FABRICATION OF GEAR TYPE INJECTION

MOULDING MACHINE

A PROJECT REPORT
2024-2025
Submitted by

23211166 RAGUL S
23211167 RAJAGURU V G
23211170 ROHAN S
23211169 ROHAN VIJAYAN DEVEVDRA
23211171 SANJAI K
23211173 SANKAR P

Under the guidance of

Mr. M VIMALKUMAR.,M.E.,
A report submitted in partial fulfilment of the requirements for the award
of

DIPLOMA IN MECHANICAL ENGINEERING (FULL TIME)

of the State Board of Technical Education and Training
Government of Tamil Nadu

DEPARTMENT OF MECHANICAL ENGINEERING

THE KONGU POLYTECHNIC COLLEGE
MALLUR, SALEM – 636 203.
 THE KONGU POLYTECHNIC COLLEGE
MALLUR, SALEM – 636 203.

Department of Mechanical Engineering

This is to certify that the project work titled

FABRICATION OF GEAR TYPE INJECTION
MOULDING MACHINE
Is the bonafide record carried out by
__________________ of final semester Diploma in
Mechanical Engineering (Full Time) during the year 2024 -2025

Project Guide Head of the Department

Submitted for the Board Examination held on __________

Internal Examiner External Examiner

ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT
At this pleasing moment of having successfully completed our
project, we wish to convey our sincere thanks and gratitude to our beloved
chairman Mr. P. RAMALINGAM, B.Sc., BL., HRDI., for providing us the great
opportunity with all facilities required for successful of our project work.

We express our profound gratitude to our Principal

Mr. P. SARAVANAN, M.E., for forwarding us to do our project and offering
adequate duration in completing our project.

We extend our sincere thanks to Mr. N MANIKANDAN, B.E., HOD,

Department of Mechanical Engineering, who have given encouragements and good
suggestions at times to complete the project effectively.

We express our sincere thanks to our project work in charge

Mr. L JAYAKUMAR, B.E., Lecturer in Department of Mechanical Engineering,
for his valuable guidance & kindly suggestions which enables us to complete the
project successfully.

We are grateful to thank and relish our gratitude to cordial Project

Guide Mr. M VIMALKUMAR, M.E., Lecturer in Department of Mechanical
Engineering who have induced to innovate this project with his technological
intents, guidance and advice throughout the course of this project.

We convey our sincere and heart full thanks to other

teaching and non teaching faculty members in our department for their kind
and valuable help which facilitate us to complete the project work
successfully. We also convey our heart full thanks to all our friends for their
kindly help rendered by them.
 CONTENT

1 INTRODUCTION 1
2 LITERATURE REVIEW 10
3 OBJECTIVES OF THE PROJECT 14
4 COMPONENTS USED 16
5 COMPONENTS DESCRIPTION 18
6 WORKING PRINCIPLE 37
7 FABRICATION TECHNIQUES 39
8 ADVANTAGES AND DISADVANTAGES 45
9 CONCLUSION 47
REFERENCES 49
ABSTRACT
 ABSTRACT

The project deals about the injection moulding machine. The main
principle is to compress the plastic material in a barrel and the compressing
motion is developed by rotating the gear box arrangement. The plastic material is
heated by the heater surrounding the barrel. Then it is converted into molten state.
The molten plastic is injected through the nozzle in barrel to the die by the
compressing force. After completing this process, we will get the product from
the die. Commercial products like bushes, couplings, switches etc., can be
produced.
INTRODUCTION

1
 CHAPTER 1
INTRODUCTION

Injection molding is a manufacturing process for producing parts by injecting

material into a mold. Injection molding can be performed with a host of materials,
including metals, plastics, elastomers, confections. Most commonly thermoplastics
and thermosetting polymers. Material for the part is fed into a heated barrel, mixed,
and forced into a mold cavity, where it cools and hardens to the configuration of the
cavity. These can be used to mass-produce toys, kitchen utensils, bottle caps, and cell
phone stands to name a few

Fig no: 1.1 Injection molding machine

2
1.1 INJECTION MOLDING

Injection molding 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 the thermoplastic
and thermo setting polymers. Injection molding 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 molding machine molds can be
fastened in either a horizontal or vertical position. The majority of machines are
horizontally oriented, but vertical machines are used in some niche applications
such as insert molding, allowing the machine to take advantage of gravity.

Types of Injection Molding Machine:

These Machines are classified primarily by the type of driving systems they
use: hydraulic, mechanical, electrical, or hybrid.

 Hydraulic: Hydraulic presses have historically been the only

option available to molders until Nissei Plastic Industrial Co., LTD
introduced the first all-electric injection molding machine in 1983.
Hydraulic machines, although not nearly as precise, are the
predominant type in most of the world, with the exception of Japan.

3
 Fig no: 1.2 Hydraulic Injection molding machine

 Mechanical: Mechanical type machines use the toggle system for

building up tonnage on the clamp side of the machine. Tonnage is
required on all machines so that the clamp side of the machine does
not open (i.e. tool half mounted on the platen) due to the injection
pressure. If the tool half opens up it will create flash in the plastic
product.

4
 Fig no: 1.3 Mechanical Injection molding machine

Electric: The electric press, also known as Electric Machine

Technology (EMT), reduces operation costs by cutting energy
consumption and also addresses some of the environmental
concerns surrounding the hydraulic press. Electric presses have
been shown to be quieter, faster, and have a higher accuracy,
however the machines are more expensive. Hybrid injection
(sometimes referred to as "Servo-Hydraulic") molding machines
claim to take advantage of the best features of both hydraulic and
electric systems, but in actuality use almost the same amount of
electricity to operate as an electric injection molding machine
depending on the manufacturer.

5
 Fig no: 1.4 Electrical Injection molding machine

Advantages of using Injection Molding Unit:

Following are the advantages

 Detailed Features and Complex Geometry: The injection molds are
subjected to extremely high pressure. As a result the plastic within the
molds is pressed harder against the mold compared to any other molding
process. Due to this excessively high pressure, it is possible to add a large
amount of details into the design of the part. Furthermore, due to high
pressure during the molding process, complex and intricate shapes can
easily be designed and manufactured which otherwise would have been too
complicated and expensive to manufacture.
 High Efficiency: Once the injection molds have been designed to the
customer‘s specifications and the presses pre-programmed, the actual
molding process is very quick compared to other methods of molding.
Plastic injection molding process hardly takes times and this allows more
parts to be manufactured from a single mold. The high production output

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 rate makes plastic injection molding more cost effective and efficient.
Typically, hot-runner ejection mold systems produce parts with more
consistent quality and do so with faster cycle times, but it‘s not as easy to
change colours nor can hot runners accommodate some heatsensitive
polymers. Learn more about the key differences between hotrunner and
cold-runner systems.
 Enhanced Strength: In plastic injection molding, it is possible to use fillers
in the injection molds. These filler reduce the density of the plastic while it
being molded and also help in adding greater strength to the part after it has
been molded. In fields where parts need to be strong and durable, plastic
injection has an option that other molding processes do not offer.
 Ability to Use Multiple Plastic Types Simultaneously: One of the major
advantages of using plastic injection molding for manufacturing parts is the
ability to use different types of plastic simultaneously. This can be done
with the help of co-injection molding, which takes away the worry about
using a specific type of plastic.
 Automation to Save Manufacturing Costs: Plastic injection molding is an
automated process. A majority of the injection molding process is
performed by machines and robotics which a sole operator can control and
manage. Automation helps to reduce manufacturing costs, as the overheads
are significantly reduced. Furthermore, with reduced labour force the
overall cost of manufacturing the parts is reduced and this cost saving can
easily be passed on to the customer. Furthermore, automation allows for
making precise and accurate injection molds.

7
 Computer aided design (CAD) and computer aided manufacturing (CAM)
allow close tolerances during the making of the molds. Injection Molded Plastics
Market Analysis: The global injection molding machine market size accounted
for USD 17.05 billion in 2017 and is estimated to expand at a CAGR of 3.5% by
2025. Growing demand for lightweight and durable products coupled with
increasing adoption from the automotive and packaging industries is likely to
drive this growth over the forecast period. The rising importance of lightweight
materials in the automotive industry is expected to boost the use of plastic
materials in automotive component manufacturing, which, in turn, will drive the
market. Rapid growth in population, growing industrialization, along with
technological advancements, have augmented the demand for automotive in
emerging markets. It is used in applications such as interior and exterior trim
components, electronic subassemblies, and under-hood applications. Plastic
Injection Molding Manufacturing Process: The Injection Moulding Process is one
of the plastic based product manufacturing process, this process utilizes a
specialized machine called injection moulding machine which is fundamentally
divided into two parts mould and injector. Wide range of plastic product can be
manufactured from this machine, for each differently shaped product a separate
mould is required, thus multiple products of same or different material can be
manufactured on same Injection Moulding Machine by simply changing its
moulds. The raw material is plastic granules which are supplied to Injection
Moulding Machine via Hooper & Feeder arrangement along with required
additives, these raw material are mixed in a mixer usually integrated within the
Machine followed by which these granules are converted to their semi-solid state
utilizing heaters of the injection moulding machine followed by which this semi-

8
solid plastic is injected into the mould using screw or plunger arrangement. The
mould is then cooled down utilizing the chiller sub-system of machine and part is
ejected out of mould by ejector pins at command of the operator, these parts are
then collected and placed in their respective bins, followed by appropriate
packaging prior to sale

9
LITERATURE REVIEW

10
 CHAPTER 2
LITERATURE REVIEW

Design and Fabrication of Mini Injection Molding Machine Pratibha

Patil International Journal for Research in Applied Science and Engineering
Technology Injection molding is considered to be one of the most prominent
processes for mass production of plastic components. The objective of this
project is to design and fabrication of mini injection molding machine to
produce the electrical holder and we reduce the machine cost by developing
this machine. The scope of the studies are performed which is the study will
be using a Polypropylene material reinforced with glass fibers. The project
can be divided into four stages. First step is design of the mini injection
molding machine and second is the preparation of the material and
development of the machine, then third step is injection molding machine
used to produce electrical holder. The prepared electrical holder is more cost
Design and Fabrication of Mini Injection Molding Machine

Pratibha Patil International Journal for Research in Applied Science and

Engineering Technology Injection molding is considered to be one of the
most prominent processes for mass production of plastic components. The
objective of his project is to design and fabrication of mini injection molding
machine to produce the electrical holder and we reduce the machine cost by
developing this machine. The scope of the studies are performed which is
the study will be using a Polypropylene material reinforced with glass fibers.
The project can be divided into four stages. First step is design of the mini
injection molding machine and second is the preparation of the material and

11
development of the machine, then third step is injection molding machine
used to produce electrical holder. The prepared electrical holder is more cost
A wide variety of injection molding technologies is now applicable to small
series and mass production

Gabor Jüttner AIP Conference Proceedings, 2014 Micro plastic parts open
new fields for application, e. g., to electronics, sensor technologies, optics,
and medical engineering. Before micro parts can go to mass production,
there is a strong need of having the possibility for testing different designs
and materials including material combinations. Hence, flexible individual
technical and technological solutions for processing are necessary. To
manufacture high quality micro parts, a micro injection moulding machine
named formicaPlast based on a two-step plunger injection technology was
developed. Resulting from its design, the residence time and the accuracy
problems for managing small shot volumes with reproducible high accuracy
are uncompromisingly solved.

Adelina Hrituc Simple equipment for studying the injection molding

process Adelina Hrituc MATEC Web of Conferences, 2018 The injection
molding process is largely applied to obtain plastic parts. The problem of
finding a simple equipment able to allow the study of the injection process
was addressed in the research presented in this paper. Aiming to solve the
problem, the main requests valid for the proposed equipment were
formulated. Considering some possible versions of the equipment
subassemblies, the ideas diagram method and the method of imposed
decision were applied to select the most convenient version of the injection

12
equipment. As a result, a constructive solution for a simple injection
molding equipment that could be used to develop some experimental
researches was identified.

13
OBJECTIVES OF THE PROJECT

14
 CHAPTER 3

OBJECTIVES OF THE PROJECT

Here we have fabricated the gear type injection molding machine. It‘s a new
innovative concept. This equipment has been mainly developed for molding the
plastic materials in plastic molding industries.

15
COMPONENTS USED

16
 CHAPTER 4
COMPONENTS USED

 MS PIPE

 GEAR ARRANGEMENT

 MOTOR

 WIRES

 FRAME

 MS rod

 Switch

 Metal Screw

17
COMPONENTS DESCRIPTION

18
 CHAPTER 5
COMPONENTS DESCRIPTION

5.1 DC MOTOR

A DC motor is any of a class of rotary electrical motors that converts

direct current (DC) electrical energy into mechanical energy. The most common
types rely on the forces produced by magnetic fields. Nearly all types of DC
motors have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current in part of the motor.

Fig no: 5.1 DC viper motor

DC motors were the first form of motor widely used, as they could be
powered from existing direct-current lighting power distribution systems. A DC
motor's speed can be controlled over a wide range, using either a variable supply

19
voltage or by changing the strength of current in its field windings. Small DC
motors are used in tools, toys, and appliances. The universal motor can operate
on direct current but is a lightweight brushed motor used for portable power
tools and appliances. Larger DC motors are currently used in propulsion of
electric vehicles, elevator and hoists, and in drives for steel rolling mills. The
advent of power electronics has made replacement of DC motors with AC
motors possible in many applications.

D.C. Motor (Permanent Magnet):

Description of dc motor
An electric motor is a machine which converts electrical energy to
mechanical energy. Its action is based on the principle that when a current-
carrying conductor is placed in a magnetic field, it experiences a magnetic
force whose direction is given by Fleming’s left hand rule.
When a motor is in operation, it develops torque. This torque can
produce mechanical rotation. DC motors are also like generators classified
into shunt wound or series wound or compound wound motors.

Fleming’s Left Hand Rule

Keep the force finger, middle finger and thumb of the left hand
mutually perpendicular to one another. If the fore finger indicates the direction
of magnetic field and middle finger indicates direction of current in the
conductor, then the thumb indicates the direction of the motion of conductor.

20
 Fig no: 5.2 Fleming’s Left Hand Rule

Principle of Operation of Dc Motor:

A uniform magnetic field in which a straight conductor carrying no
current is placed, the conductor is perpendicular to the direction of the
magnetic field. The conductor is shown as carrying a current away from the
viewer, but the field due to the N and S poles has been removed. There is no
movement of the conductor during the above two conditions. When the
current carrying conductor is placed in the magnetic field, the field due to the
current in the conductor supports the main field above the conductor, but
opposes the main field below the conductor.

Conductor:
Movement of Conductor:
Reduce the flux density in the region directly below the conductor. It is
found that a force acts on the conductor, trying to push the conductor
downwards as shown by the arrow. If the current in the conductor is reversed,

21
the strengthening of flux lines occurs below the conductor, and the conductor
will be pushed upwards.

Magnetic flux
Current carrying Conductor
Fig no: 5.3 Principle of Dc Motor
Now consider a single turn coil carrying a current. In view of the reasons
given above, the side of the coil will be forced to move downwards, whereas
the other side will be forced to move upwards. The forces acting on both the
coil sides will be of same magnitude. But their direction is opposite to one
another. As the coil is wound on the armature core which is supported by
the bearings, the armature will now rotate. The commutator periodically
reverses the direction of current flow through the armature. Therefore the
armature will have a continuous rotation.
A simplified model of such a motor is shown. The conductors are wound
over a soft iron core. DC supply is given to the field poles for producing flux.
The conductors are connected to the DC supply through brushes. A simple 2-
pole DC electric motor has 6 parts, as shown in the diagram below.
 An armature or rotor
 A commutator
 Brushes
 An axle

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  A field magnet
 A DC power supply of some sort
The result is to increase the flux density in to the region directly above the
conductor.

Fig no: 5.4 Operation of an Electric Motor

An electric motor is all about magnets and magnetism:

 A motor uses magnets to create motion.

 Opposites attract and likes repel.

So if there are 2 bar magnets with their ends marked north and south, then the
North end of one magnet will attract the South end of the other. On the other
hand, the North end of one magnet will repel the North end of the other (and
similarly south will repel south). Inside an electric motor these attracting and
repelling forces create rotational motion. In the diagram above, you can see two
magnets in the motor, the armature (or rotor) is an electromagnet, while the
field magnet is a permanent magnet (the field magnet could be an
electromagnet as well, but in most small motors it is not to save power).

23
Electromagnets And Motors

An electromagnet is the basis of an electric motor. You can understand

how things work in the motor by imagining the following scenario. Say that
you created a simple electromagnet by wrapping 100 loops of wire around a
nail and connecting it to a battery. The nail would become a magnet and
have a North and South Pole while the battery is connected.
Now say that you take your nail electromagnet, run an axle through the
middle of it, and you suspended it in the middle of a horseshoe magnet as
shown in the figure below. If you were to attach a battery to the electromagnet
so that the North end of the nail appeared as shown, the basic law of
magnetism tells you what would happen: The North end of the electromagnet
would be repelled from the north end of the horseshoe magnet and attracted
to the south end of the horseshoe magnet.
The South end of the electromagnet would be repelled in a similar way.
The nail would move about half a turn and then stop in the position shown.
We can see that this half-turn of motion is simple and obvious
because of the way magnets naturally attract and repel one another. The key to
an electric motor is to then go one step further so that, at the moment
that this half-turn of motion completes, the field of the electromagnet flips.
The flip causes the electromagnet to complete another half-turn of
motion. You flip the magnetic field simply by changing the direction of the
electrons flowing in the wire (you do that by flipping the battery over). If the
field of the electromagnet flipped at just the right moment at the end of each
half-turn of motion, the electric motor would spin freely.

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 Fig no: 5.5 Electromagnet

Armature:

The armature takes the place of the nail in an electric motor. The
armature is an electromagnet made by coiling thin wire around two or more
poles of a metal core. The armature has an axle, and the commutator is
attached to the axle. In the diagram above you can see three different views of
the same armature: front, side and end-on. In the end-on view the winding is
eliminated to make the commutator more obvious. The commutator is simply
a pair of plates attached to the axle. These plates provide the two connections
for the coil of the electromagnet.

25
 Fig no: 5.6 Armatures
Commutator and brushes:

The "flipping the electric field" part of an electric motor is accomplished

by two parts: the commutator and the brushes. The diagram at the right
shows how the commutated and brushes work together to let current flow
to the electromagnet, and also to flip the direction that the electrons are
flowing at just the right moment. The contacts of the commutator are
attached to the axle of the electromagnet, so they spin with the magnet. The
brushes are just two pieces of springy metal or carbon that make contact with
the contacts of the commutator.

26
 Fig no: 5.7 Commutator and brushes

Putting It All Together

When you put all of these parts together, what you have is a complete
electric motor. In this figure, the armature winding has been left out so that it is
easier to see the commutator in action. The key thing to notice is that as the
armature passes through the horizontal position, the poles of the electromagnet
flip. Because of the flip, the North Pole of the electromagnet is always above
the axle so it can repel the field magnet's North Pole and attract the field
magnet's South Pole. If you ever take apart an electric motor you will find
that it contains the same pieces described above: two small permanent
magnets, a commutate, two brushes and an electromagnet made by winding
wire around a piece of metal. Almost always, however, the rotor will have
three poles rather than the two poles.

There are two good reasons for a motor to have three poles:
1. It causes the motor to have better dynamics. In a two-pole motor, if the
electromagnet is at the balance point, perfectly horizontal between the
two poles of the field magnet when the motor starts; you can imagine the
armature getting "stuck" there. That never happens in a three-pole motor.

27
 2. Each time the commutate hits the point where it flips the field in a two-
pole motor, the commutate shorts out the battery (directly connects the
positive and negative terminals) for a moment. This shorting wastes
energy and drains the battery needlessly. A three-pole motor solves this
problem as well.
3. It is possible to have any number of poles, depending on the size of the
motor and the specific application it is being used in.

5.2 SHAFT

Fig no: 5.8 MS Shaft

A shaft is a rotating machine element, usually circular in cross section,

which is used to transmit power from one part to another, or from a machine
which produces power to a machine which absorbs power. The material used for
ordinary shafts is mild steel. When high strength is required, an alloy steel such
as nickel, nickel-chromium or chromium-vanadium steel is used. Shafts are

28
generally formed by hot rolling and finished to size by cold
drawing or turning and grinding.

5.3 MS PIPE

MS Pipe, MS Tube refers to Mild Steel Pipe or Mild Steel Tubes used for
industrial and domestic use.

A pipe is a tubular section or hollow cylinder, usually but not necessarily

of circular cross-section, used mainly to convey substances which can flow —
liquids and gases (fluids), slurries, powders and masses of small solids. It can
also be used for structural applications; hollow pipe is far stiffer per unit weight
than solid members.

In common usage the words pipe and tube are usually interchangeable, but
in industry and engineering, the terms are uniquely defined. Depending on the
applicable standard to which it is manufactured, pipe is generally specified by a
nominal diameter with a constant outside diameter (OD) and a schedule that
defines the thickness. Tube is most often specified by the OD and wall
thickness, but may be specified by any two of OD, inside diameter (ID), and
wall thickness. Pipe is generally manufactured to one of several international
and national industrial standards. While similar standards exist for specific
industry application tubing, tube is often made to custom sizes and a broader
range of diameters and tolerances. Many industrial and government standards
exist for the production of pipe and tubing. The term "tube" is also commonly
applied to non-cylindrical sections, i.e., square or rectangular tubing. In general,

29
"pipe" is the more common term in most of the world, whereas "tube" is more
widely used in the United States.

Fig no: 5.9 MS Pipe

5.4 MS SHEET

Sheet metal is metal formed by an industrial process into thin, flat pieces.
Sheet metal is one of the fundamental forms used in metalworking, and it can be
cut and bent into a variety of shapes. Countless everyday objects are fabricated
from sheet metal. Thicknesses can vary significantly; extremely thin sheets are
considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate steel or "structural steel".

30
 Fig no: 5.10 MS Sheet

Sheet metal is available in flat pieces or coiled strips. The coils are formed
by running a continuous sheet of metal through a roll slitter.In most of the
world, sheet metal thickness is consistently specified in millimeters. In the U.S.,
the thickness of sheet metal is commonly specified by a traditional, non-linear
measure known as its gauge.

The larger the gauge number, the thinner the metal. Commonly used steel
sheet metal ranges from 30 gauge to about 7 gauge. Gauge differs between
ferrous (iron-based) metals and nonferrous metals such as aluminum or copper.
Copper thickness, for example, is measured in ounces, representing the weight
of copper contained in an area of one square foot. Parts manufactured from
sheet metal must maintain a uniform thickness for ideal results.

31
 There are many different metals that can be made into sheet metal, such
as aluminium, brass, copper, steel, tin, nickel and titanium. For decorative uses,
some important sheet metals include silver, gold, and platinum (platinum sheet
metal is also utilized as a catalyst). Sheet metal is used in automobile and truck
(lorry) bodies, airplane fuselages and wings, medical tables, roofs for buildings
(architecture), and many other applications. Sheet metal of iron and other
materials with high magnetic permeability, also known as laminated steel cores,
has applications in transformers and electric machines. Historically, an
important use of sheet metal was in plate armor worn by cavalry, and sheet
metal continues to have many decorative uses, including in horse tack. Sheet
metal workers are also known as "tin bashers" (or "tin knockers"), a name
derived from the hammering of panel seams when installing tin roofs.

5.5 WIRES

A wire is a single usually cylindrical, flexible strand or rod of metal.

Wires are used to bear mechanical loads or electricity and telecommunications
signals. Wire is commonly formed by drawing the metal through a hole in
a die or draw plate. Wire gauges come in various standard sizes, as expressed in
terms of a gauge number. The term 'wire' is also used more loosely to refer to a
bundle of such strands, as in "multistranded wire", which is more correctly
termed a wire rope in mechanics, or a cable in electricity.

Wire comes in solid core, stranded, or braided forms. Although usually

circular in cross-section, wire can be made in square, hexagonal, flattened
rectangular, or other cross-sections, either for decorative purposes, or for

32
technical purposes such as high-efficiency voice coils in loudspeakers. Edge-
wound coil springs, such as the Slinky toy, are made of special flattened wire.

Fig no: 5.11 Wires

5.6 METAL SCREW

A screw and a bolt (see Differentiation between bolt and screw below) are
similar types of fastener typically made of metal and characterized by
a helical ridge, called a male thread (external thread). Screws and bolts are used
to fasten materials by the engagement of the screw thread with a similar female
thread (internal thread) in a matching part.

Screws are often self-threading (also known as self-tapping) where the

thread cuts into the material when the screw is turned, creating an internal thread
that helps pull fastened materials together and prevents pull-out. There are many
screws for a variety of materials; materials commonly fastened by screws
include wood, sheet metal, and plastic.

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 5.7 RACK AND PINION

A rack and pinion is a type of linear actuator that comprises a circular

gear (the pinion) engaging a linear gear (the rack). Together, they convert
between rotational motion and linear motion: rotating the pinion causes the rack
to be driven in a line. Conversely, moving the rack linearly will cause the pinion
to rotate.

The rack and pinion mechanism is used in rack railways, where the
pinion mounted on a locomotive or a railroad car engages a rack usually placed
between the rails, and helps to move the train up a steep gradient. It is also used
in arbor presses and drill presses, where the pinion is connected to a lever and
displaces a vertical rack (the ram). In pipelines and other industrial piping
systems, a rack displaced by a linear actuator turns a pinion to open or close a
valve. Stairlifts, lock gates, electric gates, and the mechanical steering
mechanism of cars are other notable applications.

The term "rack and pinion" may be used also when the rack is not
straight but arcuate (bent), namely just a section of a large gear.

A single pinion can simultaneously drive two racks, parallel but

opposite; which will always be displaced by the same distance, only in opposite
directions. Conversely, by applying opposite forces to the two racks one can
obtain pure torque on the pinion, without any force component. This double rack
and pinion mechanism can be used, for example, with a pair of pneumatic
actuators to operate a valve with minimum stress.

34
 The teeth of a rack and pinion pair may be either straight (parallel to the
rotation axis, as in a spur gear) or helical. On the pinion, the profile of the
working tooth surfaces is usually an arc of involute, as in most gears. On the
rack, on the other hand, the matching working surfaces are flat. One may
interpret them as involute tooth faces for a gear with infinite radius. In both parts
the teeth are typically formed with a gear cutter

Fig no: 5.12 Rack and Pinion

5.8 NOZZLE

A nozzle is a device designed to control the direction or characteristics of

a fluid flow (specially to increase velocity) as it exits (or enters) an enclosed
chamber or pipe.

A nozzle is often a pipe or tube of varying cross sectional area, and it can
be used to direct or modify the flow of a fluid (liquid or gas). Nozzles are
frequently used to control the rate of flow, speed, direction, mass, shape, and/or

35
the pressure of the stream that emerges from them. In a nozzle, the velocity of
fluid increases at the expense of its pressure energy.

Fig no: 5.13 Nozzle

 Atomizer nozzles are used for spray painting,

perfumes, carburetors for internal combustion engines, spray
on deodorants, antiperspirants and many other similar uses.
 Air-aspirating nozzles use an opening in the cone shaped nozzle to inject
air into a stream of water based foam (CAFS/AFFF/FFFP) to make the
concentrate "foam up". Most commonly found on foam extinguishers
and foam handlines.
 Swirl nozzles inject the liquid in tangentially, and it spirals into the
center and then exits through the central hole. Due to the vortexing this
causes the spray to come out in a cone shape.

36
WORKING OF THE PROJECT

37
 CHAPTER 6
WORKING OF THE PROJECT

 The injection – moulding machine is shown in the process consists of

feeding the compounded plastic material as granules, pellets or powder
through the hopper at definite time intervals into the hot horizontal cylinder
where it gets softened.
 Pressure is applied through a Motor driven piston to push the molten
material through a cylinder into a mould fitted at the end of the cylinder.
While moving through the hot zone of the cylinder, a device called torpedo
helps spread the plastic material uniformly around the inside wall of the hot
cylinder sand thus ensures uniform heat distribution.
 The molten plastic material from the cylinder is then injected through a
nozzle material from the cylinder is then injected through a nozzle into the
mould cavity.

Fig no: 6.1 Working Drawing

38
FABRICATION TECHNIQUES

39
 CHAPTER 7
FABRICATION TECHNIQUES

7.1 FABRICATION

Fabrication is the act of taking raw stock material and turning it into a part
for use in an assembly process. Fabrication has a great deal to do with
manufacturing. Fabrication is an industrial term that refers to the manipulation of
raw materials (such as steel) for the making of machines and structures. Steel and
other metals are cut and shaped during the fabrication process. Fabrication is a
very hands-on part of the manufacturing process.

7.2 FABRICATION PROCESS

7.2.1 CUTTING

Fig no: 7.1 Cutting machine

40
There are many ways to cut nowadays. The old standby is the saw. Others now
include plasma torches, water jets, and lasers. There is a wide range of
complexity and price, with some machines costing in the millions.

7.2.2 WELDING

Fig no: 7.2 Welding Works

Welding is the act of joining two pieces of metal together. A variety of types
of welding exist for use in different applications and for the range of metals used
in manufacturing. Welding is a fabrication process that joins materials,
usually metals or thermoplastics, by using high heat to melt the parts together and
allowing them to cool, causing fusion. Welding is distinct from lower temperature
techniques such as brazing and soldering, which do not melt the base metal
(parent metal).

In addition to melting the base metal, a filler material is typically added to

the joint to form a pool of molten material (the weld pool) that cools to form a

41
joint that, based on weld configuration (butt, full penetration, fillet, etc.), can be
stronger than the base material. Pressure may also be used in conjunction with
heat or by itself to produce a weld. Welding also requires a form of shield to
protect the filler metals or melted metals from being contaminated or oxidized.

These processes use a welding power supply to create and maintain an electric arc
between an electrode and the base material to melt metals at the welding point.
They can use either direct current (DC) or alternating current (AC), and
consumable or non-consumable electrodes. The welding region is sometimes
protected by some type of inert or semi-inert gas, known as a shielding gas, and
filler material is sometimes used as well.

7.2.3 GRINDING

Fig no: 7.3 Grinding Works

42
Grinding is an abrasive machining process that uses a grinding wheel or grinder
as the cutting tool. Grinding is a subset of cutting, as grinding is a true metal-
cutting process. Grinding is very common in mineral processing plants and the
cement industry. It is the only economical method of cutting hard material like
hardened steel. It produces very smooth surface , suitable for bearing surface.
Surface pressure is minimum in grinding. It is suitable for light work,which will
spring away from the cutting tool in the other machining processes.

7.2.4 MACHINING

Fig no: 7.4 Machining works

This is the process of removing metal from a piece of material. It might be

done on a lathe, where the material rotates against a cutting tool, or in some other
cutting machine where a rotating tool is moved in a variety of ways against a
stationary piece. Drills fall into this latter category. The range of motion of the
cutting head is defined by the number of axes.

43
There are many other types of fabrication processes that are less common than the
ones in the list above. There are also constantly new types of fabrication methods
being developed.

44
ADVANTAGES AND
APPLICATIONS

45
 CHAPTER 8
ADVANTAGES AND APPLICATIONS

8.1 ADVANTAGE

 The daily using components can be easily made.

 The cost of the project is very less.

 High electricity consumption.

 Textile products can be produced.

 Less skilled labour is enough.

 Different shape of the components can be made according to the die what
are used.

8.2 APPLICATIONS

 Plastic industries
 Toys indistires
 Fiber industries

46
CONCLUSION

47
 CHAPTER 9
CONCLUSION

This project will be designed and constructed for the small-scale production
of small plastic articles. Hence, it can be recommended for small-scale investors
that are willing to produce small plastic articles such as key holders, clothes pegs,
flat rulers, bottle covers/caps and tally.

48
REFERENCES

49
 REFERENCES

[1]. S.Joshibaamali And K.Geetha Priya, ‗Automatic Duster Machine‘,

International Journal of Emerging Technology In Computer Science &
Electronics (IJETCSE) ISSN: 0976-1353 Volume 13 Issue 1 –MARCH 2015.

[2]. Mr. Sunil R. Kewate , Mr Inzamam T. Mujawar, Mr. Akash D. Kewate ,

Mr.Hitesh R. Pant‘, Development of New Smart Design to Erase the Classroom
Blackboard of Schools/Colleges‘, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 57-61 .

[3]. Dong Yeop Kim, Jae Min Lee1, Jongsu Yoon, Tae-Keun Kim1, Bong-Seok
Kim, And Chang-Woo Park,‘ Wall Shape Recognition Using Limit Switch
Module‘,International Journal of Control Theory and Computer Modeling
(IJCTCM) Vol.4, No.1/2, April 2014.

[4]. Mojtaba Khaliliana,, Ali Abedi, Adel Deris Zadeh, Energy procedia 14(2012)
, 1992-1997

[5]. Gaurav Gangurde, Design and Development of Board Cleaning System,

International Journal of Research and Scientific Innovation ISSN 2321 – 2705
Volume III, Issue III, March 2016.

[6] Dong Yeop Kim, Jae Min Lee1, Jongsu Yoon, Tae-Keun Kim1, Bong-Seok
Kim, And Chang-Woo Park,(2014), ― Wall Shape Recognition Using Limit
Switch Module‖, International Journal of Control Theory and Computer
Modeling (IJCTCM) Vol.4, No.1/2.

50