CHAPTER 1

INTRODUCTION

1.1. INTRODUCTION TO PLASTIC INJECTION MOULDING

MACHINE
Injection moulding machine offers many advantages to alternatives manufacturing
methods, including minimal losses from scrap (since scrap pieces can be melted and
recycled), and minimal finishing requirements. Injection moulding machine differs from
metal die casting, in that molten metals can simply be poured, and plastic resins must be
injected with force. It is most common used method for mass production of plastic articles
of a heated cylinder, heating the materials in the heating chamber, and forcing the molten
metal into a closed mould, where the final solidification of the molten metal in form of the
configuration of the mold cavity takes. The intending injection machine will be made from
mild steel and medium carbon steel. It can only be used for the production of small
components such as key holder, bottle cap, tally, ruler, and clothes peg. The mild steel is
used for the construction of supporting plates, hopper, mainframe, mould, and platens,
handle, and tie bars. This is because; they are not subjected to constant heat. It is easily
weld able, and has good work ability but show poor response to heat treatment. An
injection moulding machine is a piece of equipment consists of two basic elements, the
injection unit and the clamping unit. Injection moulding can be used with a variety of
plastic resins. The chosen resins forth is process are polyethylene; polypropylene, ABS,
and fluorocarbons, because of characteristics of intricate shapes can easily be produced.

Fig 1.1 Injection moulding machine

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The advantages of small injection moulding process include good surface finish of the
product can be produced, less scrap and flashes are produced, and the process has
relatively low labour costs.

Injection Moulding is a manufacturing process for producing parts from both thermoplastic
and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced
into a mould cavity where it cools and hardens to the configuration of the mould cavity.
The plastic injection moulding industry has devolved over they ears from producing combs
and buttons to producing a vast array of products for many industries including
automotive, medical, and aerospace and consumer products. The Machine parts analysis
using feature-based methodology. This approach allows robust design of part components.
This is also useful for parting plane and product layout

Injection moulding of plastics products, a manufacturing operation particularly suited for

development by local entrepreneurs or through diversification by existing manufacturers
are the subject of this final report on specific industrial growth opportunities in Carroll
County. Like the four previous reports in this special series, this study is an outgrowth of
an extensive analysis of the economic resources and development potentials of the county.
Injection molding is an ancient technology that has been used since the late
1800's. Injection molding machines incorporate a huge screw to force molten plastic into
the mold at high pressure. An injection mold consists of two halves that are forced together
to form a cavity in the shape of the part to be produced.

It is a manufacturing process for producing parts by injecting molten material into a mould.
Material for the part is fed into a heated barrel, mixed (Using a helical shaped screw), and
injected (Forced) into a mould cavity, where it cools and hardens to the configuration of
the cavity. Injection moulding is a manufacturing process for producing parts by injecting
molten material into a mould. Injection moulding can be performed with a host of
materials mainly including metals, (for which the process is called die-
casting), glasses, elastomers, confections, and most commonly thermo plastic and thermo
setting polymers. Material for the part is fed into a heated barrel, mixed (Using a helical
shaped screw), and injected (Forced) into a mould 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, moulds are made by a mould-maker (or toolmaker) from metal, usually
either steel or aluminium, and precision-machined to form the features of the desired part.
Injection moulding is widely used for manufacturing a variety of parts, from the smallest
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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. Injection moulding is
used to create many things such as wire spools, packaging, bottle caps, automotive parts
and components, toys, 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 moulding is the most common
modern method of manufacturing plastic parts; it is ideal for producing high volumes of
the same object. Injection moulding uses a ram or screw-type plunger to force
molten plastic material into a mould cavity; this solidifies into a shape that has conformed
to the contour of the mould. Thermo plastics also have an element of safety over thermo
sets; if a thermo-setting polymer is not ejected from the injection barrel in a timely
manner, chemical cross linking may occur causing the screw and check valves to seize and
potentially damaging the injection moulding machine. Injection moulding consists of the
high pressure injection of the raw material into a mould which shapes the polymer into the
desired shape. Moulds can be of a single cavity or multiple cavities. In multiple cavity
moulds, each cavity can be identical and form the same parts or can be unique and form
multiple different geometries during a single cycle. Moulds are generally made from tool
steels, Aluminium moulds are typically ill suited for high volume production or parts with
narrow dimensional tolerances, as they have inferior mechanical properties and are more
prone to wear, damage, and deformation during the injection and clamping cycles;
however, aluminium moulds are cost effective in low volume applications.

1.2. OBJECTIVE
The main aim of the research work is to design, construct and testing of small injection
moulding machine while the specific objectives of the research work are to design and
construct a small injection moulding machine, and testing. The scope of the work is to
design and construct a cost effective and environmentally friendly small injection
moulding machine for them production of small plastic articles.

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Design of efficient plastic injection moulding machine
 Suitable for small part production
 Low in cost
 Take low effort to run

1.3. PROPOSED SYSTEM

The project work will involve design concept, operations, design analysis that will entail
design of injection plunger, motor selection, design of the handle, and the leverage on the
handle of the machine. Also, assembly drawings of the machine, recommended materials
and equipment for the construction of design machine will be provided to assist investors
that want to venture into construction of this machine. Development of small injection
moulding machine for forming small plastic articles in small-scale industries was borne out
of the fact that most injection moulding machines were of big size and most small-scale
industries in developing countries could not avoid buying them due to their costs. In
solving this problem, there is a need to design small injection moulding machine that
avoidable by small scale industries for production of small plastic articles, this is the
rationale behind this work.

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 CHAPTER 2

LITERATURE REVIEW
Injection moulding has been a challenging process for many manufacturing and researchers
to produce products meeting requirement at the lowest cost. Faced with global competition
moulding industry, using the trail and error approach to determine the process parameters
for injection moulding is no longer good enough. Factors that affect the quality of a
method part can be classified into four categories. Part design mould design, machine
performance and processing conditions. The part and mould design are assumed as
established and fixe. During production, quality characteristic may deviate due to drifting
or shifting of processing condition caused by machine wear, environment change or
operator fatigue.
Determine optimal process parameter setting critically influence productivity, quality, and
cost of production in the plastic injection moulding (PIM) industry. Previously, production
engineers used either trail and error method or Taguchi’s parameter design method to
determine optimal process parameter setting for PIM. However, these methods are un
suitable in present PIM because of the increasing complexity of product design and the
requirement of multi response quality characteristics.

2.1. RESEARCH PAPER BY PREVIOUS SCIENTIST

Kamble.S.A, et. al. [1]In this paper discusses, it is necessary to start out with quality
components. Injection moulded parts can be moulded to a high quality standard by
focusing on these areas of plastic technology correct part design, Accurate selection
material processing plastic. the purpose of this design deals with the first of these three
issue part design. the problem which may occurs in the development phase of the product
are solved in the design phase itself. So the rework and modification of mould is avoided
by minimizing the wastage and scraps.

Ching-Chih Tsai, et. al. [2] In this work, pragmatic techniques for mechatronic design and
injection speed control of an ultra high-speed plastic injection moulding machine. PI
controller and a fuzzy PI controller are used, compared and then implemented into a digital
signal processor (DSP) using standard C programming techniques. Deals with mechatronic
design and injection Speed control of an ultra-high Speed Plastic Injection Moulding
Machine

5
Liu.W, [3] This paper deals with the microscopic features of cavitations erosion and the
solution in the plastic injection moulding machines The failure of nozzle unit in the plastic
injection moulding machines was discovered to be cavitations erosion, rather than
corrosion Three types of erosion pits in different size order have been discovered The
cavitations erosion with substituting stainless steel to aluminium has been successful.

Medrea.C, [4] this deals with Failure Analysis of H13 Working Die Used in Plastic
Injection Moulding the die was made from AISI H13 steel and was intended for the
production of plastic cups used for the outer closure of cylindrical aluminium cans in
coffee packaging. Corrosion damage and wide crack are observed by necked eye. Design
deficiency and improper cooling conditions generated a complex fatigue- corrosion
cracking mechanism that lead to the damage of the die after half of its predicted service
life.

Khan. S. F, et. al. [5] This paper presented the design process and manufacturing of a
bench top and inexpensive injection moulding machine for use as learning and teaching
equipment and in a manufacturing lab. The design use a horizontal plunger type of
injection equipped with clamping system. The maximum volume of barrel is 290cc
combined with injection plunger 60 mm provides ideal capacity for lab. The design
concept and process preliminary test result are discussed. The flow rate increases with
increase of motor speed and the packing time decrease with increase of motor speed. At
2500rpm the flow rate is 0.42m/s and packed time is 15 sec.

Korapatti.S.B, [6] This paper presents the design and simulation of plastic injection
moulding machine for producing a plastic products. The plastic part was designed into two
different types of products, but in the same uses function. One half is exploitation clip
function and another half is exploitation tic function. For mould design the product was
designed into two changeable inserts to produce two different type of plastic product in one
mould base. From the analysis and simulation we can define the most suitable injection
locations, material, temperature and pressure for injection.

Gurjeet Singh, [7] The term quality has become a “catch all” term used in describing the
various characteristics of an object. It is nearly impossible to define the term consistency.

6
The quality is any particular or specific characteristics of a product development design
object that contains or relates information about the object. This is primarily a chunk of
geometry distinguished by it’s ability to perform a function with one or more other. In this
primary processing conditions are studied from concept development to manufacturing of
the product. Various responses of quality of injection moulding processes has been studied
on the basis of performance parameters and methods. This paper aims to present plastic
injection moulding process conditions. The processing conditions satisfied quality based
product manufacturing.

Sreedhar.CH, [8] This paper states the advantages in using plastic materials, there is a non
going trend of replacing metal with injection moulded plastic parts in a wide variety of
applications. More and more parts with critical end-use applications requirements are
becoming candidates for conversion to plastics. Plastics are light- weight, sturdy and
corrosion resistant; have a high strength-to-weight ratio; and once employed in
transportation applications; for instance, provide one amongst the best ways in which to
extend fuel savings by making vehicles additional light weight.

Gerber.A.G, [9] It designates that CFD-based Predictive Control of Melt Temperature in

Plastic Injection Moulding. Unique method of coupling computational fluid dynamics
(CFD) to model predictive control (MPC) for controlling melt temperature. The CFD to
generate, via open-loop testing, a temperature and input dependent system model for multi-
variable control of a three-heater barrel on an injection moulding machine. CFD can be
used to dramatically reduce the time associated with open-loop testing through physical
experiments.

Sasikumar.C, et.al [10] Shows Analysis of Premature Failure of a Tie Bar in an Injection
Moulding Machine. Premature failure of a tie bar made of AISI 4140 steel in a 150-ton
plastic injection-moulding machine has been analyzed. Although the nominal tensile stress
acting on the tie bars (95.5 MPa) is far lower than the yield strength of this material (750-
900MPa). The solution is a hydraulic clamping mechanism rather than a toggle clamp
mechanism for the mould will minimize the cyclic strain on the tie rods.

Lucchetta.G, [11] states a new approach to the optimization of Blends composition in

Injection Moulding of Recycled Polymer. Recycled polymers are usually blended with
virgin polymers to obtain the best trade-off between co stand low melt viscosity.

7
This last constraint is necessary to avoid short shots and to minimize the clamp force of the
required injection moulding machine and, therefore, the process cost. A new approach to
the minimization of the overall manufacturing cost.

2.2. GAPS IN LITERATURERE VIEW

Reducing and lowering the cost of injection moulding with quick mould change
system:
One of the best practices requires a fully automated mould change. Not only will this
decrease change over time, but it will also make the manufacturer lot more flexible in his
production quantity.

Using biopolymers and biodegradable plastics: -

Enhancing Biopolymers Additives Are Needed for Toughness, Heat Resistance & Process
ability Plastics are going “green,” but they will need some help to get there. Biodegradable
polymers derived from renewable resources are attracting lots of interest and publicity,

Use of polypropylene material

 Polypropylene, a synthetic resin built up by the polymerization of propylene.

 Polypropylene is moulded or extruded into many plastic products in which

toughness, flexibility, light weight, and heat resistance are required.

 Polypropylene (pp), also known as polypropylene, is a thermoplastic polymer

used in a wide variety of applications including packaging and labelling,
textiles (e.g., Ropes, thermal underwear and carpets), stationery, plastic parts
and reusable containers of various types, laboratory equipment, loud speakers,
automotive components, and polymer bank notes.

 Polypropylene has a variety of different unique properties that makes it

invaluable in applications, where rigidity and stiffness are needed. As a result,
polypropylene is used in everything from plastic containers to wall siding
laminates.

 Where rigidity and stiffness are needed. As a result, polypropylene is used in

everything from plastic containers to wall siding laminates. Easy to produce,
assembly and an economic material

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CHARTERISTIC

 Light in weight
 Excellent resistance to stress and high resistant to cracking (i.e. it has high
tensile and compressive strength)
 High operational temperatures with a melting point of160°C
 Excellent dielectric properties
 Non-toxic
 Easy to produce, assembly and an economic material
 It is often used in applications where rigidity and stiffness are needed. When
polyethylene is in capable of providing mechanical properties that are
specified, in many cases, it is polypropylene that takes its place.

2.2.1. PORTABLE INJECTION MACHINE

We are trying to make portable and easy to transfer type machine which take very less area
and which ultimately reduces the overall cost and the machining cost of the product. The
machine can be easily transportable from one place to another the installation and un
installation of the system will be easy.

These are the basic and main motive of our project which certainly reduces the effort and
can be made easily available for everyone.

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 CHAPTER 3
THEORETICAL BACKGROUND

3.1. MANUFACTURING OPERATION

The operations required to produce plastics products by injection molding Include
 Preparation of the molding material,
 Melting the material,
 Forcing the material through a nozzle and into a mold,
 Ejecting the molded product
 Machining and finishing the product.
 Operations 1 through 4 may be performed without interruption on a single
combination of processing machinery.

Molding materials are frequently ready for immediate use when they are delivered by the
supplier, but they may require pre-molding preparation. Plastic material fed to the injection
machine must be reasonably free of moisture if internal voids and surface defects are to be
avoided. Consequently, drying may be necessary to remove moisture from the surface of
molding resins or, in the case of such hygroscopic materials as nylon, acrylics, and styrene
blends, to drive out adsorbed water.

Pre-molding preparation may also require addition of colorants, lubricants, other resins,
and scrap material which is to be reworked. These materials are generally blended in to the
virgin resin in some sort of tumbler.

After any necessary preparation, the molding material is transferred, either Mechanically or
manually, to a hopper which feeds the material to the heating cylinder of the injection-
molding machine. Heat and mechanical agitation convert the cold, granular feed material
into a homogeneous plastic melt of controlled viscosity. Temperature in the cylinder is
controlled by wraparound electrical resistance heaters. Mixing action is provided by
forcing the melt past baffles or spreaders or by use of a rotating screw mechanism within
the cylinder.

The plastic melt is forced through a nozzle and into the mold. Nozzle temperature is
controlled to allow continued cleans hots of plastic in to the mold with out hard eningand
breaking or drooling. The mold accepts a metered amount of plastic molding material

10
and cools it quickly and uniformly, usually by transferring the heat to water or some other
medium which is circulated through channels buried in the mold.

When the molding compound has set, the mold is opened and the molded part is forced out
of the mold cavity. Some molded articles require some form of machining or finishing.
Thermoplastics products can be machined with the same equipment used for wood or
metals, except that allowance must be made for the greater heat sensitivity of the plastics
product. They may be sawed, routed, drilled, turned, tapped, threaded, and sheared.
Articles may be finished by buffing and polishing if surfaces are cooled or kept in constant
motion, by tumble finishing, and by solvent polishing.

3.2. COMPONENTS
 Bearing
 Hopper
 Stepper motor
 Die
 Pneumatic punch
 Table
 Heater
 Gear
 Barrel

3.2.1. BEARING
A bearing is a machine element that constrains relative motion to only the desired motion,
and reduces friction between moving parts. The design of the bearing may, for example,
provide for free linear movement of the moving part or for free rotation around a fixed
axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on
the moving parts. Most bearings facilitate the desired motion by minimizing friction.
Bearings are classified broadly according to the type of operation, the motions allowed, or
to the directions of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical
systems, and transfer axial and radial loads from the source of the load to the structure
supporting it. The simplest form of bearing, the plain bearing, consists of a shaft

11
rotating in a hole Lubrication is often used to reduce friction. In the ball bearing and
roller bearing, to prevent sliding friction, rolling elements such as rollers or balls with a
circular cross-section are located between the races or journals of the bearing assembly. A
wide variety of bearing designs exists to allow the demands of the application to be
correctly met for maximum efficiency, reliability, durability and performance.

The term "bearing" is derived from the verb "to bear" a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form, size,
roughness and location of the surface. Other bearings are separate devices installed into a
machine or machine part. The most sophisticated bearings for the most demanding
applications are very precise devices; their manufacture requires some of the highest
standards of current technology.

CONSTRCTIONS:- Ball bearings are composed of four main parts, two rings (races).
The rolling element (balls) and the ball separator (retainer).

Fig 3.1 Ball Bearing

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SPECIFICATION
1. Dimension:- important dimensions to consider when specifying bearings
include.
 Bore:- the bearing industry uses a standard numbers system for bearing
with metric diameters bores. For bores size 04 and up multiply by 5 to
obtain the bore in milli meter. If the bore is a hex this refers to
dimension across the flats. If the bore is tapered this refers to the
smaller diameters.
 Outside diameters:- the outside diameters of bearing include the
housing if a housed unit, but excludes the flanges if a flanged bearing.
The outer ring width is the overall width of the outside of the bearing
 Overall width:- the overall width of the bearing or the bearing
assembly include the locking collar, if present
2. Operating specification:- important operating specification is to considers
when searching for bearing includes rated speed, dynamic axial or thrust load
and dynamic radial load.
 Rated speed:- the rated speed for bearing running with grease
lubrication is lower than a bearing with oil,
 Dynamic axial or thrust load:- Dynamic axial or thrust load is the
calculated constant axial load.
 Dynamic radial load:- the dynamic redials load id the calculated
constant axial load, which a group of identical bearings with stationery
outer rings can theoretically endure for a ratting life of one million
revolutions of the inner ring.
 Bearing load, fatigue and lifespan:- optimum bearing life is obtained
when the balls and raceway have absolute minimum surface content
supplemented with proper lubrication. Loads for ball bearings are
subject to static or dynamic loads, as well as axial and radial loads. this
means four variables need to be accounted for to determine working
load for a bearing. Ball bearing can be handled substantially more radial
and dynamic loads than the axial and static loads. Calculated life of
bearing is based on its load, operating speed and environmental factors.
Industry standards typically required that 90% of bearing

13
3.2.2. HOPPER
 A storage container used to dispense granular materials through the use of
a chute to restrict flow, sometimes assisted by mechanical agitation
 A paint ball loader
 A manufacturing line hopper
 Hopper (particulate collection container), a large container used for dust
collection
 Feeder (livestock equipment)

Fig 3.2 Hopper

3.2.3. STAPPER MOTOR

A stepper motor, also known as step motor or stepping motor is a brushless DC electric
motor that divides a full rotation in to a number of equal steps. The motor's position can
then be commanded to move and hold at one of the steps without any position sensor for
feedback an open loop controller, as long as the motor is carefully sized to the application
in respect to torque and speed.

14
Switched reluctance motors are very large stepping motors with a reduced pole count, and
generally are closed-loop commutated.

Brushed DC motors rotate continuously when DC voltage is applied to their terminals. The
stepper motor is known by its property to convert a train of input pulses (typically square
wave pulses) into a precisely defined increment in the shaft position. Each pulse moves the
shaft through a fixed angle.

Stepper motors effectively have multiple "toothed" electromagnets arranged around a

central gear-shaped piece of iron. The electromagnets are energized by an external driver
circuit or a micro controller. To make the motor shaft turn, first, one electromagnet is given
power, which magnetically attracts the gear's teeth. When the gear's teeth are aligned to the
first electromagnet, they are slightly offset from the next electromagnet. This means that
when the next electromagnet is turned on and the first is turned off, the gear rotates slightly
to align with the next one. From there the process is repeated. Each of those rotations is
called a "step", with an integer number of steps making a full rotation. In that way, the
motor can be turned by a precise angle.

Fig 3.3 Motor

15
TYPES
There are three main types of stepper motors:
1. Permanent magnet stepper
2. Variable reluctance stepper
3. Hybrid synchronous stepper

Permanent magnet motors use a permanent magnet (PM) in the rotor and operate on the
attraction or repulsion between the rotor PM and the stator electro magnets. Variable
reluctance motors have a plain iron rotor and operate based on the principle that minimum
reluctance occurs with minimum gap, hence the rotor points are attracted toward the stator
magnet poles. Where as hybrid synchronous is a combination of the permanent magnet and
variable reluctance types, to maximize power in a small size.

3.2.4. DIE
A die is a specialized tool used in manufacturing industries to cut or shape material mostly
using a press. Like molds, dies are generally customized to the item they are used to create.
Products made with dies range from simple paper clips to complex pieces used in advanced
technology.

Fig 3.4 Die

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3.2.5. PNUMATIC PUNCH
Punching is a forming process that uses a punch press to force a tool, called a punch,
through the work piece to create a hole via shearing. Punching is applicable to a wide
variety of materials that come in sheet form, including sheet metal, paper, vulcanized fiber
and some forms of plastic sheet. The punch often passes through the work into a die. A
scrap slug from the hole is deposited into the die in the process. Depending on the material
being punched this slug may be recycled and reused or discarded.

A punching machine is a machine tool for punching and embossing flat sheet materials to
produce form-features needed as mechanical element and/or to extend static stability of a
sheet section.

Punch presses are developed for high flexibility and efficient processing of metal
stampings. The main areas of application are for small and medium runs. Those machines
are typically equipped with a linear die carrier (tool carrier) and quick change tools. Today
the method is used where the application of lasers are inefficient or technically impractical.
CNC is the abbreviation of Computer Numerically Controlled.

Fig 3.5 pneumatic punch

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SPECIFICATION
 Cylinder Tube: For bore of 19, 25, 40, and 50 mm hard drawn, polished brass
aluminum tube and for bores of 65, 75, 100, 125, 150, 200, 250 and 300 mm
seamless honed & hard chrome plated steel tube is used.
 Piston Rod: High tensile steel, Ground & hard chrome plated.
 Seals : Buna "N" ( Nitrile elastomer )
 End cover & piston: Close grained cast iron.

 Pressure Range: 10 Kg/cm2 (150 PSIG) for compressed air. 25 Kg/cm2 (350 PSIG)
for oil.
 Cushions: For 19 and 25 mm Bore rubber shock absorbers as optional. Above 25
mm bore adjustable cushions as standard.
 Consumption : Liters of free air per 100 mm single stroke at 5 Kgf/cm2

PRINCIPAL
After programming the work pieces and entering length of bars the control automatically
calculates the maximum number of pieces to be punched (for example, 18 pieces of a bar
of 6000mm).Once the desired number of work pieces is entered, the bar is pushed toward
the stop. The machine is fully automated once the production process is launched.

3.2.6. HEATER
A heater is an object that emits heat causing other objects to achieve a higher temperature.
Creating and controlling heat is a crucial factor for an extremely wide range of applications
and industrial processes. From small heaters keeping a few batteries warm to large
industrial dryers and complex injection molding machines, heaters are versatile devices
that require very specific design elements to tail or them to the application.

3.2.7. PRINCIPAL OF HEATING

 Heating is a complex process governed by the principles of thermodynamics,
fluid mechanics, and heat transfer. Heat transfer, in particular, is useful
knowledge as it will help inform important aspects of heater selection and
system design.
 Heat transfer is the movement of heat from one area (or object) to another,
always from areas of high concentration (hot) to areas of low concentration
(cool). There are three methods of heat transfer:

18
 Fig 3.6 heater

3.2.8. BARREL
A barrel, cask, or turn is a hollow cylindrical container with a bulging center, traditionally
made of wooden staves bound by wooden or metal hoops. Traditionally, the barrel was a
standard size of measure referring to a set capacity or weight of a given commodity.

Fig 3.7 Barrel

Someone who makes barrels is called a "barrel maker" or cooper. Barrels are only one type
of cooper age. Other types include, but are not limited to, the making of buckets,

3.2.9. GEAR
A gear or cogwheel is a rotating machine part having cut teeth, or in the case of a
cogwheel, inserted teeth (called cogs), which mesh with another toothed part to transmit
torque. Geared devices can change the speed, torque, and direction of a power source.
Gears almost always produce a change in torque, creating a mechanical advantage, through
their gear ratio, and thus may be considered a simple machine. The teeth on the two
meshing gears all have the same shape. Two or more meshing gears, working in a
19
sequence, are called a gear train or a transmission. A gear can mesh with a linear toothed
part, called a rack, producing translation instead of rotation. The gears in a transmission are
analogous to the wheels in a crossed, belt pulley system. An advantage of gears is that the
teeth of a gear prevent slippage.

When two gears mesh, if one gear is bigger than the other, a mechanical advantage is
produced, with the rotational speeds, and the torques, of the two gears differing in
proportion to their diameters. In transmissions with multiple gear ratios such as bicycles,
motorcycles, and cars the term "gear" a sin" first gear" refers to a gear ratio rather than an
actual physical gear. The term describes similar devices, even when the gear ratio is
continuous rather than discrete, or when the device does not actually contain gears, as in a
continuously variable transmission

Fig 3.8 gear

MATERIALS USED IN GEAR

1. Cast iron is used in gear because cast iron is a group of iron carbon alloys with a
carbon content greater the 2% and silicon (1-3) %.
2. Cast iron used in gear because it is relatively in expensive, rust resistant and
easy to mold.
3. It has 3 to 5 times compression strength compare to steel and it has good
machine ability, good sensibility, excellent resistance to wear, low notch
sensitivity, low stress concentration, durability, resistance to deformation and
20
 low cost.
4. It has constant properties between 20 to 350 degree Celsius.

WHY CHOSE THE SPUR GEAR

1. Spur gears are simple components, very easy to design and install in drive
mechanisms
2. These are very straight forward and they are ideal for limited spaces.
3. These gears are suitable for driving systems because they have more power
transmission efficiency.
4. A spur gear is built with teeth made straight and parallel to the axis of gear.
Eliminating any issue of axial thrust allowing ball bearing to be installed.
5. Spur gear are more efficient compared to helical gears with the same size
6. They offer constant velocity
REFEANCE: Rufus Ogbuka Chime

3.2.1. BEARING BLOCK

A pillow block is a pedestal used to provide support for a rotating shaft with the help of
compatible bearings & various accessories. Housing material for a pillow block is
typically made of cast iron or cast steel.
A pillow block usually refers to a housing with an included anti-friction bearing. A pillow
block refers to any mounted bearing wherein the mounted shaft is in a parallel plane to the
mounting surface, and perpendicular to the center line of the mounting holes, as contrasted
with various types of flange blocks or flange units. A pillow block may contain a bearing
with one of several types of rolling elements, including ball, cylindrical roller, spherical
roller, tapered roller, or metallic or synthetic bushing.

The type of rolling element defines the type of pillow block. These differ from "plummer
blocks" which are bearing housings supplied without any bearings and are usually meant
for higher load ratings and a separately installed bearing.
Bearing housings are usually made of grey cast iron. However, various grades of metals
can be used to manufacture the same, including ductile iron, steel, stainless steel, and
various types of thermoplastics and polyethylene-based plastics.
The bearing element may be manufactured from 52100 chromium steel alloy (the most
common), stainless steel, plastic, or bushing materials such as SAE660 cast bronze, or
SAE841 oil impregnated sintered bronze, or synthetic materials.

21
 Fig 3.9 Bearing Block
SPECIFICATION
The properties of the pedestal bearing due to their higher efficiency.
 The bearings used are pedestal bearings due to their higher efficiency.
 The material of the bearing is alloy steel due to its high strength values.
 The specification of the bearings used are:
 Bore dia. = 25 mm
 Outer dia. = 45mm
 Width = 15mm
 Dynamic load = 7800N
 Static load = 3750N

22
 CHAPTER 4

METHODOLOGY

Start

Study of plastic injection moulding process

Market survey and problem definition

Study of research paper an literature review

List of required equipment’s

Design calculations of parts

Analysis of the frame

Part modeling in software

Fabrication of parts

Assemble the parts in workshops

Calculate the output parameters

Check quality of the output part

Finish

23
4.1. DESIGN AND COMPONENTS SPECIFICATION

Main frame table 130cm X 60cm X 100cm

Barrel L=45cm, D=8cm
Screw thread 25cm
Pneumatic punch Eject 5cm
Die 5cm X 5cm
Stepper motor P= 24 W, Model= L298
Heater 500W
Gear1 D1= 13cm, T1=38
Gear2 D2=7cm, T2=22
Hopper D=20cm, H=30cm
Table 4.1 measurement of components

4.2. DESIGN
This design concept encompasses the following:
 Maximum volume of the melt needed to fill the mould. This entails plunger
travel, diameter of the barrel , melt density and melt mass;
 Design of barrel which entails diameter of the barrel and maximum piston
travel;
 Design for plunger.
 While the design analysis entails the following units:
 The injection unit comprises of the hopper, barrel, heater bands, nozzle, and
injection plunger.
 The clamping unit consists of the mould, platens, and the handle known as the
locking device.
 The electrical panel comprises of temperature control ,contactors, thermo
couple, heat resistance wire, and knob (control button).

4.3. DESINGNING COMPONENTS

The component design activity is an activity of the product design activity for creating
a component design the product architecture identifies a set of adaptable components that
may be used to implement a work product family. A component design is
a design specification for one of these adaptable components.
24
4.3.1. MAIN FRAMETABLE
A table is a collection of data items that have the same description, such as account totals or
monthly averages it consists of a table name and subordinate items called table elements.
A table is the COBOL equivalent of an array you can easily repeat data items.

FIG 4.1 main frame table

4.3.2. BARREL
A barrel, cask, or turn is a hollow cylindrical container with a bulging center, traditionally
made of wooden staves bound by wooden or metal hoops. Traditionally, the barrel was a
standard size of measure referring to a set capacity or weight of a given commodity.
Someone who makes barrels is called a "barrel maker" or cooper. Barrels are only one type
of cooperage. Other types include, but are not limited to, the making of buckets, vats ,tubs ,
butter churns, hogsheads, firkins, kegs kilder kins, tierces, rundles, puncheons, pipes, tuns,
butts, pins, and breakers.

25
 Fig 4.2 barrel

4.3.3. RECIPROCATING SCREW

In a reciprocating screw injection molding machine, material flows under gravity from the
hopper on to a turning screw. The mechanical energy supplied by the screw, together with
auxiliary heaters, converts the resin into a molten state

Fig 4.3 reciprocating screw

4.3.4. GEAR
A gear or cogwheel is a rotating machine part having cut teeth, or in the case of a cog
wheel, inserted teeth (called cogs), which mesh with another toothed part to transmit
torque. Geared devices can change the speed, torque, and direction of a power source.
Gears almost always produce a change in torque, creating a mechanical advantage, through

26
their gear ratio, and thus may be considered a simple machine. The teeth on the two
meshing gears all have the same shape. Two or more meshing gears, working in a
sequence, are called a gear train or a transmission. A gear can mesh with a linear toothed
part, called a rack, producing translation instead of rotation The gears in a transmission are
analogous to the wheels in a crossed, belt pulley system. An advantage of gears is that the
teeth of a gear prevent slippage.

When two gears mesh, if one gear is bigger than the other, a mechanical advantage is
produced, with the rotational speeds, and the torques, of the two gears differing in
proportion to their diameters. In transmissions with multiple gear ratios such as bicycles,
motorcycles, and cars the term "gear" a sin "first gear" refers to a gear ratio rather than an
actual physical gear. The term describes similar devices, even when the gear ratio is
continuous rather than discrete, or when the device does not actually contain gears, as in a
continuously variable transmission

Fig 4.4 gear

4.3.5 HOPPER
 A storage container used to dispense granular materials through the use of a
chute to restrict flow, sometimes assisted by mechanical agitation

 A paint ball loader.

 A manufacturing line hopper.

 Hopper (particulate collection container), a large container used for dust

collection.

 Feeder (live stock equipment)

27
 Fig 4.5 Hopper

4.3.5. STAPPER MOTOR

Dc Motor. Motor is a device which transforms the electrical energy into mechanical
energy. The working principle of the motor is the interaction between the magnetic field
and the current to produce a force within the motor which helps the motor to do work.

Fig 4.6 Stepper Motor

4.3.6. PNUMATIC PUNCH

Punching is a forming process that uses a punch press to force a tool, called a punch,
through the work piece to create a hole via shearing. Punching is applicable to a wide

28
variety of materials that come in sheet form, including sheet metal, paper, vulcanized fiber
and some forms of plastic sheet. The punch often passes through the work into a die. A
scrap slug from the hole is deposited into the die in the process. Depending on the material
being punched this slug may be recycled and reused or discarded.

A punching machine is a machine tool for punching and embossing flat sheet- materials to
produce form-features needed as mechanical element and/or to extend static stability of a
sheet section. fiber and some forms of plastic sheet. The punch often passes through the
work into a die. A scrap slug from the hole is deposited into the die in the process.
Depending on the material being punched this slug may be recycled and reused or
discarded.

A punching machine is a machine tool for punching and embossing flat sheet- materials to
produce form-features needed as mechanical element and/or to extend static stability of a
sheet section.

Punch presses are developed for high flexibility and efficient processing of metal
stampings. The main areas of application are for small and medium runs. Those machines
are typically equipped with a linear die carrier (tool carrier) and quick change tools. Today
the method is used where the application of lasers are inefficient or technically impractical.
CNC is the abbreviation of Computer Numerically Controlled.

Fig 4.7 Pneumatic punch

4.3.7. BEARING BLOCK

A pillow block is a pedestal used to provide support for a rotating shaft with the help of
compatible bearings & various accessories.
A pillow block usually refers to a housing with an included anti-friction bearing. A pillow
29
block refers to any mounted bearing wherein the mounted shaft is in a parallel plane to the
mounting surface, and perpendicular to the center line of the mounting holes, as contrasted
with various types of flange blocks or flange units. A pillow block may contain a bearing
with one of several types of rolling elements, including ball, cylindrical roller, spherical
roller, tapered roller, or metallic or synthetic bushing. The type of rolling element defines
the type of pillow block. These differ from "Plummer blocks" which are bearing housings
supplied without any bearings and are usually meant for higher load ratings and a
separately installed bearing.

Fig 4.8 bearing block

4.4. ASSEMBLY OF MACHINE

The procedures for assembling the machine are as follows: -
 fixing the mainframe,
 position the supporting plates and bolt them together with the tie bars,
 bolt the barrel to the supporting plate2,
 mount the plunger assembly through the supporting plates1 and 2to the barrel,
 positioning of the driven unit to the plunger assembly: the driven unit are spur
gear, the reduction gearbox and electric motor,
 mount the handle (locking device) through the supporting plate 4 to the platen,
and
 Install the mould to supporting plate 3 and the platen.

4.5. MATERIAL
The following materials used in the construction of this machine are medium carbon steel
used for injection plunger, barrel and nozzle. Mild steel was used for hopper, supporting
plates, tie bars, platen, mould, bolts, and main frame. Other materials used are
thermocouples, limit switches, knobs (control button), bolts, and 4-core flexible wires, heat
30
resistance wires, and contactors, red and light green paints.

4.5.1 MATERIAL SELECTION

Materials are selected based on designed and metallurgical properties of the materials such
as mach inability, formability; weld ability that greatly influences the construction methods
and other joining methods. Other factors considered are cost of the materials; and
mechanical properties of the materials. All the general finishing operation was carried out
on the machine such as grinding of all rough edges using a hand grinding machine.

4.5.2 EQUIPMENT
The equipment used are as follows: electric motor, other such as mainframe is cut into
sizes using oxyacetylene gas welding, facing operation mould, barrel, injection plunger,
and handle were faced using the lathe machine., drilling operation, milling operation, and
tapping operation using drilling machine, milling machine and tapping machine
respectively. Components such as the drilling operation on the lathe machine were
performed on the components such as the mould, barrel, tie bars, and the supporting plates.
Milling operation was carried out on the barrel, and the spur gear teeth. Tapping operation
was also carried out on the tie bars. All the general finishing operation was carried out on
the machine such as grinding of all rough edges using a hand grinding machine. Cutting
saw or frame cutting were used for cutting the various metals into sizes and required
shapes. Metals such as the supporting plates, platen, tie bars, barrel, injection plunger, and
hopper were cut sizes using manual hacksaw.

4.6. OPERATION PROCEDURE

The operational principles of this machine are as follows: switch on the heater for one
hour, and set the electric controllers to the desired temperature, and fill the hopper with
materials (high density polyethylene and master batch). When beginning to inject the
molten resins to the mould, make sure the mould is close and there are two limit switches
that determine the stroke of forward and backward movement of the injection plunger.
That is when the injection plunger reaches the maximum forward stroke pre determined for
the particular mould, a limit switch will be actuated and this will stop the electric motor
movement. The same way goes to the backward stroke and this determined the amount of
molten resins that goes in to the mould. If the mould functions properly, the finished
product will fall out of the mould on its own.

31
 CHAPTER 5
EXPERIMENTAL ANALYSIS

5.1. PLASTIC MATERIAL

 Thermoplastics:-Thermoplastics are the plastics that do not undergo chemical

change in their composition when heated and can be molded again and again.
They are easily molded and extruded in to films, fibers and packaging.
Examples include polyethylene (PE), polypropylene (PP) and polyvinyl
chloride (PVC).
 Thermosetting plastics:-Thermosetting plastics which are formed by heat
process but are then set (like concrete) and cannot change shape by reheating.
They are hard and durable. Thermo sets can be used for auto parts, air craft
parts and tires. Examples include polyurethanes, polyesters, epoxy resins and
phenolic resins.

5.1.1. POLYPROPYLENE MATERIAL

 Polypropylene, a synthetic resin built up by the polymerization of propylene.
 Polypropylene is molded or extruded into many plastic products in which
toughness, flexibility, light weight, and heat resistance are required.
 Polypropylene (pp), also known as polypropylene, is a thermo plastic polymer
used in a wide variety of applications including packaging and labeling,
textiles (Ropes, thermal underwear and carpets), stationery, plastic parts and
reusable containers of various types, laboratory equipment, loudspeakers,
automotive components, and polymer bank notes.
 Polypropylene has a variety of different unique properties that makes it
invaluable in applications, where rigidity and stiffness are needed. As a result,
polypropylene is used in everything from plastic containers to wall siding
laminates.

32
5.2. SPECIFICATIONS OF POLYPROPYLENE MATERIAL
 Specific Gravity:0.90
 Melting Point:160°C
 Tensile Strength: 31.027 N/mm2
 Hardness:R95

5.3. MOULDING ENERGY

Energy efficiency of productive processes is one of the most important strategies to
achieve it. The market demands products made with lower carbon footprint and with
environmentally friendly materials. There duct ion of energy and resource consumptions is
relevant for the plastic industry, not only from the environmental point of view, but also for
production cost reduction. The plastic processing sector is an intensive consumer of
electrical energy. It is estimated that the cost of energy represents between 4% and 10% of
the operational costs in a processing plant.

The energy consumption of the Colombian plastic and rubber industry is well above the
average consumption of the whole manufacturing industry. As shown in Figure 1, the
plastic industry historically requires around twice the energy to obtain the same production
(given in Colombian pesos) than the whole Colombian manufacturing industry.

Fig 5.1 energy consumption

33
 CHAPTER 6

CONCLUSION
Designing of machining components are considered very important task now a days. There
are several Design analysis Software’s are used. This design result can be used to pre-
calculate the production & manufacturing process of machine in order to achieve faster
breakeven point. Analysis/simulation provides an insight into the nature of processing and
consequently offers valuable inputs to wards the design of the Parts. This study is intended
to be the stepping stone for incorporating more the use of Injection Moulding simulation
software in the product design, mould design, and product development that involves the
use of injection moulding process.

6.1. FUTURE SCOPE

The presented plastics injection molding curriculum provides a benefit to students and
leads them to the field of plastics processing. The well-designed four-stage project gives
students an opportunity to apply what they have learned from classroom lectures, as well as
previous knowledge and skills, to complete the hands-on projects. The sequence of lectures
and lab sessions was arranged in a way so that students had necessary knowledge and skills
to complete each stage of their project, and in turn it reinforced and enhanced what they
learned. The course content is very large, covering a wide range of topics related to plastics
injection molding. This seems to be excellent to those capable students who have a strong
background. However, it probably overwhelmed the students with little background. How
to reduce the course content and keep the essential lectures would be the future topic for
course improvement.

 Plastic injection moulding industry is now facing the very heavy competition;
most of the plastic injection moulding companies is working on mercy profits
and low technologies.

 Speed up all the moulding machines. For this point you need to be sure that
your machines are suitable for high speed running

 Even if your machine are high speed, but if you are in shortage of automation
system in your injection moulding plants, then you need a lot of labour to pick

34
 up the molded plastic components from the machine and you need to stack or
collect them before packing. All these need labours and this will reduce the
production capacity, in the same time the labour cost will be highly increased.

 In the project we have used manual plunger arrangement for pressing the
molten plastic instead of that we can have hydraulic arrangement for the
automatic control that will reduce production time.

 Also for the batter and quick heating to melt the plastic insulation can be done
which will reduce the heat loss.

35
REFERENCES
1. Injection moulding hand book. Ms Snehal A. Kamble,(Dec2003).
2. Ching-Chih Tsai, Shih-Min Hsieh, Huai-En Kao. “Mechatronic design and
injection speed control of an ultra-high speed plastic injection moulding
machine” in mechatronics (March2009).
3. William Liu. “The microscopic features of cavitation erosion and the solution
in the plastic injection moulding machines” in Engineering Failure Analysis
(January2014).
4. C.Mendra, N.Kyriakou “This deals with Failure analysis of H13 working die
used in plastics injection moulding the die was made from AISI H13 steel”.
(October 2014).
5. S.F.Khan, K U murani and R A Siregar “the design process and
manufacturing of a bench top and in expensive injection moulding machine
for u seas learning and teaching equipment and in a manufacturing lab.”
(July2008).
6. Korapatti Surendra Babu “This paper presents the design and simulation of
plastic injection moulding machine for producing a plastic” (December2003).

7. Gurjeet Singh, “It is nearly impossible to define the term consistency. The
quality is any particular or specific characteristics of a product development
design.” (January2007).
8. CH. Sreedhar “Plastics are light-weight, sturdy and corrosion resistant; have a
high strength-to-weight ratio.” (August2008).
9. A.G. Gerber, R. Dubay, A. Healy. “CFD-based predictive control of melt
temperature in plastic injection moulding” in Applied Mathematical
Modelling (September2006).
10. Sasikumar, S. Srikanth, S.K. Das “Premature failure of a tie bar made of AISI
4140steelina150 to plastic injection moulding machine has been an alysed.”
(September2012).
11. G. Lucchetta” This last constraint is necessary to avoid short shots and to
minimize the clamp force of the required injection moulding machine and,
therefore, the process cost.” (December2009).

36