

requirement regulating to the nature of the diploma course.

(DR. HARJEET SINGH) (MR. PRABAL KUMAR)

H.O.D Lecturer (Proctor 5th sem.)

Polymer tech. evening Polymer tech. evening

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Content

S.no. Topic page no.

I. Acknowledgement…………………….…………….…………….....4

II. Preamble…………………………………………..…………………5

III. Chapter 1

Introduction…………………………………………..….…….……..6

General Information…………………………………………….……7

List of Machine………………………………………………....…….8

IV. Chapter 2

About Training Work………………………………………..………14

List of Product………………………………………………..…..….15

Production Department………………….…………………………..16

Raw Material…………………………….………………..………..16

V. Chapter 3

Injection Moulding Machine………………….…………………..…18

Types of Injection Moulding Machine…………..…………………..19

Structure of Injection Moulding Machine…………………………..20

Defect…………………………………………………………….…23

Basic Opration…………………………………………………..…..24

Process…………………………………………………………....…25

Cycle Time……………………………………………………….…25

Injection Mould Tool…………………………………………….…26

Plastic Mould Tool…………………………………………………26

Plant Layout………………………………………………………..29

VI. Conclusion…………………………………………………………30

VII. Safety precaution……………………………….…………….……31

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Acknowledgement

It is always a pleasure to remind the fine people in the Engineering Workshops for their

sincere guidance I received to uphold my practical as well as theoretical skills in engineering.

Firstly I would like to thank H.O.D Harjeet Singh (Department of plastic engineering) for

convincing me the fact “Whatever a man can imagine, that can be achieved”, treating me as a

son of his own and guiding me to taste the real flavor of engineering.

Secondly I would like to thanks GM (ABHY JAIN) and Quality Manager ( Mr. .AJIT JAIN)

of the company for allowing me to training in the company and the positive attitude he

showed for my work, always allowing me to question him and giving prompt replies for my

uncertainties in all the fields including educational, social and managerial to labor work. And

I always great him for his aspects of crew resource management who always said, “I may be

wrong”.

“Knowledge is power and unity is strength.”

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Preamble

As a part of academic requirement for the polymer technology & engineering course. I had

undergone an industrial training programme at For Paras Techno Plast Pvt. Ltd

Paras Techno Plast is manufacturing of mostly washing machine & Refrigerator parts.

In this ensuring section, the activities of each department and processes etc. learned by me

during the period of training programme have been narrated.

I am in debt and grateful to the Paras Techno Plast particularly all the concerned person who

had provided me an opportunity to learn through our insight detailed infraction of the

manufacturing process in our industry. The training programme was one of the most fruitful

and exciting experience I had undergone.

I am confident that exposure of the training has added into my theoretical as well as practical

knowledge for plastic processing.

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Chapter 1

Introduction

Company profile

Paras Techno Plast is a provider of cutting edge plastic technology solutions with .20+

years of experience. We service multiple Fortune 50 clients in the Automotive, Lighting &

Industrial segments.

Paras Techno Plast is an end to end solution provider, assisting our global clients with

product design, tool design & development, injection molding & complete assemblies. They

are leaders in molding precision components with complex requirements for demanding

applications. 

Working with German, Asia customers over 2 decades has helped us instill a disciplined

work culture which is entirely quality driven and which imbibes best practices from different

production systems.

Paras Techno Plast have two plants in which the first and second plant both are situated at

bawana.

The first plant which is located at B-231, Sector-3, DSIDC Industrial Area, Bawana, New

Delhi-110039(INDIA)

Company provides many work condition and facilities to the workers.

Company produces the various types of polymer component of various purposes. In which

the part produced at the customer requirement.

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General Information

Name of company : - Paras Techno Plast

Year of establishment: - 1985

Address : - Unit-1, B-231 Bawana Industrial area

DSIDC Sector-3, New Delhi-110039

Legal status :-Proprietorship

Nature of business :-Manufacture/Supplier/Import & Export

Contact person

& designation :-Mr.Devwankar (marketing Dept.)

E-Mail ID : -parastechplastic@yahoo.co.in

info@tecnomacplast.com

Name of Banker :-Axis Bank

Total Manpower :-Managerial-4/technical-5/non-technical-50

Total-59

Export percentage :-25%

Major export market :-German/Asia

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List Of Machine

In paras techno plast there are six injection molding machine in which four are horizontally

press the material & two vertically.

Machines

Injection Molding Machine

EDM Machine

Surface Grinders

CNC Milling

Milling Machine

Lathes

Radial Grinding

EDM MACHINE

Wire EDM Machining Process

Wire EDM machining (Electrical Discharge Machining) is an electro thermal production

process in which a thin single-strand metal wire in conjunction with de-ionized water (used to

conduct electricity) allows the wire to cut through metal by the use of heat from electrical

sparks.

Due to the inherent properties of the process, wire EDM can easily machine complex parts

and precision components out of hard conductive materials.

How Wire EDM Works

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Wire EDM machining (also known as "spark EDM") works by creating an electrical

discharge between the wire or electrode, & the work piece. As the spark jumps across the

gap, material is removed from both the work piece & the electrode.

To stop the sparking process from shorting out, a non conductive fluid or dielectric is

also applied. The waste material is removed by the dielectric, and the process continues.

FIGURE-- EDM Machining

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SURFACE GRINDING

Surface grinding is the most common of the grinding operations. It is a finishing process that

uses a rotating abrasive wheel to smooth the flat surface of metallic or nonmetallic materials

to give them a more refined look or to attain a desired surface for a functional purpose.

The surface grinder is composed of an abrasive wheel, a work holding device known as

a chuck, and a reciprocating or rotary table. The chuck holds the material in place while it is

being worked on. It can do this one of two ways: ferromagnetic pieces are held in place by a

magnetic chuck, while non-ferromagnetic and nonmetallic pieces are held in place by

vacuum or mechanical means. A machine vise (made from ferromagnetic steel or cast iron)

placed on the magnetic chuck can be used to hold non-ferromagnetic work pieces if only a

magnetic chuck is available.

Factors to consider in surface grinding are the material of the grinding wheel and the material

of the piece being worked on.

Typical work piece materials include cast iron and mild steel. These two materials don't tend

to clog the grinding wheel while being processed. Other materials are aluminum, stainless

steel, brass and some plastics. When grinding at high temperatures, the material tends to

become weakened and is more inclined to corrode. This can also result in a loss of magnetism

in materials where this is applicable.

The grinding wheel is not limited to a cylindrical shape and can have a myriad of options that

are useful in transferring different geometries to the object being worked on. Straight wheels

can be dressed by the operator to produce custom geometries. When surface grinding an

object, one must keep in mind that the shape of the wheel will be transferred to the material

of the object like a mirror image.

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Spark out is a term used when precision values are sought and literally means "until the

sparks are out (no more)". It involves passing the work piece under the wheel, without

resetting the depth of cut, more than once and generally multiple times. This ensures that any

inconsistencies in the machine or work piece are eliminated.

FIGURE-- SURFACE GRINDING

CNC MACHINE

At Machinery World, trade in high-grade CNC Machines that are highly acclaimed by the

clients due to their precision engineered technology. Our CNC Machine is manufactured

from quality components and remits high performance. The CNC Machine offered by us is

widely demanded in the domain due to its high corrosion resistivity. The CNC Machine that

we provide is dimensionally accurate and is highly result oriented. For the convenience of the

clients, we offer different varieties of this CNC Machine that are CNC Lathe Machine, CNC

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Turning Centre, CNC Vertical Machining Centre, and CNC Hydraulic Press Brake.

FIGURE—CNC MACHINE

MILLING MACHINE

Milling operates on the principle of rotary motion. A milling cutter is spun about an axis

while a work piece is advanced through it in such a way that the blades of the cutter are able

to shave chips of material with each pass. Milling processes are designed such that the cutter

makes many individual cuts on the material in a single run; this may be accomplished by

using a cutter with many teeth, spinning the cutter at high speed, or advancing the material

through the cutter slowly. Most often it is some combination of the three. [2] The speed at

which the piece advances through the cutter is called feed rate, or just feed; it is most often

measured in length of material per full revolution of the cutter.

As material passes through the cutting area of a milling machine, the blades of the cutter take

swarfs of material at regular intervals. This non-continuous cutting operation means that no

surface cut by a milling machine will ever be completely smooth; at a very close level

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(microscopic for very fine feed rates), it will always contain regular ridges. These ridges are

known as revolution marks, because rather than being caused by the individual teeth of the

cutter, they are caused by irregularities present in the cutter and milling machine; these

irregularities amount to the cutter being at effectively different heights above the work piece

at each point in its rotation. The height and occurrence of these ridges can be calculated from

the diameter of the cutter and the feed.] These revolution ridges create the roughness

associated with surface finish.

FIGURE—MILLING MACHINE

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CHAPTER-2

ABOUT TRAINING WORK:

There are several types of machine in which injection moulding machine is one , Training

was gained on this with the help of some technical expert .knowledge was also gained from

here about the Injection Moulding Machine as well as several other machines just as CNC

MACHINE,LATHE MACHINE,DRILL MACHINE SURFACE GRINDER MACHINE.

Knowledge that how a injection machine work & how to control it as well as how can

manage this machine as per the shape of mould was received by the technical expert, about

which machine information was provided that is semi automatic machine.

Refrigerator Pad Stand was working at the time of training & to set all the system of this

machine by the help of key board which is adjust near to the barrel system the information

was provided by the helper.

In case of Refrigerator Pad Stand the temperature of barrel had been 175 to 195 and pressure

was about 60 to 65rpm .similarly many other things. why the flash is comes out in the

product and why weld lines is come this all could also be understand, weld lines is comes out

due to several things as low cooling time, high ejection pressure etc .Other most important

factor due to which weld line come out on the product shape that is material quality as well as

mould polishing which can affected the shape of product.

The Refrigerator Pad Stand are made by POLYPROPELENE (PP) because of their softness

PP is used for this purpose.

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In this mould two sliders was connected to give the shape of molten polymer .Toggle type

clamping was existing in this machine to give the clamping force.

The core or punching part of mould was moving on the tie bars with the help of toggle clamp

which was located on the each corner of the supporting plate ,the alignment should be proper

for the safety .

The weight lifting machine was used for the purpose of lifting the mold which moved all the

direction by the buttons remote. The machine should be in manual position at the time of

clamping the mold and then mold should be adjusted slowly slowly it was necessary to see

that the face of nozzle and mould sprue face was one another or not so that molten polymer

can move properly into the mould .

In case of sticking the plastic on the surface of mould mallet was used to remove it due to

which the surface of the core & cavity could be disappear then loose the clamping and the

mould was removed from the injection moulding machine with the help of weight lifting

machine and then with the help of this weight lifting machine take it into the tool room to

repair it with the help of experts .The experts suggested to do the again pollissing on the

surface of core part and after that all again clamped it on the machine and also again set all

the things and start the operation.

List Of Product

Washing Machine Parts

Reflectors

Inverter Bezzel

Water Pump Parts

IC Cards

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Remotes

Aging Sockets

Containers

Customized Mold

Refrigerator Parts

Spoons

Production Department

Raw Material

Material Detail Application

PC Polycarbonates Electronics and automotive components

PPS Poly phenylene sulfide

Electrical/Electronics and automotive, gear and pump parts

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PBT Polybutylene terephthalate

Electrical and automotives components

NYL-6 polyamide Threads, ropes, filaments, nets, tire cords, hosiery and knitted garments and gun frames

SAN Styrene acrylonitrile Food containers, kitchenware, computer products, packaging material, battery cases and plastic optical 

ABS Acrylonitrile butadiene styrene

Musical instruments, automotive trim components, automotive bumper bars, medical devices for blood access, enclosures for electrical and electronic assemblies etc.

PPG Polypropylene glycol Electronic, food and medical devices

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CHAPTER-3

Injection molding machine

(Techno Mac Plast(TX160) 5TON)

One of the Most common methods of converting plastics from the raw material form to an

article of use in the process of Injection Molding. This process is used for thermoplastic

materials and other polymeric material which may be successively melted, reshaped and

cooled..

Advantage of injection molding process

Parts can be produce at high production rates.

Large volume production is possible.

Relatively low labor cost per unit.

Parts require little or no finishing.

Many different surfaces, color, and finishes are available.

Good decoration is possible.

Process permits the manufacture of very small parts which are almost impossible to

Fabricated in quantities by other methods.

Minimum scrap loss result as runner, gates and rejects can be reground and reused.

Same items can be molded in different materials, without changing the machine or

mould in some cases.

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Figure of injection molding machine

Type of injection molding machine

There are various types of injection molding machine available in the market but two of

injection molding machine are used in the Paras Techno Plast .The two types of injection

molding machine are given below:-

Horizontal press injection molding machine

Vertical press injection molding machine

1. Horizontal press injection molding machine

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In which the barrel motion is parallel to the bed and mould opened in the horizontal axis.

2. Vertical press injection molding machine

In which the mould opened in the vertical axis. It is require to the production of metallic

parts.

Structure of injection molding machine

Hopper

A funnel shaped container mounted over the feed throat of a molding machine. It holds fresh

material to be gravity fed into the feed zone of heating barrel. Hopper are normally designed

to hold an average of material for a given machine size.

Figure:- Hopper of injection molding machine

Barrel

A metallic cylinder in which the injection screw resides in the molding machine. Barrel

works in the reciprocated motion, it have two strokes.

1. Forward stroke

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2. Suck back stroke

Screw

A helical flighted, metal shaft which rotates within the heating cylinder of a mould

machine, shearing, blending and advancing the melting material. After rotating, the screw is

pushed forward which injects the plastic into the mould.

The screw has three zones with a ring-plunger assembly.

Figure :- screw used in injection moulding machine

1. Feed zone

The feed section is located under the hopper and the rear section of the screw. The flight

depth is its maximum, and the material from the hoppers fills the flight of the screw. The feed

section has a constant channel depth throughout its entire length.

2. Transition zone

The heating occurs in two ways. One is the convection of heat from the heater barrel. The

second is the conversion of mechanical energy from turning the screw, into the energy, by

shearing the plastic.

3. Metering zone

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It is acts as a pump and mixing of the melt material, removing the material plasticized in the

transition zone.

Nozzle

A device mounted at the end of the heating barrel which focuses plastic material to flow

from the machine into the mould.

Clamping Unit

That section of the molding machine containing the clamping mechanism. This is used to

close the mould and keep it closed against injection pressure created by injection process.

The clamp unit also contains the ejection mechanism.

Moving Platen

The Platen of the molding machine that Travels (open and close). It connected to the clamp

unit.

Tie Bars

Large Diameter Rods that connect stationary platen A to stationary platen B. The moving

platens contain bushings which are used for sliding over the tie bars, allowing the moving

platen to travel between to the 2 stationary platens.

Toggle Clamp

It is used to describe the use of a mechanical system open and close the clamp unit of a

Molding Machine. It is operated by a relatively small hydraulic cylinder.

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Figure :- Toogle type clamping

Defect

An imperfection in the molded part that results in the product not meeting original design

specifications. These defects can be visual, physical or hidden.

Defects Causes

Flash Injection pressure too high

Clamp pressure too low

Warp Non uniform cooling rate

Bubble Injection pressure too high

Too much moisture in materials Non uniform cooling rate

Unfilled sections Insufficient shot volume

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Flow rate of material too low

Sink marks Injection pressure too low

Non uniform cooling rate

Ejectors marks Cooling time too short

Ejection force too high

Basic Operation

Before starting process, we should make sure the molding machine is in the proper working

order, and that the mould we plan to use was designed for the particular machine we plan to

use. Follow the step-by-step procedure provided below to control the setting on the machine.

Step 1 - Set the melt temperature

Step 2 - Set the mould temperature

Step 3 - Set the switch over position

Step 4 - Set the screw rotational speed

Step 5 - Set the back pressure

Step 6 - Set the injection pressure to the maximum

pressure

Step 7 - Set the holding pressure

Step 8 - Set the injection velocity to the machine

maximum

Step 9 - Set the set the holding time

Step 10 - Set the cooling time

Step 11 - Set the mould open time

Step 12 - Set the injection volume

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Step 13 - Switch to automatic operation

Step 14 - Set the mould opening

Step 15 - Set the ejector stroke, start position, and velocity

Step 16 - Set the holding pressure

Process

The process begins with the mixing and melting the raw material molten material moves

through the barrel of the machine and is forced injected into the mould. As the plastic fill and

pack the mould, ready for finishing steps and assembly.

1. Fill - The molten material flows into the mould. Flow characteristics are determined

by melt temperature, pressure and shear rate.

2. Pack - When melt plastic is compressed, it is important to fill the mould - avoiding

over packing or under packing pressure determine part weight and part dimension. Over

packing can cause dimensional problem and difficulty in ejecting the part, while under result

in short shots, shink, part weight variation, and warpage.

3. Hold - It is affected by injection speed plastic temperature, plastic pressure, and

cooling temperature and time. After the mould packed, the is held in the mould until it is

partially solidified and the freezes.

4. Cooling - It is generally the longest part of the molding cycle.

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Cycle Time

The process of cycle time of injection molding machine is depending on the part weight, part

thickness, material properties, and the machine setting specific to a given process.

The injection molding cycle can be divided into several stages. They are mold

closing, filling, packing , cooling, mold opening and ejection.

Cooling time is a function of :

Mold wall temperature

Melt temperature

Material properties

Part wall thickness

Injection Mold Tool

i. It provides the passageway for molten material to travel from the injection barrel

mold.

ii. It allows the air which to be mold trapped inside. When the mold closes to escape. If

the air could not be vented then the molded component would contain voids and air bubbles

and have poor surface finish.

iii. It cools the molding unit. It set the temperature of the mold controlled because it is

important that molding cools at the similar to the water cooling system.

iv. By means of ejectors, the finished product or part is pushed from the mold with the

help of specified link.

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Plastic Mold Tool

To fixed the one half of the mold and align the two halves by entering the holes of guide pins.

And the passageways in the mould connecting the mold to sprue with the help of gate and

runner.

Standard Equipments

Clamping system.

Heavy duty hard core plated tie bars.

Variable stages opening and closing speed ejectors.

Dual guard safety hydraulic system.

Screw and barrel.

Pyrometer temperature control.

Independent injections speed and pressure control.

Manual, semi & automatic control mode selector.

Energy saving hydraulic circuit.

Shot counter and hour meter.

Sealed oil reservoir with air filter.

Sprue breaking facility.

Heavy duty oil cooled and water cooled.

Maintenance Of Injection Molding Machine

1. Maintenance of Electrical Part

2. Maintenance of Hydraulic Part

3. Maintenance of Clamping System

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4. Maintenance of Injection System

Maintenance of Electrical Parts

Electrical part is the brain of the injection molding machine, if not pay attention to

maintenance, is easily to cause the electrical component loosing to occur open circuit and the

machine failure because machine vibrations.

We should implement the following preventive maintenance steps:-

1. The terminal block and wiring, periodic inspection and tighten.

2. When checking high voltage components inside the machine.

3. The stopper regularly checks the degree of its wear and tear on the pulley and fixed

loose wiring connections.

4. Replacing the mold, not to allow the cooling water flow to the control box.

5. Check the control box temperature is too high, so as not affect the computer work.

6. If need to the change relay. Use the specified voltage relay.

7. Regularly remove dust the electric box.

Maintenance of hydraulic system

In injection molding machine, injection pressure is major factor to determine the product

quality good or bad, so the stability of hydraulic is very important. The failure of the

hydraulic mainly from the improper working temperature and oil pollution.

1. The pressure of the oil due to oxidation and deterioration.

2. The pressure to reduce oil viscosity caused by the following:-

I. Pump damage

II. Leakage and pressure drop.

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Caused by clamping force and injection pressure decreased at the same time.

3. When replace the hydraulic oil, twisting the oil filter to clean it and just like clean the

valve.

4. Regular check the tube fittings, flanges and other fixed position, found loose in a

timely manner fastening.

5. When the hydraulic system failure, operators are not allowed to tamper with privetly,

should be immediately reported to the maintenance department.

6. All parts of hydraulic system should be without high frequency vibration.

7. Hydraulic and hydraulic motor run if, there should not be any unusual noise.

Maintenance of Clamping System

1. Daily check the manual central lubrication system, lubrication distribution and

lubricant hose, pull the handle one time before starting, check to ensure adequate lubrication

of the lubrication point.

2. Keep the feet moving template slip and slide cleaning and lubrication.

3. Adjust the mold position only when the mold maximum opened.

4. Control mold open and clamping stroke in the most appropriate location, so that the

mold smooth clamping opening and reduce the impact.

Maintenance of Injection System

1. Keep clean the two guiding cylinder pillar of the injector.

2. When the plastic temperature is normal but molded parts continue to appear black

spots or discoloration, we should check the injection screw.

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Plant layout

Order by costumer

Mould Design

Mould in 3d effect

Mould put in machine

Raw material

Make product

Quality checking

Keep store

Dispatch the order

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Conclusion

In this work we have to investigate the use of injection moulding machines.

The PP used in the injection moulding machine to make the Refrigerator Pad Stand.

The different shapes of die’s are used in the injection moulding machine for different

parts.

The trouble shooting is used in the injection moulding machine to remove the

defectiveness on the products such as flash & bubbles etc.

The atmosphere have not affected by the injection moulding process.

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Safety Precaution

1. Always run the machine in safety mode.

2. In working period do not talk to other, By this accident may caused.

3. Before handing the machine it is ensure that machine has running or closed.

4. Please only operator should handing the machine or maintenance trainer people.

5. Your safety is industrial safety, so don’t forget it.

6. Safety is not costly.

7. Please follow safety precaution in practical life, coz this is our base of life.

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