A Project Report

On
DESIGN AND MANUFACTURING OF
WATCH DIAL CASE

Submitted to
CENTRAL INSTITUTE OF TOOL DESIGN, Hyderabad

In Partial fulfilment of the requirements for awarding the Certificate

of

MASTER CERTIFICATE COURSE IN

COMPUTER AIDED TOOL ENGINEERING
NSQF BATCH – 28

By

Mr. RAVI KIRAN MATHA

Mr. VIVEK K
[Link] NITHIN KUMAR
Mr. AKHIL RAJA RAO K

Under the esteemed guidance of

Mr. Y SRINIVAS

CENTRAL INSTITUTE OF TOOL DESIGN

(A Government of India Society – Ministry of MSME)

Balanagar, Hyderabad – 500037

Email: citdcadcam@[Link]
 CENTRAL INSTITUTE OF TOOL DESIGN
(A Government of India Society – Ministry of MSME)

Balanagar, Hyderabad
Department of CAD/CAM

CERTIFICATE

Certified that this MCTE project entitled Design and Manufacturing of watch
dial case carried by [Link] KIRAN MATHA, Mr.K VIVEK,
[Link] KUMAR&Mr. AKHIL RAJA RAO K bearing roll numbers
03, 08, 01 and 07 respectively from NSQF batch 28 and partial fulfilment for
the award of MASTER CERTIFICATE COURSE IN COMPUTER AIDED
TOOL ENGINEERING (MCTE) at the Central Institute of Tool Design,
Hyderabad for a period of Six months during the academic year 2018-2019.
It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report deposited in the
department library. This project report has been approved as it satisfies the
academic requirements in respect of MCTE project prescribed for the said
certification.

Signature of the faculty in- charge Signature of the

HOD

Signature of the Examiner

1.
2.
 ACKNOWLEDGEMENT

We would like to thank Department of CAD/CAM, Central Institute of

Tool Design, Balanagar, Hyderabad, for allowing us to do this project and
for giving us resources and support to work on this project.

We are highly indebted to Mr. R K Pavitra kumar , Principle Director of

CITD, Hyderabad, who has given me this opportunity to undergo for project
in Central Institute of Tool Design.

We would also thank with immense gratitude, Mr. K. BABU RAO, Assistant
director of CAD/CAM department of CITD, Hyderabad, for the constant
support and guidance for the fulfilment of the project.

We are grateful to our project guide Mr. Y SRINIVAS, Department of

CAD/CAM, CITD, Hyderabad, for his constant support in completing the
project & for their continuous feedback and suggestions for the progress of
the project.

We are thankful to members of CAD/CAM department, CITD, Hyderabad, for

their valuable support and guidance.

With a sense of achievement and satisfaction, as we reflect up on our project

activity, we are filled with a deep sense of gratitude towards the few whose
help and support was instrumental in the completion of the project
Administrator.
 DESIGN ANDMANUFACTURINGOF WATCH DIAL

CONTENTS
ABSTRACT 6

CHAPTER1: INTRODUCTION 7
[Link] toPlastic Molding 7
[Link] theProject 7

CHAPTER2: PLASTICS 8
[Link] 8
[Link] ofplastics 8
[Link] plastics 8
[Link] 9
[Link] /Elastomers 9
[Link] and applications of plastics 10
[Link] 10
[Link] 11
[Link] Properties of Plastics 12
[Link] moldingprocesses 13

CHAPTER3: INJECTIONMOULDING
15
[Link] MouldingMachine 15
[Link] 16
[Link] unit 16
[Link] 17

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[Link] ofInjectionMouldingMachine 18
[Link] 20
[Link] used for injection moulding 22
[Link] 22
[Link] 23
[Link] 25
[Link] 26
[Link] die 27
[Link] Material 28
[Link] ofstandard mouldbase 29
[Link] System 33
[Link] cooling 35
[Link] 36
[Link] 39
[Link] 40
[Link] 40
[Link]&disadvantages 40

CHAPTER4: MODELLING ANDFABRICATION 41

[Link] Considerations for Mould 41
[Link] Design Considerations 41
[Link] MouldDesign 42
[Link] 43

CHAPTER5: DESIGNINGSOFTWARE 47
[Link] toSolid works 47
[Link] Component 48
[Link] Mould 48
[Link] 50

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CHAPTER6: SIMULATION&ANALYSIS 52
[Link] 52
[Link] 52
[Link] Summary 53
[Link] 64

CHAPTER7: PROCESS PLANNING &ENTPRENEURAL 6

STEPS 6
7.1 Entrepreneurial Steps 66

7.2 Process Planning andDetails 67

CHAPTER8: CONCLUSION

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ABSTRAC
T

Injectionmoulding isaprocessthatmouldsplasticthrough
heatandpressureby injecting
moltenplasticpolymerintothedesiredmouldandallowing ittogetcooledand
[Link]
ouldof WATCH DIAL CASE,in which thecomponentanditsmouldare
[Link]
thedesignofallpartsofa machine mouldandfabricationmethodsof core
andcavity. Solidworks-2017isusedas softwaretodesignallthe partsof
[Link] this software
[Link],Part,Assembly,MouldandDrafting
areusedtocompletethedesign procedure.

The mouldanalysishasbeencarriedoutinaSolidworksadd-
innamedsolidworks- [Link]
ofmouldhasbeencontemplatedinordertofabricatecoreand cavity
platesandusethemtoruntheinjectionmoulding
[Link]
usingAluminumblockshavinghardnessmeasurementof60HRC,tensileyieldstr
engthof
[Link]
operationsareperformedby CNC Millingmachine toget therequired profile
of the component. Themachiningoperations likemilling anddrillingare
deliberatelyplannedtomatchtheparametersrequiredformaking
coreandcavity
[Link]
injectionmoulding processwithit [Link]
workdoneinthis project is detailed in thetechnical report.

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CHAPTERl

INTRODUCTIO
N
[Link] Moulding

Intheprocessofplastic moulding,themoltenplastic
ispouredinthedieofdesired
shape,correspondingtotheshapeofneededproductandthenallowedtosolidify
tillit acquires thatshape. Some advantagesofplastic mouldingare high
production rates, repeatablehightolerances,widerangeofmaterialsused,low
laborcost,minimalscrap losses,andlittleneedto
[Link],theprocessof
plasticmouldingconsistsoffeeding
rawmaterialgranulesandadditives,[Link]
rawmaterialthenentersaheatedbarrelwithreciprocatingscrewandthemolten
plasticis then injectedwithconsiderableforceintoa two-partmouldtoolfor
theitembeingproduced. Theprocessofplasticmouldingusually
beginswithanindustrialdesignerorengineerwho
[Link]
o [Link],they
canthenbemanipulated
(injectionmoulded,extrudedetc.)[Link]
e theymust then be cooled to solidifythem.

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CHAPTER
2

PLASTICSANDMOULDINGPROCE
SS
[Link]
ics

Plasticsare
theorganicmaterialswhichcanbemouldedintovariousshapesthroughthe
[Link] are preparedfromnatural and
syntheticresins.
Naturalresinsincludeshellac,wax,[Link]
therecurring chemicalreaction [Link]
simpleorganiccompound combine and formahighmolecularweight
composition.
[Link]
havewiderange
ofproperties,someofwhichareunattainablefromanyothermaterials,andinmo
stcases, theyare relativelylow incost.

[Link]
Plastics
 Lightweight combinedwith adequate strength.
 Easyto mouldin todifferent shapes.
 theyhavelow thermal conductivityand providegood insulation to heat.
 Theyhavegoodresistanceto corrosion.
 Theyhavegoodresistanceto most of the chemicals.
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
 Theycan be easilyproduced in differentcolors.
 Theyhavegoodelectricalinsulators.
 As compared to metals theyhavebetter resistanceto shock and
vibration

[Link]
Plastics
Plastics areagainclassified based on theirmechanical and
thermalbehavior.
 Thermoplastics (Thermoplastic polymers)
 Thermosets (Thermosettingpolymers)

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[Link]

[Link]
e totally
[Link]
simultaneous [Link]
arelinearpolymerswithoutanycrosslinkages
instructurewherelongmolecularchainsarebondedtoeachotherbysecon
dary [Link] havetheproperty ofincreasingplasticity by
increaseintemperature which breaks thesecondarybonds between
individual chains.
Someof thethermoplasticsare
Acrylics,PVC,Nylon,Polypropylene, Polystyrene, Poly-methyl-
Methacrylate,ABS(AcrylonitrileButadiene Styrene), Teflon, Polythene
(HDPE &LDPE),etc.

[Link]

[Link]
areformed intoapermanentshapeandcuredorset by
chemicalreactionssuchasextensivecross [Link] cannotbere-
meltedorreformed intoanothershapebutdecomposed
uponbeingheatedtovery
[Link],thermosetscannotberecycled whereas
thermoplastics can be recycled.
The term thermoset implies that, heat is required to
permanently set the [Link]
thermosetsarecomposedoflongchainwithstronglycrosslinkedto
[Link]
arebrittlecomparedto [Link], vulcanized rubbers,
polyesters, silicones,phenolic, unsaturated polyestersresinsand
amino resins(Ureaand melamine‘s)areexamples of thermosets.

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Advantagesofthermosetsfor
engineeringdesignapplicationincludeoneor moreof the following:
 High thermal &dimensional
stability
 High
rigidity
 High
weight

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[Link] & APPLICATIONOF PLASTICS

[Link]

Table 2.1:Data properties &application for Thermoplastics

NAME PROPERTIES APPLICATION

Strong, tough, hard, Dashboard &car trims,
ABS Chemicalresistant, durable. Toysphones, handles,
electrical products.
Tough, hard, light, self- Bearing, gear, rope,
Nylon lubrication, chemical Hinges&catches,
resistant, machines well, engineeringapplications.
easyto extrude, injects well
Acetate(Cellulose) Tough, stiff, hard, Toolhandles,penbodies,
transparent light, heat frames forglasses
resistant
Acrylic/Perspex Stiff, durable, insulator, Car light cover, bath
machines &polishes well, shower trays
easyto get scratches
Polypropylene/ Tough, light, chemical Containers, pots, plastic
Polyprotein resistant, easy to scratch, seats, ropes, netsetc.
quitesoft
Toys, boxes, electrical
Polystyrene Light,stiff, transparent, Productcases,packaging,
brittle, water resistant, vacuum forming.
tough.
Insulator, chemical Packaging, bags, bottles
LDPE / HDPE resistant,toughflexible, soft domestic applications
/ Hard, stiff.
Cables, holes, sheet,
PVC Stiff, hard, tough, light Fabric,
gutterswindows,
extrusions.

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[Link]

Table 2.2:Data properties &application for Thermosets

NAME PROPERTIES APPLICATION

Urea Strong, brittle, hard, stiff, Electricalfittings,handles

Formaldehyde insulator &knobs

PolyesterResins Liquid rawstate, hard Casing, boning fiber

insulator, chemical (Glass,Kevlar, Carbon
resistant,brittle without fiber)
fiberreinforcement

Epoxy Resins Good insulator, brittle, Adhesives,bondingfibers,

chemical resistant encapsulations

Melamine Hard, strong, Adhesives,bondingfibers,

Formaldehyde heat resistant encapsulations

Polycarbonate Hard, strong, transparent, Spectacle lenses6

high refractiveindex

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[Link] Plastics

Table 2.3:Data properties &application for MPP

PROPERTIES THERMOPLASTICS THERMOSETS EFFECT

Increasessurvivability
High during emergenciesor
temperature Poor to good Excellent normalusage athigh
mechanical temperature
performance
Affects pulling
Coefficient of Verylow to moderate Moderate to very tension, wire
Friction high processing &flexing

Measure of stretch
before breaking
Elongation Poor to good Good to excellent encountered during
installation,
processing &flexing
Wide range in both
TensileStrength Poor to excellent Poor to excellent material types,
impacts, durability
and strip ability
Colourability Good to excellent Poor to excellent Affects identification
in low light condition

Heat Poor to good Good to excellent Becomesverysoftas

Deformation it nears its melting
point
Cold Poor to excellent Good to excellent Affects storage,
Temperature handling, installation
Compatibility andusage incold
environments

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[Link] MouldingProcesses

Thebasicideainplasticmouldingisinsertingmoltenliquidplasticintoarea
dy shapedmould,forexample themouldof [Link]
thenallowedtocool,andthenthe
[Link]
m-moulda widevariety
ofplasticproductsincluding:gardenpots,cabinets,officetraysandboxes,
barriers, barricadesand traffic signage and displays forproduct and
marketingpromotions.

Types of plastic
mouldingprocess

2.6.1. Injection Molding

InInjectionMolding,meltedplastic isforcedintoa mold

[Link],the
[Link]
usedinmass-
[Link]
adeinthe
1930‘[Link],kitchenutensils,bottleca
ps,andcell
phonestands to
nameafew.

2.6.2. BlowMolding

Blowmolding islikeinjectionmolding
exceptthathotliquidplasticpoursoutofa barrelvertically
[Link]
conformtothe inside shape of the mold. Whenitiscooled, the hollow
partisformed. Examples of blow moldingproducts arebottles, tubes
and containers.

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Equipment‘s needed insetting-up a blow molding business are
relatively higher than injection molding.

2.6.3. CompressionMolding

Inthistype ofplastic molding,aslugofhardplastic

ispressedbetweentwoheated moldhalves.

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2.6.4. FilmInsert Molding

Thisplasticmolding
techniqueimbedsanimagebeneaththesurfaceofamoldedpart. A
material like film or fabric is inserted into a mold. Plastic is then
injected.

2.6.5. Gas Assist Molding

Alsocalledgasinjectionmolding
isusedtocreateplasticpartswithhollowinteriors.
Partialshotofplasticisthenfollowedbyhigh-
pressuregastofillthemoldcavity with plastic.

2.6.6. Rotational Molding

Hollowmoldspackedwithpowderedplasticare securedtopipe-
likespokesthat extendfroma [Link] moldsrotateon
[Link] the whole
moldtoaclosedfurnaceroom causingthe powder tomeltandsticktothe
[Link] themoldsturnslowly, thetoolsmoveintoacooling
room. Here,sprayedwater causesthe plastic tohardenintoa hollow
[Link] of
plasticmolding,[Link]
akes about 40-45 minutes.

2.6.7. StructuralFoamMolding

Structuralfoammoldingisaprocessofplasticmoldingusually
usedforpartsthat
[Link]
asmallamountof nitrogenorchemicalblow agentintothe plastic
materialmakesthe wallsthicker. Foaming
[Link]
skinformsandsolidifiesinthe [Link]
canbeused with anythermoplastic that can beinjection molded.

2.6.8. Thermoforming
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Inthisplasticmolding process,sheetsofpre-extrudedrigidplasticsare
horizontally heatedandsuckeddownintohollowone-piece
[Link] solidifies, its shape conforms to that of
themold.

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CHAPTER
3

INJECTIONMOULDIN
G

[Link]
MouldingMachine

Withsomany ofoureveryday productsbeing madeofplastic,itiseasy

tounderstandwhy
[Link]
30%ofallplasticproducts areproducedusing an
injectionmoldingprocess.Ofthis30%,alargeamountofthese productsare
produced by using custominjectionmolding [Link]
is used to create many things such as wire spools, packaging, bottle caps,
automotive
dashboards,pocketcombs,somemusicalinstruments(andpartsofthem),one-
piecechairs
andsmalltables,storagecontainers,mechanicalparts(includinggears),andmo
stother [Link]
isthemostcommonmodernmethod of manufacturingparts; it is ideal
forproducinghighvolumes of thesameobject.
Sixsteps areinvolved intheinjection moldingprocess, after theprototypehas
been made and approved.
Thefirststeptotheinjectionmolding processistheclamping
[Link] clampingunitisoneofthreestandard
[Link] arethemold,the
[Link]
holdsthemoldwhilethe
meltedplasticisbeinginjected,themoldisheldunderpressure
whiletheinjectedplasticis cooling.
[Link]
his processaspelletsthatare putintoa large [Link] pelletsarethen
fedtoa cylinder;here
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theyareheateduntiltheybecomemoltenplasticthatiseasilyforcedintothemold
.The plasticstays in themold,whereitis being clamped under pressureuntil
it cools.
Thenextcoupleofstepsconsistofthedwellingphase,whichisbasically
making sure
[Link]
g phase, thecooling process
beginsandcontinuesuntiltheplasticbecomessolidinsidetheform.

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Fig.3.1:Injectionmoul
ding
Theinjection mouldingmachine consists
ofthreemaincomponentsviz;
[Link]: Clamping designsare of three types: Toggle,
[Link] clampsprovide bothhigh
speed and highforcewhen they
aredesirableandaremostsuitedtorelatively low-
[Link]- tonnagemachinehydraulicclamping
unitisusedwhichisconnectedtothemoving [Link] is used toapplythe
clamping forceto keep the mould closed whileinjecting.
3.1.2.
InjectionUnit:Itconsistsoftheinjectormachineandrelatedmechanism
which meltsthe rawmaterialandinjectsitintothe die
athighpressureandwithinthe stipulatedtime. This system confines
and transports the plastic as it progresses
throughthefeeding,compressing,degassing,melting,injection,andpac
king [Link] consistsof the following parts:

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[Link].
Hopper:Thermoplasticmaterialissuppliedtomoulderintheformofs
mall
[Link]
vity fed from thehopper throughthe hopper throat into
thebarreland screw assembly.

[Link]. Reciprocatingscrew:Thereciprocating
screwisusedtocompress,melt and conveythe material.
Thereciprocatingscrew consistsof threezones;
 Feedzone
 Compressingzone (Transition zone)
 Meltingzone
[Link].
Nozzle:Itconnectsthebarreltothespruebushingofthemouldandfor
msa
[Link]
ouldbe settothematerialsmelttemperatureorjustbelowit,depending
onthe recommendationofthematerialsupplier. Whenthe
barrelisinitsfullforward
position,radiusofthenozzleshouldnestandsealintheconcaveradiusi
nthe spruebushing [Link] purging ofthe
barrel,the barrelbacks out from thesprue, so thepurging
compounds canfreefallfrom the nozzle.
[Link]:Itconsistsofcoreandcavity
thatformstheimpressionforthepartto be mouldedalongwithalltheother
mechanismrelatedtomouldbaseandejector
[Link],stationary
[Link] well asmoulding
plates(bases)thathousethecavity,sprueandrunnersystems,ejector
pins,[Link]
aheatexchangerinwhichthe
moltenthermoplasticsolidifiestothedesiredshapeanddimensionaldetai
lsdefined bythecavity.
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[Link]:Theinjectionmouldconsistsofand impression
‘intowhichplastic [Link] be
definedasthatpart ofthe mould whichimpartsshapeto
[Link] members viz
The‗cavity‘whichisthefemaleportionofthemouldandgivesthemo
ulding its external form.
The‗core ‘which is themaleportion of themould
andformstheinternalshape ofthe moulding.

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[Link] ofInjection MouldingMachine

PlasticInjectionMoulding process
demandsprecisecontrolofmelttemperature,melt
viscosity,injectionspeed,injectionfollow-uppressure,switchover
pointfromspeedto pressure,cycle [Link] thatdifferentpolymershave
differentcharacteristicsand differentlimitationsinprocessing.
Shearrateandshear stressinfluencemelttemperature, viscosity, densityand
flow behavior ofpolymer.
Somepolymersarehygroscopic;somepolymerhaslimitedthermally
stabletime whichisdifferentatdifferenttemperature. Suchpolymers have
limitedresidence [Link] changes in each parameter have its own
influences on other parameters.
Hence,processcontrolbecomes very
[Link] machine specifications and
capabilities whileorderingthemachine.
Whileselectinginjectionmouldingmachinethefollowing
specificationsare required to be evaluated.

Table 3.1:Injection MouldingMachine Specifications and theirmeaning

INJECTION UNIT To understand

Maximumsweptvolumecc/[Link] gr. Calculation of max. Shotweight for a

material.

Maximummeteringstrokein mm. Dependence of quality of melt for

consistencyofmoulding.

Maximuminjection speed g/s or cc/s Howitensuresmeltto spreadthroughout

wheninfluidcondition- [Link]
relationship with freezingtime.

Maximuminjection pressureKg/cm2 How itovercomes resistance toflow during

filling and; pressure phaseon account of flow
ratio and; viscosity.

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Maximum Injection [Link]/sec. Howittakescareofdifficultyinfillingfor thinner
walled and high flow ratio parts.

Plasticizingrateg/s or Kg/hr. How it influences cycle time.

CLAMPINGUNIT To understand

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Clearance between Tie bars and platen size How itaccommodates mould.
mmx mm

Maximumdaylightmmandmouldopenstroke Its significance for ejection ofdeep parts.

mm

Minimum mould height Itsrelationshipwithmouldopenstrokeand

daylight.

Clampingforce Its dependence on cavity pressure and

method to compute cavitypressure.

HYDROMOTOR To understand

TorqueKgm andrpm Torque requirement for viscosity-of-melt.

DRIVE POWER To understand

Power supplyfrequency60 or50 Hz. Its influenceon speeds.

Pump-motor rating. Kw To match the application-usageof machine.

 Conventional/ProportionalandCartridge
CONTROLS Valve HydraulicControls
 Electrical / solid state / microprocessor
controls
 Open loop or closed loopcontrols

NO LOAD CYCLE TIME Itindicatesthetimefornon-processingpart ofthe

cycle time

Injectionmoulding machinesconsistofamaterialhopper,aninjection
ramorscrew-type plunger,[Link],they
holdthemouldsinwhichthe componentsareshaped. Presses arerated
bytonnage, whichexpresses the amount of
[Link]
ng the injectionprocess.

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Determinedby [Link]
projectedareaismultiplied
byaclampforceoffrom1.8to7.2tonsforeachsquarecentimeteroftheprojecteda
[Link] a rule of thumb,4or 5tons/incanbe used [Link] the
plastic materialisvery stiff,itwillrequire moreinjectionpressure
tofillthemouldandthusmoreclamptonnage to
[Link]
sedand the sizeof thepart; larger parts requirehigherclampingforce.

[Link]
cess

Injectionmouldingismostcommonly
usedtoprocessboththermoplasticandthermosetting
polymers,withtheformerbeingconsiderably
moreprolificintermsofannualmaterial
[Link],thermoplasticsalsohaveanele
mentof
safetyoverthermosets;ifathermosettingpolymerisnotejectedfromtheinjectio
nbarrelina timelymanner,chemicalcrosslinking
mayoccurcausingthescrewandcheckvalvestoseize and
potentiallydamaging theinjection mouldingmachine.
Whenthermoplasticsaremoulded,typically
Pelletizedrawmaterialisfedthrougha hopperintoa heatedbarrelwitha
[Link] screwdeliverstherawmaterial
forward,mixesandhomogenizesthethermalandviscousdistributions
ofthepolymer,and reducestherequiredheatingtimeby mechanically
shearingthematerialandaddinga significantamountoffrictionalheating
[Link] check valve andcollectsat
the front ofthe screw into a volume knownas ashot.
Ashotisthevolumeof
materialthatisusedtofillthemouldcavity,compensatefor shrinkage, and
provide a cushion (approximately 10% of the total shot volume, which
remainsinthebarrelandpreventsthescrewfrombottomingout)totransferpress
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urefrom the screw tothe mouldcavity.
Whenenoughmaterialhasgathered,the materialisforcedat high pressureand
velocityinto the partforming cavity.

entire
thicknessOncethegatesolidifies,nomorematerialcanenterthecavity;accordin
gly, the screw reciprocates andacquiresmaterialforthe next cycle while
thematerialwithinthe mouldcoolssothatitcanbeejectedandbedimensionally
[Link]
dramaticallyreducedbytheuseofcoolinglinescirculatingwateroroilfromarese
rvoir.
Oncetherequiredtemperaturehasbeenachieved,themouldopensandanarray
ofpins, sleeves, strippers,etc. aredriven forward to re-mouldthe article.
Pre-mouldedormachinedcomponentscanbeinsertedintothe cavity
whilethemould
[Link]
hem
.Thisisa processknownasInsertmouldingandallowssingle
partstocontainmultiple
[Link]
metalscrews,
[Link],sprue,ga
temarks, and ejectorpin marksareusuallypresent on thefinal part.
Noneofthesefeatures are typicallydesired, butareunavoidabledueto
thenatureofthe process. Dimensionaldifferences can beattributed
topressure-induced deformation
duringinjection,machiningtolerances,andnon-
uniformthermalexpansionandcontraction of
[Link]
various coefficients of thermalexpansion.

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Fig.3.2: Mouldingprocess

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[Link] forinjection
moulding

The term"polymer"
describesclassesofmoleculeswithlargenumbersofrepeating
[Link]
feature distinguishingpolymersfromothermoleculesistherepetitionofmany
similar,identical,or complementarysubunits.
Mostmanufacturersdecideuponpolyethyleneasthepolymerofchoicefor
theplastic
mouldingprocessbecauseofitsavailability,easeofuse,andsuitableproperties.
According to recent reports 80% - 90% of all polymers used in the plastic
mouldingindustry arepolyethylene compounds(HDPE, LPDE and
LLPDE).AlthoughPVC, nylons,and polypropylene compoundsarealso used.

[Link]
on
The term"nylons"referstothegroupofplasticsknownaspolyamides.
Nylonis usedin theproduction offilm and fiber, but is alsoavailable
asamoulding compound.
Therearemanytypesofnylonavailable(e.g.nylon6,nylon66,nylon6/6
-6, nylon6/9,nylon6/10, nylon6/12,nylon11,and nylon12).The
materialisavailableasa homo-polymer,co-
[Link] alsobeblendedwithother engineering
plasticsto [Link]
processing
viainjectionmoulding,rotationalmoulding,castingorextrusionintofilmor
fiber.
Chemical
Composition

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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
ItspropertiesaredeterminedbytheRandR'[Link]
ylon
6, 6,R' =6CandR=4Calkanes

[Link]
[Link] stabilized systems allowsustained
o
performanceattemperatures up to 185 C.

Table 3.2: Properties ofNylon

PhysicalProperties Value
2
TensileStrength: 90 -185 N/mm
2
NotchedImpact Strength: 5.0 -13.0 K J/m
-6
Thermal Coefficient 80 x10
ofExpansion: o
Max. Continued 150 -185 C (302 -
o
UseTemperature: 365 F) o
MeltingPoint: 190 -350 C (374 -
o
662o F) o
Glass Transition Temp. 45 C (113 F)
(Nylon 66): 3
Density: 1.13 -1.35 g/cm

[Link]
Byfarthemostpopularthermoplasticcommodity
usedinconsumerproducts (especiallyproductscreatedby
rotationalmoulding),polyethyleneiscreatedthroughthe polymerization of
ethylene (i.e.,ethane).
Chemical Composition
The ethylenemolecule is C2H4(CH2=CH2)

EthylenePolyethylenePolymer
 LDPE(LowDensityPolyethylene)isdefinedbyadensityrangeof0.910-
3
0.940g/cm .Ithasahighdegreeofshortandlong chainbranching,
which meansthatthechainsdonotpackintothe
[Link] therefore less strong
Department Page30
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
intermolecular forces as the instantaneous-dipole induced-
[Link]
[Link] degreeofbrancheswithlong
chainsgivesmoltenLDPEuniqueand desirable flowproperties.

Department Page31
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

 HDPE(HighDensityPolyethylene)isdefinedbyadensityofgreaterorequal
3
to0.941g/cm .HDPEhasalowdegreeofbranching andthusstronger
intermolecularforces andtensile [Link]
producedby chromium/silica catalysts, Ziegler-Nattacatalysts
ormetallocenecatalysts. Thelack ofbranchingisensured
byanappropriate choiceof catalyst.

 MDPE(MediumDensityPolyethylene)isdefinedbyadensityrangeof0.926-
3
0.940g/cm .MDPEcanbeproducedby
chromium/silicacatalysts,Ziegler- Natta
catalystsormetallocenecatalysts.

 LLDPE(Linear-LowDensityPolyethylene)isdefinedbyadensityrangeof
3
0.915 -0.925 g/cm . is asubstantially linear polymer, with
significant numbersofshortbranches,commonly
madebycopolymerizationofethylene with short-chain alpha-
olefins (e.g. 1-butene, 1-hexene, and 1-octene).

Properties
 LDPEProperties:

Table 3.3:LDPE Properties

LDPEPhysical Properties Value
TensileStrength: 0.20 -0.40
2
N/mm
NotchedImpact Strength: no break
-6
Thermal Coefficient 100 -220 x10
ofExpansion: o o
Max. Continued 65 C (149 F)
UseTemperature: o o
MeltingPoint: 110 C (230 F)
o o
Glass Transition -125 C (-193
Temperature: F)
Density: 0.910 -0.940
3
g/cm

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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

 HDPEProperties:
Flexible,translucent/
waxy,weatherproof,goodlowtemperaturetoughness(to
-60'C),easyto process bymostmethods, low cost, good chemical
resistance.
Table 3.4:HDPE Properties
HDPEPhysical Properties Value
TensileStrength: 0.20 -0.40
2
N/mm
NotchedImpact Strength: no break
-6
Thermal Coefficient 100 -220 x10
ofExpansion: o o
Max. Continued 65 C (149 F)
UseTemperature: o o
MeltingPoint: 126 C (259 F)
Density: 0.941 -0.965
3
g/cm

[Link]
Athermoplasticpolymer,polypropylene(alsocalledpolypropene)has
properties between that ofLDPEand HDPEand is oneof themostversatile
polymers available.

Chemical Composition

Properties
Semi-rigid, translucent, good chemical resistance, tough, good
fatigue resistance, integralhinge property,good heat resistance.

Department Page33
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

Table 3.5: PolypropyleneProperties

PhysicalProperties Value
TensileStrength: 0.95 -1.30
2
N/mm 2
NotchedImpact Strength: 3.0 -30.0 K J/m
-6
Thermal Coefficient 100 -150 x10
ofExpansion: o o
Max. Continued Use 80 C (176 F)
Temperature: o o
MeltingPoint: 160 C (320 F)
o o
Glass Transition Temp. (a -20 C (-4 F)
tactic): o o
Glass Transition Temp. 100 C (212 F)
(isotactic): 3
Density: 0.905 g/cm

[Link]
Majorthermoplasticmaterialswithavery
widevarietyofapplications,the essentialmaterialsfor
[Link]
monomer(VCM)isformedby combining
ethylene(obtainedfromoil)withChlorine (produced
fromtheelectrolysisofsaltwater).VCMmoleculesare polymerizedtoform
PVCresin,towhichappropriateadditives are incorporatedtomake a
customizedPVC compound.

Chemical Composition
Thevinyl chloridemolecule is C2H3Cl

Vinyl Chloride Polyvinyl Chloride

Monomer(VCM) Polymer

Properties
Ahighly
versatilepolymer,[Link]
plasticizedtomakeitflexibleforuseinflooring orunplasticized(PVC-
U)forusein buildingapplications andwindow frames.
Department Page34
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

Table 3.6:PVC Properties

PhysicalProperties Value
2
TensileStrength: 2.60 N/mm
2
NotchedImpact Strength: 2.0 -4.5KJ/m
-6
Thermal Coefficient 80 x10
ofExpansion: o o
Max. Continued 60 C (140 F)
UseTemperature: o o
MeltingPoint: 212 C (413 F)
o o
Glass TransitionTemperature: 81 C (178 F)
3
Density: 1.38 g/cm

[Link]/
die

Mouldor dieare thecommontermsusedtodescribe the toolusedtoproduce

plasticpartsin
[Link],theywereusually
only usedin mass production wherethousands of parts
werebeingproduced.
Thedesignofthemouldpurely
dependsonthedesignofthecomponentandits criticality. Thus,
wehavesingle cavity, multi-cavity, spit mould, insertmouldsetc.
Toeasemaintenanceandventing,cavitiesandcoresare
[Link] inserts, and sub-assemblies, also called inserts,
blocks, or chase blocks. Bysubstituting
interchangeableinserts,onemouldmay
[Link] complexpartsare formedusing
[Link] that move into a
cavity perpendicular to the draw direction, to form overhanging part
[Link],theslidesarepulledawayfromtheplasticpar
tby using stationary―anglepins‖onthestationary
[Link] cause theslides to
movebackward when themovinghalf of themould opens. Thepart is then
ejectedandthe [Link] Closingactionof the mould causes the
slidestomove
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
[Link]
einserted toallow a new plastic layer toform around thefirstpart.
Thisisoftenreferredtoasover moulding. This system can allow forproduction
ofone-piecetiresand wheels.

colour,isinjection-
[Link],forinstance,madeby this
process havemarkings that cannot wear off, and remain legiblewith
heavyuse.
Amouldcanproduce severalcopiesofthesamepartsina
single"shot".The number
of"impressions"inthemouldofthatpartisoftenincorrectly
[Link] withone impressionwilloftenbecalleda
singleimpression(cavity)mould.Amouldwith2
ormorecavitiesofthesamepartswilllikely
bereferredtoasmultipleimpression(cavity) mould. Some
extremelyhighproductionvolumemoulds(like thosefor bottle caps)canhave
over 128 cavities.

[Link]
erial
Thechoiceofmaterialtobuildamouldfromisprimarily
[Link] cost,number of partstobe
[Link] for makingthe plastic moulds is:
 AluminumFilled Epoxy
 Aluminum
 ToolSteel
 StainlessSteel
 HotWork DieSteel
 Beryllium-Copper
Ingeneral, steel mouldscost moretoconstruct, but their longer
lifespanwill offset
thehigherinitialcostoverahighernumberofpartsmadebeforewearing
[Link]- hardenedsteelmouldsare lesswear-resistantandare usedfor
lowervolumerequirements ora largerComponentwithhardnessis38-
Department Page36
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
[Link] heat
treatedaftermachining;theseareby
farthesuperiorintermsofwearresistanceand lifespanwithhardness50-
[Link] less,and
whendesignedandmachinedwithmodemcomputerizedequipmentcanbee
conomical for moulding tensorevenhundreds
[Link] areasof
themouldthatrequirefastheat removalor areasthatseethemostshear
heat generated. Themoulds aremanufactured byCNCand
EDmachiningprocesses.

Department Page37
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

 SpecificHeat Capacity
 ThermalConductivity
 Density
 Hardness
 YieldStrength

[Link] ofa
StandardMouldBase
[Link].TopClamping Plate
a)Holdsthestationarypanofthemouldtothestationaryplatenoftheinj
ection machine.
b)Material = MS / C-45

[Link].Locating Ring
a)Fits into a counterborein thetop clampingplate
b)Used to locate themouldon the platen ofthe press
isproperlyaligned c)Material = MS / OHNS

[Link].Cavity RetainerPlate
a)Partofthestationarysectionofthemouldintowhichtheleaderorguid
epins aremounted.
b)Also use to hole the core,cavityaspur
bushing c)Material = MS / C-45

[Link].CoreRetainerPlate
a)Top plateof themovablesection ofthe mould
b)Forms thepartinglineofthe mould with cavityretainer plate
c)Used to hold the leader pin bushingas wellas thecore
andcavityblock d)Material = MS / C-4

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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

b)Material = MS / C-45

[Link].BottomClamping Plate
a)Holdsthemovingportionofthemouldtothemovableplatenoftheinje
ction machine
b)Material = MS/ C-45

[Link].Parallel(Rails)
a)Mountedonthebottomclampingplateunderthesupporttoformaspa
cethat allows ejector bar to movewhen the piecepart
areejected
b)Material = MS / C-45

[Link].Ejector RetainerPlate
a)Counterboredtoholdtheheadsofejectorpins,ejectorretainerpinsa
ndsprue puller
b)Material = MS / C-45

[Link].Ejector Plate
a)Bolted togetherwith the ejector retainer plate to form a unit
b)Acts as abackup plate for thepins in the ejectorretainer plate
c)Used fortransmittingtheforcefrom theactuatingsystem to the
ejector element d)Material = MS / C-45

[Link].Ejector Pins
a)Insomecases,thesepinsareusedtoapplyforceonthemouldedparti
norder to eject
b)Material = OHNS, Hardened&Grounded, 48-52 HRC

[Link].SpacerButton
a)Pressed into thebottom clampingplatean act as land for
the ejector plate b)Material = OHNS

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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

[Link].Pillars
a)Roundbarsplacesbetweenthesupportplateabottomclampingplat
eandis bolted to thebottom clampingplate
b)Use as anadditional support for core
retainerplate c)Material = OHNS

[Link].Sprue
Bushing
a)Butted up againstthe nozzle ofthe injection machine
b)Hasaconicalshapethroughwhichthematerialisforceintothemouldt
hrough runner andgate.
c)Material = En-24, 45-48HRC

[Link].SpruePullerPin
a)Located directlyunder theopeningof thesprue
b)Used to pull themouldedsprueout of
thebushing c)Threetypes of
spruepullergenerallyuse are,
 Z–Type
 ReverseTaper
 Sucker Pin
d)Material = OHNS, Hardened &grounded, 48-52HRC

Fig.3.3: Stem puller and Spruepuller

Department Page40
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

[Link].Return / PushBack/ Safety Pins

a)Located in the ejector retainerplate
b)Forces the Ejector system to its rear position as the
mould is closed c)Material = OHNS, Hardened
&Grounded, 48-52HRC

[Link].Leader/ GuidePins
a)Hardened andgroundedsteel pins pressed into one
ofthe plates b)Used to aligntwo halvesofthe mould
c)Material = En-31, 50-54HRC

[Link].Bushing
a)Hardened andgroundedsteel bushingpressed into one
ofthe plates b)Serves as aboringsurface
c)Material = En-31, 50-54HRC

Fig.3.4: Typical mouldbaseshowingthe various components

Department Page41
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

[Link] System
The feed system of amould consists of the followingthreeparts:
 Sprue
 Runner
 Gate

Fig.3.5: Feed system

[Link]
ue
Itisthepassagethroughwhichthemeltisforcedintodiewhereitsolidifie
sto form theparts.
Table3.7:Minimum SprueDiameter

MassofMouldedParts(in Minimum SprueDiameter

g m) (in mm)
10 3.5
10-20 4.5
20-40 5.5
40-150 6.5
150-300 7.5

Fordifferentmaterialstobeused,thespruediametershouldbemultiplied
bythe followingfactor:

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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

 Acrylic-2.0
 Nylon-0.8
 SoftenedPVC-0.8
 CelluloseAcetate -0.8
 Polyethylene-0.8

[Link]
ner
Itisachannelmachine intothemouldplate
toconnectthespruewiththeentrance
totheimpression(gate).Inthebasictwoplatemould,it
ispositionedintheparting surface. The walls of runner channel must
be smooth to prevent any type of restrictionstothe [Link] the runner
hastobe removed withthe moulding,there must notbeany
[Link]
[Link]‗in
lineofdraw‘.Thewayinwhichrunneris placed in a multi Cavitymould is
called ‗RunnerLayout‘.
Other factors to be
considered:
 Cross-section shapeof the runner
 Sizeof runner
 Runner layout
Factors to be consideredto determine
runner size:
 Wallsectionand volumeof moulding
 Distanceof impression from themain runner orsprue
 Runnercooling consideration

[Link]
te
Gates are
smallchannelsoranorificethatismachinedintheconnectingtherunner
withtheimpression. They havesmallcross-
Sectionareasomeoftheeffectsor importanceofgates arelisted below;
Department Page43
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL


Itfillstheimpressionwithmaterialinexcessthatisrequiringtocomp
ensatefor changein sizeof the component (i.e. shrinkage).

Becauseofreducedcrosssectionareaofgatesthevelocityincrease
sandthus the friction which leads to development of beats.

[Link]
Thestandardmethodofcoolingispassing acoolant(usually
water)througha
seriesofholesdrilledthroughthemouldplatesandconnectedby
hosestoforma [Link]
‗Flowway‘.Thetotal systemofflowway
iscalled‗Circuit‘.Thecoolantabsorbsheatfromthemould(which
hasabsorbedheatfromthe hotplastic)andkeepsthe
mouldatapropertemperature to
[Link]
a greatercooling
periodisneeded;whereasineaseofacoldmould,themeltsolidifies
beforereaching theextremitiesofthe impression.
Thus,acompromisebetweentheabove two should beoneto obtain
theoptimummouldingcycle.
The coolingof themoulddepends on the followingfactors:
 Typeandgradeof thematerial ofmould
 Typeof flow within the impression
 Wall Section ofmoulding
 Lengthof feed system

The advantages of coolingin a mould are:

 Reducecycletime
 Control formation of crystalline areas
 Freezepan
Department Page44
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL
 Improves surfacefinish
 Minimizeweld line
 Minimizes flow marks and otherblemishes

Department Page45
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 DESIGN ANDMANUFACTURINGOF WATCH DIAL

Graph3.1: Pressure (or)Temperature – Time

[Link]
Table 3.8: MouldingDefects
DEFECTS DESCRIPTIONS CAUSES
Blister Raisedorlayeredzoneo Tool or materials is too hot
nsurfaceof thepart

Blackorbrownburntare  Tool lacks venting

as
Burn Marks (Air  Injection speed is too high
onthe partlocatedat
Burn/Gas Burn/
furthest points from
Dieseling)
gateor where air is
trapped
 Master batch isn‘t
Localized changeof mixing
color properly
ColorStreaks
 Previous colored
material
―dragging‖in nozzle or
Delaminating Thin mica like check
Contamination of thematerial
layersformed in part
wall e.g. pp mixed with ABS

Excess material in
thinlayer exceeding
Flash normal Mould is over packed

Department Page46
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

part geometry
 Parting line on the tool is
damaged
Burrs  Too much injection speed
 Clampingforcetoo low
 Dirtand contaminant around
toolingsurfaces.

 Particles on thetoolsurface
Embedded Foreign particle(burnt  Contaminatedmaterialorforeign
Contaminates material or other) debris in the barrel
embedded in thepart  Toomuchshearheatburningthe
material prior to injection
Directionally "off tone"
FlowMarks wavylinesInjection Injection speed set too slow
patterns

Partdeformedbyturbulent  Poor tool design,

flowof material gate/runner
Jetting
position
 Injection speed set too high

Caused by the melt-front

flowing
Smalllines on back side
aroundanobjectstandingproudin
Knit Lines of the corepins
a plastic partaswellasattheendof
(WeldLines) orwindowsin parts that
fillwhere themelt-frontcomes
look like just lines
together again

 Excess waterin thegranules.

Polymer breakdown  Excessivetemp in barrel.
Polymer from hydrolysis,  Excessive screw speeds
Degradation oxidation etc. causing high shear heat
 Materialkeptinthebarrelfortoo
long
Department ofCAD/CAMEngineering,CITD
Page37
 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

 Excessive material or walls

too
thick.
 Lack of material&gas vents
Short Shot Partial part  Injection speed or pressure
(Non-Fill or too low
Short
 Mould too cold
Mould)
Circular pattern  Moistureinthe material
aroundgate Moisture
Splay Marks in the material 
(SilverStreaks) caused byhotgas Trappingofgasin"rib"areas
String like remnant due to
 Nozzle excessiveinjection
temperaturetoo high
from
Stringiness  Gate hasn't frozen off
previous shot transfer
 Poorplacement of the
in new shot
heater bands inside the
tool.
 Lack of holdingpressure
Empty space within  Fillingtoo fast
Voids part (airLackof  Mould out of registration
holding pressure  Insufficientresin in the
pocketis cavity, Un-melt on
WeldLine commonlyused) themelt pool.
 [Link]
(Knit Discoloredlinewheret low
Line/Meld wo fronts meet  Time for transition
Line / between injection and
Transfer transfer is too early
Line)
Warping Distorted part  Coolingis too short
(Twisting)  Material is too hot
 Lack ofcooling
aroundthetool

Manyofthesedefectsarecausedbyanon-
[Link] ratecanbecausedby non-
[Link],
bycontrollingthe coolingrate wecanavoid maximumtypeof defects.

Department Page38
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

[Link]
Polymers have high thermal expansion coefficient, and significant
shrinkage can
[Link]
be [Link]
expressedasthereductioninlinear sizethatoccursduring cooling
toroomtemperaturefromthemoulding temperaturegivenfor the
[Link] arethereforemm/min of thedimension under
consideration.
Shrinkageisaffectedby anumberof factors,any
ofwhichcanaltertheamountof contraction experiencedby a given polymer.
The mostimportant factors are injection pressure,
compactiontime(Holdingtime),mouldingtemperatureand partthickness.
As injectionpressureisincreased,forcing
morematerialintothemouldcavity,shrinkageis [Link]
thecompactiontimehasthe similareffect,assuming thepolymerinthe
gatedoesn‘tsolidifyandseal off the cavity;
maintainingthepressureforcemorematerial into thecavity
[Link]
temperature,shrinkage islessathigher [Link],thicker
partsshowthe higher
[Link],forthickerpansolidificationisdonelayerby layerandfinally
reachesthe
[Link],gatewillbesolidifiedatsomepointleadstoisolati
ng the part from thegate.

Department Page39
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

Graph3.2: Effect of mouldtemperatureand pressureon shrinkage

Department Page40
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

[Link]
ing
Itistheprocessofremovingtrappedairfromtheclosedmouldandvolatilegase
sfrom [Link]
cancausecorrosionofthemould,
Discolorationduetocompressionoftrappedairasplastictriestoforceout,poo
rweld linestrengthandvolatilegaseswillbeabsorbedby
theplasticcausingvoids,blisters, bubbles and varietyof other defects
[Link]
Storage
Manufacturersgotogreatlengthstoprotectcustommouldsdue
totheirhighaverage
[Link]
gestpossible lifespan foreachcustommould.
Custommoulds,suchasthoseusedforrubberinjectionmoulding,are
storedin temperature andhumidity controlled environments to prevent
warping. They arealso protected from environmental degrades
bycoveringthem with protectiveliquids likeoil.

[Link]&Disadva
ntages

Advantages
 High production rates
 Designflexibility
 Repeatabilitywithin tolerances
 Wide rangeof material and color can beprocessed
 Relativelylowlabor
 Littleto no finishingof parts
 Minimum scrap loses
 Incompletelymouldedcomponent can be remolded
Disadvantages
 Forpractical implementation, largeproduction lines arenecessary
 High initial toolingcost

Department Page41
ofCAD/CAMEngineering,CITD
  DESIGN
There ANDMANUFACTURINGOF PLASTICID
are some design restrictions, CARD
so not all HOLDER
compounds or
durometers are suitable forinjection moulding.

CHAPTER
4

MODELLINGANDFABRICATIO
N

[Link] Consideration for Mould

The amountof resinrequiredtofillthesprue,runner and cavitiesof a

mouldisa shot.
Trappedairinthemouldcanescapethroughairventsthataregroundintotheparti
ng lineof themould,oraroundejectorpinsandslidesthatareslightly
smallerthantheholesretaining
[Link],itiscompressedby
thepressureofthe
incomingmaterialandsqueezedintothecornersofthecavity,whereitpreventsfi
llingand canalsocauseother [Link]
aircanevenbecomesocompressedthatitignitesandburns the
surroundingplasticmaterial.
Toallowforremovalofthemouldedpartfromthemould,themouldfeatures
must notoverhang
oneanotherinthedirectionthatthemouldopens,unlesspartsofthemouldare
designedtomovefrombetweensuchoverhangswhenthemouldopens(utilizing
components calledLifters).
Sidesofthepartthatappearparallelwiththedirectionofdrawaretypically
angled slightly,calleddraft,to
[Link]
[Link]
dependentonthe depth of the cavity: thedeeper the cavity, the moredraft
necessary.
Shrinkagemustalsobetakenintoaccountwhendetermining
[Link] skinistoothin,then the
mouldedpartwilltendtoshrinkontothecoresthatformwhile
Department Page42
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER
coolingandclingtothosecores,orthepartmaywarp,twist,blisterorcrackwhenth
ecavity is pulled away.

[Link] Design Considerations



InjectionSpeed:Injectionspeedisthefillingspeedofthemoltenmaterial
intothe mould with the forwardmovement of ascrew. Unit:
cubiccentimeter (cc)/sec


InjectionPressure([Link]):Injectionpressureisthetermforthepressu
reappliedto the moltenmaterialwhena screw
movesforwardtoinjectitfromthe nozzle athigh speed. Unit:Bar

ShotCapacity:Themaximumamountofplasticmeltthatcanbeinjectedf
romthe barrel ofan injection mouldingmachine inasingleshot.
Unit:grams of polystyrene.


InjectionRate:Theinjectionrateisexpressedintermsofthevolumeofth
emolten material which can beinjected in the unit time. Unit:cm3/s.


BackPressure:Themoltenmaterialisplasticizedandkneadedbytherot
ationofa screwandtransferredtothetipofthescrew,where
themoltenmaterialaccumulates andrecoils,causing
[Link],
slightpressureisappliedtothe injection cylinderside whichiscalled
back pressure. Unit:bar.


ClampingForce:Clampingforce(CF)istheforcewhichkeepsthemouldcl
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER
osed during
[Link](F)shouldbebiggerthantheforc
e (f) which makes the mould open duringinjection.

[Link]
MouldDesign
a) Check the model feasibilityto design
b) Identifythe critical
andmajordimension c)
Decidepartingline
d) Add draft to themodel
e) Add shrinkageto themodel
f) Generate surface as per thedecided
partingline g) Split core and cavity
h) Check fordraft analysisand clearance
analysis i) Feed systemcreation
j) Create coolingholes
k) Conduct concept
reviewmeeting l)
Changethemodel as review
m)Preparedetail drawingofinsert
p) BOM andrevisionrecord to be updated

Department Page44
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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

[Link]

Table 4.1: Runner Diameter forVarious Materials

Material Typical Diameter

Acetyl, Polystyrene, PVC 3-10

ABS, SAN, 4-10

Polycarbonate, Polypropylene

Acetyl 4-10

Acrylic 8-10

Impact Acrylic 8-13

Nylon 2-10

Polyethylene 2-10

Calculationofrunner diameter
D =√ W ×√ L /3.7
Where,
d =diameterof runner (in mm)
L=length of runner (inmm)
=14.94mm W=part weight
(ingm)=6.32gm Therefore,
diameterofrunner is 6.35mm

 GateDepth

Thedepthofgateshouldbesufficientforthematerialtoreachtheextremitieso
fthe impression.
h =n×t
Where, h =depth ofgatein mm

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n =material constant = 0.9

t =thickness of wallin mm = 2
Therefore, depth ofgate= (0.9 x1.5)=1.8mm

 Width ofgate

Thewidth ofgatecontrols the rate offlowof material

D=n× √ A /30
Where, w =width ofgatein
mm n =material constant
= 0.9
2 2
A =Surfaceareaof cavityin mm =26420.21mm
Therefore, width ofgate= 4.8762mm

 Compensation forshrinkage

Table 4.2:Material Constant forVarious Shrinkage

Material Materialconstant(n)

PE, PC, PS, PA 0.6

PP 0.7

PA,Acrylic,CelluloseAcetate 0.8

PVC,ABS 0.9

Whenthepolymersolidifiesinsidethecavity
toshrinksandthuswegetacomponentof
[Link];dim
ensionof the mould cavitymustbemadelarger than the specifiedpart
dimensions.
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Dc=Dimension ofcavityin
m
Dp =Dimension of thepart in mm
S=Shrinkage ratio of polymermaterial
=0.4%to 0.9% (std. value0.7%)

D C=D P×1.007

 MoldWeight Calculation
w =H×L×W×δ
Where,
H =height of mould in mm=80
L=Length of mould in mm =120
W=Width of mouldinmm =40
-3 3
δ =Densityforsteel (EN24) =7.30×10 g/mm
-3
80×120×40×7.30×10
=2.8032kg

 MoldCostEstimation
Material = stainlesssteel
Raw material cost =(Total weight of the mould (kg) xRaw
materialcost/kg)
= (2.8032 x350)
=Rs 1000.5
MachiningCost = (Millinghr. xRs/hr)+ (H.T Rs/kg)=Rs 1500
Total Cost = (Raw Material
+MachiningCost)=(1000.5 +1500) Total Cost =
Rs2500.5

 TonnageCalculation
Projected areaofcomponent
=LxW ProjectedLength = 66
Total forceactingon die(F)= (projected areaxspecific injection(MPa)/10000)
= (2970 x10.45/ 10000)
=3.10365 (3.1 tonsapprox.)
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Locking force required =Fx1.3 (factor ofsafety)

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= (3.1 x1.3)
=4.03 tons(approx. 4 tons)

 ShotWeight
Calculation Component
volume=18.169 cc
Component
density=1.02gm/cc Shot
Weight = (volumex
density)
= (18.169 x1.02)
=18.532gm

RunnerLength = 14.94mm
3
Runner volume =473.13mm
Runner shot weight = (Runner volume xdensity/ 1000)
=473.13 x1.103 /1000
=0.5219 gm.
Total shotweight + Runner shot weight = (18.532+0.5219)
=19.0539 gm.

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CHAPTER
5

DESIGNONSOFTWAR
E
5.1Solidworks

CADSoftwaresareusedtovirtually visualizeacomponent,beforeitisbeing
[Link]‗stherearesomanymodelingsoftware'savailableinth
emarket, for example AUTOCAD,
Pro/EorCREO,CATIA,Unigraphics&[Link] softwarehasitsown
importance,basedonuserinterface,[Link] project,
weusedSolid workssoftwareformodeling
thecomponent,simulationandtoextract the coreand cavity.
Solidworksis asuiteofdesignsoftware supporting
productdesigndevelopedby Dassault [Link] apps,eachwitha
distinctsetof capabilitiesfor a user role
[Link]-Windowsandprovidesappsfor
2Ddesign.3D CAD parametric featuremodeling,3D
directmodeling,finiteElementAnalysisand
simulation,schematicdesign,technicalillustrations,andviewing
[Link] worksisstand-alone designsoftwaretodirectly
interactwiththegeometry usingadirect
[Link] softwareusedforstructuraland
thermal simulation and itconsistsof flow simulation also.

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j) Mechanism
Along withthesemodules,therearealsosub-
[Link],in part modulethereareSolid, Composite,
Sheet metal and bulk.

5.2Designingof Component

TheComponentisdesignedkeeping inmind
allthedesignconsideration,itsworking environment and properties
ofmaterial,

Fig. 5.1: Design of Component in Solid works

5.3Designingof Mould

Themould which wedesignedconsistsof the

followingcomponents a) Core
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b) Cavity
c) Assembled mould
d) Standard baseof MachineMould
e) Exploded Viewof Machine Mould

Extraction of Core and Cavity:

Inordertoextractthecore andcavity,weneedtoenterintoMouldCavity
whichisa [Link]
creatingthepartingsurfacewith
The helpofparting lines. By creating appropriateparting
surfaces,wecanobtaintheCoreand
[Link]
takesmoretimeformachiningsomeofthecomponents,wemadethembyjoining.F
or example, the corepin with the coreplatein tight fit and sealed for
leakage.

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 DESIGN ANDMANUFACTURINGOF PLASTICID CARD HOLDER

5.4Manufacturing

Thebasic machiningoperations performed in this project arediscussed

below:

a) Milling
Milling is the machining process of using multi-point rotary cutters
to remove materialfroma work pieceadvancingina
directionatananglewiththeaxisof the [Link] coversaWidevariety
ofoperationsonscalesfromsmallpartstolarge,heavy-duty milling
[Link] themostcommonly usedprocessesinindustry
andmachineshops today formachining
[Link],allthecomponentsexceptGuido
PinsandCorePinsaresenttoMillingtogettherequiredshapeandthenfollowedby
various operations.

b) Drilling
Drilling istheprocessofgenerating
[Link] holesarecharacterizedby
theirsharpedgeontheentrancesideandthe presence ofburrson
[Link],theinsideoftheholeusually
[Link] insertingpins and makeassemble
thedifferent parts, drillingis used

c) Boring
Boringistheprocessofenlargingaholethathasalready
beendrilled(orcast),by meansofasingle-pointcutting
toolandisusedtoachievegreateraccuracyofthediameterof a
[Link],allthe holes wherever
requiredarecounterboredandthe drilled holes arebored toget thediametric
accuracy.
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d) Grinding
Grinding isanabrasivemachining processthatusesagrinding
wheelasthecutting [Link]
[Link]
machiningofveryhardmaterialsthanregularmachiningasitissuitedto
takingvery shallow [Link]
mouldaregrindedtogetthedimensionalaccuracyandgoodsurface finish. In
this plastic mould, two types of grinding are used; Surface and
Cylindrical [Link]
usesarotatingabrasivewheeltoremovematerial,creating aflat [Link]
surfacegrinderiscomposedofanabrasivewheel,aworkholding deviceknown
asachuck,eitherelectromagneticorvacuum,[Link]
calgrinding isusedto grindthe
[Link]
andtheworkpiecearerotatedby
[Link] adjusted to
producetapers. Thewheel head can beswiveled.

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CHAPTER
6
SIMULATION&ANALYSI
S
[Link]

Analysisdonefor thepart―WATCH DIAL‖ to

studyandcalculatetheflowpattern,filltime,andpackingtimebyconsideringcoo
ling systemwhichwillaffectthe [Link]
theclampforceandinjection pressure required for the mouldmesh which
will help to select to the exact injection mouldingmachineand
approximate cycle.
Simulation
Procedure

a) Import CADmodel
b) Generate themesh
c) Select gatelocation
d) Select material
e) Set mouldingcondition
f) Set Analysisparameters
g) Run Analysis
h) Fillingproblem Resolution
i) Runner balancing

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[Link] Trap
Air Trap resultshows thepossible locationswhere air trap can occur.

[Link]
WeldLineresultshowstheweldlinesthatindicatepotentialspotsofweakerstr
ucture. Thedarker theweld line, theweaker thestructure.

[Link]

Sink Mark is an indextoevaluatethe packingeffect.

 Positive value— shows correct packing.
 Negativevalue—showsover packing
 Valueclosetozero—
[Link] sink marks
on thesurfaceof themolded part.

[Link] at theendof thefill

Pressureresultshows the pressuredistribution oftheplastic at the

end of filling.
 Usethe pressureresultto analyzethe following:
 Check the pressuretransmission conditions.
 Check fordropin pressurein the runner system.
 Check the mold designforabalanced flow.
 Check forover packingand flashingof themelt.
 Examinethe extent ofpackingorholding.

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[Link]
Temperature

Temperatureresultshowstheplasticmelttemperaturedistributionattheend
offilling. Thetemperaturedistributionshowstemperaturesinall
threedimensionsfor thefully cavity.

[Link]
ature
Center temperatureisthemelttemperature ofthemiddle layer (partline)
inthe thickness [Link]
temperatureisanindicatorofthethermalenergy
[Link]
istoolow,flowhesitationoccurs, which cancause short shot problem.

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[Link]
ature

Bulktemperature isa velocity-weightedaveragetemperature

ofplasticmeltacrossthe
[Link]
ry is
[Link]
mthis data. Thebulk temperaturedistribution reflects thetrend
oftheflowpath.
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[Link]

Maximumshearrateresultshowsthepeakvalueofshearrateateachelement
duringthe fillingstage

[Link]
Maximumshearstressresultshowsthepeakvalueofshearstressateachelem
entduring the fillingstage.

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Thisresultshowsthemaximumcoolingtimeinthethicknessdirectionattheen
dof [Link] timeisthetimefromtheendofpacking
totheinstantwhenthemolded part cools to the ejection temperature.

[Link]
ector
Velocityvector is thevector plot of thevelocityvector at the end of
filling.

[Link]
nkage:

Thisresultshowsthe maximumvolume shrinkage acrossthe

partthicknessatthe endof
[Link],whichmay
causesink mark or void
[Link]
orce
Thisresultshowsaplotoftheclamping force versusthefillingtime.
Thevalueisthe requiredclampingforcesduring themolding
processinsteadoftheforcethatmolding
[Link]
[Link]
clampingforceislargerthan70percentofthemachinemaximumclampingfor
ce,there is a chanceof plasticmelt beingsqueezed outside the cavityand
causing flash.

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Graph6.1:Z-directionClampforce vs. Time

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Graph6.2:Y-directionClampforce vs. Time

Graph6.3:X-directionClampforce vs. Time

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[Link]
ate
Thisresultshowstheplotofflowrateatthesprueversusfilling
[Link],the
[Link]
erefore, inthisresult,theflowrateusually
[Link] resulting
flowrateappearsotherwise,checkifthemaximumallowedinjectionpressure
is too low.

Graph6.4:FlowRa
te

Thisresultshowsthecontributionof [Link] regioninthe

samecolorrepresents
[Link]
ndicates
[Link]
swhether the model was filled bybalancedflowpattern.

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[Link] Advisor

Thispartcanbesuccessfullyfilledwithaninjectionpressureof10.4MPa
.TheInjectionpressurerequiredtofillislessthan 66%of the
maximum injectionpressurelimitspecifiedfor
thisanalysis,whichmeansyouarewell underyour specifiedlimit.
 Youmay
beabletoreducethepartthicknessanddecreasecoolingtimebutbe
sure torun anadditionalanalysisafterchangingthe
thicknesstoensureyour part will stillfill within
thespecifiedinjection pressurelimit.


Theminimumflowfronttemperatureislessthanthestartingmeltte
mperature by
[Link]
ng problems,Increase injectionpressure requirements,cause
poorweldline integrityandappearanceand haveanegativeeffect
on theoverallproperties of the moulded part.


Thepredictedshearrateis30%greaterthanthemaximumrecomm
ended valuefor thematerialused [Link]
potentially increasingthe injection time to reducethevolumetric
flow rate.
 High shearrates can lead to plasticmaterial degradation,
discoloration , moulded partsurface
defectsandanoveralldecrease inthe mouldedpart physical
properties.


Thepredictedshearstressis30%greaterthanthemaximumrecom
mended value forthe material used forthis analysis.
 High mouldedin shear stress can cause parts to fail in their

Department end use applicationsandnon-

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uniformshearstressdistributionscancause
partshrinkage,whichcanleadtomouldedpartwarpage shear
stresscanbe decreased by increasing
themeltandmouldtemperatures,increasinginjection
times,decreasingpacking
pressureandincreasingpart,runnerandgate thickness.


Themaximumshearstresslevelshouldbewithintherecommended
maximum limit forthe materialyouselected for this analysis.
 Howeverkeepinmindthatitisalsovery importanttohaverelatively
uniform shear stress distributions across the surface
areaofyour part

 Becausenon-uniformstresslevelscanleadtonon-
uniformpartshrinkageand part warpage.

Thepredictedcoolingtimeisdeterminedwhen90%oftheparttemp
eratureis less than thematerial ejection temperature.
 Averageinjectionmouldingcoolingtimestendtorange
fromafewsecondsto
[Link]
ofyourpartmaytake longer than 60 seconds tocool.


Decreasingtheoverallwallthicknessorcoringoutverythicksection
sofyour partwillhelptoreducethecooling
time,promotemoreuniformcoolingand lower
theoverallcycletime.

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CHAPTER
7

PROCESSPLANNING&ENTREPRENEURIALSTE
PS

7.1EntrepreneurialSteps
[Link] need of the component to be made.
[Link] plan to carryout therequired operations to
makethe component. [Link] size and material for the
component.
[Link] thematerial for machine mould of that component.
[Link] the appropriateinjection mouldingmachineforthe
component. [Link] the appropriate standard mould base
for component.
[Link] thefinalcomponentinthedesigning software like
SOLIDWORKSusing itsPart module.
h.
DefinetheneedofallthepartsofthePlasticMould,whichcanperformthede
sired operations.
[Link]
ORKS
usingits part module.
[Link] allthe alreadymadeparts in SOLIDWORKS usingits
assemblymodule. [Link] proper mechanismof the
alreadymadeassemblyin SOLIDWORKS.
[Link] each part is done in SOLIDWORKS usingits drawingmodule.
m.
Studythepiecepartdrawingcarefullyandtoplantheoperationstobecarri
edoutin different stations.
[Link] should bedone accordingto thefinallymadedrafting.
[Link]
[Link] capableofhighdegreeofaccuracy they
canbeengineeredtoproduceverycomplex part.

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[Link]
fabrication,[Link]
hing should begiven.
q.
CheckthenewlymadePlasticMouldwhetheritisperformingthedesiredfu
nctionor not.
[Link] injection requirements of component are
wellunder specifiedlimit forthe component material and selected
moulding machine.

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7.2ProcessPlanningand Details

To reduce thecostsofcomponentsinplastic mouldandthusthe

costofpart tobe
made,[Link]
choosingan appropriatesequenceofoperationsandthe
[Link] processplanshould
considerthetotalcost:material,tooling,labor(time).Processplanninggenerally
includesthe followingconsiderations:
a. QuantityRequired-Total and
Annual, b. Work Piece -Shape
and Size,
c. Work Piece -Dimensional
Tolerances, d. Work Piece -
Material Limitations,
e. Equipment Available
forManufacturing. Theprocedural
sequences undertakenare:
a. Definingthe need&usefulness of
thecomponent. b. Definingthe dimensions
of the component.
c. Design the component.
d. Design thevarious parts of the plasticmoulding software
accordingto their uses. e. Aftermodelingoftheparts, assemblyis
donein software.
f. Draftingof thevariousparts &assemblyis done.
g. Draftingis sent totheworkshop, and is read
carefully. h. Final plasticmould is made
accordingto thedrafting.

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CHAPTER
8

CONCLUSIO
N
The goalof thisprojectwastodesigna safer, easier tooperate plastic
mouldwithout
[Link]
sproject, we studied plastic moulding theory, design and modeling
using Solid works and manufactured aprototypemodel to meet with the
industrial requirement.
Inevery
tool,[Link]
tool,itisnecessarytofollowthepropermethodology
ofmanufacturing,sothatonecanget accurate dimensional stabilityfor that
particular part within appropriate time.
Amoulddesignermusthave a thoroughknowledge
oftheprinciplesofthemould making asthe designofthe various parts of
themould dependson the technique adoptedfor [Link]
finalmoulddesignispreparedafter the part designhasbeenspecified
andallrequirementsaffecting
[Link]
perfectdesignandthetrailmade
[Link],Solid
workshasbeenusedformodeling,assemblyandextractionofcoreandcavity
with appropriatedimensionsby giving [Link]
gonethroughthe various specifications that are required in the process of
manufacturing of the Plastic [Link] dimensionsof the
prototype obtainedareaccordingtothe dimensions specifiedin the project.

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BIBLIOGRAPH
Y
 Fundamentals Modern ManufacturingbyMikellP. Groover
 Basic [Link]
 ToolDesign4Editions,By:[Link],[Link],
Joyjeet
Ghose
 Design of MachineTools 5thEdition, By: S.K. Basu, D.K. Pal
 Machine Tool Design and Numerical Control 3 Edition, By: N. K. Mehta
 Injection Mould DesignEngineeringbyDavid Kazmer
 Plastic Injection Moulding: Manufacturing ProcessFundamentals
by Douglas
[Link]
 [Link]
 [Link]
 [Link] Moulding
 http:// [Link]/p1astipedia/processes/injeection_moulding.aspx

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