final project me
TRANSCRIPT
PROJECT REPORT
PROJECT REPORT ON
SINGLE CAVITY HOT TIP MOULD IN
WORKORDER NO.822098N CUSTOMER-LARSEN &TOUBRO LTD. MUMBAI
By
ADTDM-04YOGESH V.NIKAM
ENROLL NO. =2004141
Production Department 1
PROJECT REPORT PROJECT REPORT
(A GOVERNMENT OF INDIA SOCIETY)
P-31, MIDC INDUSTRIAL AREA, CHIKALTHANA,AURANGABAD- 431210.
CERTIFICATE OF APPROVAL OF PROJECT WORK
This is Certify to The Mr. YOGESH VISHNU NIKAM, S/O
Mr.VISHNU NIKAM of ADTDM 2004 BATCH, Enroll no: - 2004141 has
successfully completed his project work in the Production
Department as implant training, a part of there ADVANCE DIPLOMA
IN TOOL & DIE MAKING (4 yrs.) in the partial fulfillment of course for
the award of Advance diploma in tool & die making from INDO
GERMAN TOOL ROOM, Aurangabad during the period of 12TH JAN.
2008 TO 31ST JULY. 2008.
The project has been approved as it satisfies the academic
requirements in respect of project work prescribed for the trainees.
PROD . MANAGER COURSE CO’OR. PROJECT GUIDE By
(T.A.
KARANDE)
Production Department 2
PROJECT REPORT
I am very thankful to Mr. H.D.KAPSE (General Manager. Indo-
German Tool Room).
Mr.D.SIVAIAH (Sr. Manager Training) for assigning me does the live
project in the Design Department.
I would like to express my sincere thanks to Mr. T.A.Karande,
Mr. Mahesh kande, Mr.Yogesh Dxit, Mr. Amit Gajbhiye & Mr.
S.M.Shreerame for their expert guidance and valuable time. Also
thanks for the valuable guidelines and help from Mr. Vishal Sabde
and Mr. Kailash Gaikwad.
At last I would like to thank all the members of IGTR and collogues
for their Co-operation.
Production Department 3
PROJECT REPORT This project reveals the effort taken during the implant training in
design department between the duration of 12th Jan 2008 to 31st
July 2008.
The project gives a brief introduction about the work accomplished
in design including the explored applications in ProE, Unigraphics &
other design related information.
This project is basically dependent upon different types of Moulds
such as Injection Mould; hot tip Mould & Compression Mould etc. It also
gives a view of design consideration involved in press tool, mould & die-
casting-dies. It gives the idea of the flow of design from the stage of
receive till dispatch of the tool.
Finally this project is an overview of the work in design department.
Production Department 4
PROJECT REPORT
Production Department 5
SR.NO.
DESCRIPTION
INTRODUCTION
DESIGN CONSIDERATION
PROCESSDESIGN & PROJECT DETAILS
COMPONENT DETAILS
COMPONENT MATERIAL
DETAIL MOULD CAL.& M/C DETAIL
PART DETAIL & ASSEMBLY DETAIL
PART LIST
PROCESS SHEET
JOB CARD
COST ESTIMATION
01
02
03
04
05
06
07
09
08
11
10
50-62
45-49
42-44
40-41
29-39
22-28
20-21
17-19
15-17
14
6-13
PAGE NO.
TOOL INSPECTION REPORT12 63-68
ACHIEVEMENT & CONCLUSION13 69-70
PROJECT REPORT
1 BASICSThe single most important component in the moulding process is the Mould. Some times cost of the mould overtakes machine cost and always plays a vital role in deciding the product cost.
Almost 70% of the plastic products are produced by Injection Moulding method among all the plastics processing techniques available so far. So it is obvious that a large number of Injection moulds are made everywhere. Accordingly a lot of developments in mould making techniques have taken place. Hot Runner Mould is one of such great achievements in mould making field.
1. EVOLUTION OF HOT RUNNER MOULDS
Shaping of plastic materials in an Injection mould, particularly in a multi-cavity one needs a well-laid feeding system. The feeding system carries the plastic melt, under pressure, from the nozzle of the injection moulding machine to the entry point of the mould cavity and the continuity of the pressure helps the melt to reach the extreme end of the impression. The receiving end of the melt is known as Sprue. The Sprue delivers the melt on the main feeding channel known as Runner and further branching of it is known as sub-runners. The narrow bridge between cavity and the runner or sub-runner is known as Gate. In general the combination of sprue, runner and sub-runners is regarded as RUNNER SYSTEM.
In conventional moulding process the runner system is always moulded and ejected along with the moulded article in every cycle. This moulded runner is use less and forcibly produced as waste because of the technological barrier. But elimination of the runner system in the conventional moulding process is not possible. On the other hand the total volume of the runners and sprue exceeds that of the mouldings in case of multi-impression moulds quite often. More volume means more cycle time, more manpower loss and there by
Production Department 6
PROJECT REPORTmore wastage. One can argue of reusing the scrap as seconds and mixing to virgin material, but, still the process is uneconomical.
Paying a constructive attention to eliminating moulding and ejection of
the runner system is worth the effort. Evolution of HOT RUNNER
SYSTEM is the right result of such progressive thought. Incorporation
of the Hot Runner System in the conventional mould makes it a HOT
RUNNER MOULD.
The Hot Runner Mould consists of a runner system, which remain hot
and keeps the plastics in molten condition right up to the gate point all
along the production cycle. So the runner system is never moulded
and ejected unlike conventional mould in every cycle. On injection
only the cavities are filled to form the moulding. During ejection
stroke the moulding is degated and ejected out of the mould. Perhaps
this is the reason the hot runner mould is often called as runner less
mould.
1. TYPES OF HOT RUNNER SYSTEM
Hot Runner System gives an opportunity to make either hot runner
mould or semi-hot runner mould. Hot runner moulds eliminate the
entire runner system where the Semi hot runner moulds eliminate a
part of the runner system. choice for fabrication of such types of
moulds is left to user’s economic consideration as well as geometry
and aesthetic of the product.
The classification of Hot Runner Systems is subject to the kind of
heating provision available with it. They are two types in general, i.e.
Production Department 7
PROJECT REPORTi. Externally Heated Hot Runner Systems
In this case the melt is heated from out side while passing through the feeding channel. Electrical heaters supply the heat.
ii. Internally Heated Hot Runner Systems
In this case the heater is placed inside the feeding channel and the melt is supplied with heat from inside.
A third variety of system is also available, known as Combination
System. In this type the runner system contains a mixture of both
externally and internally heated hot runner systems.Indirect heating
system.
This kind of heating system is limited to Hot Nozzles only. The indirectly heated nozzles do not have any dedicated heater. It receives the required heat from the manifold to which it is attached. This is why the nozzles for indirect heating should be made from good heat conducting materials like BeCu, Cu or other such alloys. The main advantage of this type is simplification of design. However their temperature can not be controlled directly and independently.
1. HOT RUNNER ELEMENTS
Various elements used in hot runner systems are broadly divided into
two types as per their function. These are Path Elements and
Heating System Elements.
Path Elements consists of the followings
i. Hot Sprue Bushing
ii. ManifoldProduction Department 8
PROJECT REPORTiii. Injection Nozzles
Heating System Elements consists of the followings
i. Heaters
ii. Temperature Sensors
iii. Temperature Controller
Hot Sprue Bushing
The hot sprue bushings are designated to remove the superfluous direct gate on single mouldings. Also this is used to carry plastic melt up to main runner in case of multiple gate design.
Manifold
The heart of the hot runner system is the ‘MANIFOLD’. Manifold is a heated block, which houses the runner system. Distribution of the melt to every gate points takes place in this heated block. Leading standard mould base and components’ manufacturers have standardized various types of manifolds and these are readily available. Apart from this, customized mould bases can be easily manufactured with respect to the runner system design.
Injection Nozzles
Injection nozzle also some times called as Secondary nozzles is a part of the hot runner system which provides as connecting flow path from the manifold block to the cavity entry point. There are a number of possible designs of these nozzles available in the market. Most commonly used are cylindrical in shape and usually incorporate a threaded section
Production Department 9
PROJECT REPORTwhich screws into the manifold block. A leak free joint between nozzle and manifold is essential.
Heaters
In practice electrical heaters are normally used for heating. Different types of heaters are engaged to supply heat to different sections of the hot runner system. Catridge heater, Tubular heater, Band heater and Coil heater etc. are most commonly used one.
1. Catridge heatersMost Common method of manifold heating is done with catridge heaters. They are placed inside accurately drilled and reamed holes parallel to the runner. The advantage lies with easy replacement of the heaters. Catridge heaters are commercially available as standard part in various diameters, lengths and wattage.
2. Tabular heaters
3. Band heater
4. Coil heater
Temperature Sensors
The hot runner system remains hot during its entire operation. Temperature sensor is essential to keep track of the temperature of the manifold and other components. Different types of thermocouples are used to sense the temperature and give feed back to the controlling unit.
Temperature Controller
Hot runner moulds are extremely sensitive to temperature variation in nozzle and gate area. Even a change of a few degrees in temperature can interrupt the moulding process. Many times a high volume of rejections result because of temperature variation. Exact temperature control is, there fore, an important precondition for a good and automatically operating hot runner mould. Temperature controllers receive feed back from the heaters with the help of thermocouples and
Production Department 10
PROJECT REPORTregulate the temperature of by varying the current supply. In principle each nozzle should be controlled individually for easy and smooth flow of the melt. Dedicated controllers are now available which houses a number of controllers to control multiple zones of the hot runner system.
1. ADVANTAGES AND DISADVANTAGES
2. ADVANTAGES
BENEFITS REASONS
1. Savings in material
No sprue or runner is produced
C
OM
MER
CIA
L
2. Savings in cost for
regrind
3. No investment for
grinder
4. No Investment for
robotized runner picker
5. Savings in storage cost
for scrap
6. Shorter cycle Moulding of the sprue and
runner is eliminated7. Shot size is reduced by
volume
8. Larger shot volume is
available for filling
larger number of
cavities
9. Cooling timeis reduced
10. Smaller opening stroke
than for a three plate
mould
Production Department 11
PROJECT REPORT11. Ease of manufacturing Standard parts for hot runner
system are easily available, i.e.
Sprue bushings
Manifolds
Nozzles
Heaters
Thermocouples
12. Less moving parts
compared to three
plate mould
Hot runner system become
integral and remain fixed to the
injection half
1. Simpler Automation of
the moulding process
Omission of the moulding of the
runner.
Abolition of the three plate
mould construction.
2. Increased flow length
for impression
Runner network acts as an
extension to the machine
barrel, thus length of flow is not
accountable.
3. Longer holding
pressure
Ideal positioning of the gate
allows it
4. Less pressure drop Diameter of the sprue and
runner is machined to bigger
size
5. Dimensional
repeatability
Injection is possible right on the
component which improves
more homogenious feeding. 6. Increased mechanical
strength
Production Department 12
PROJECT REPORT
DISADVANTAGES
FLAWS REASONS1. More work is
necessary in mould
design
Experienced designers are
required
CO
MM
ER
CIA
L
2. Higher mould cost Incorporation of auxiliary
equipment’s like Nozzles, Heaters,
Temperature sensors,
Temperatures etc.
3. Unit cost goes up
incase of low
production
requirement
4. Costly maintenance Careful handling is essential. Also
repair due to wear & tear and
damage costs more
1. Hazardous Thermal degradation of some
sensitive material. TEC
DESIGN CONSIDERATION
Moulds:-
Material used for the component, its applications.
Shrinkage of the material.
Calculate the weight of the component.
Study the detail of the component.
Type of mould required for the component to be produced.
Production Department 13
PROJECT REPORT Machine available for the component.
Injection pressure required.
Type of runner system & gate required.
Type of ejection system weather blade, stripper etc.
Split and side core consideration if the component is having
any groove or notch on its sides.
Cycle time required for the component for complete fill.
Effective cooling in a short duration is necessary.
Cooling channels must be lick proof.
Selection of the material for core & cavity.
Adding of shrinkage to core & cavity dimensions.
Parts in the assembly must not foul with each other in
operation.
The layout of the tool must not be oversized
SINGLE CAVITY HOT TIP MOULD
FOR BOTTOM HOUSING
Component detail
Production Department 14
PROJECT REPORT
Customer gives information to the marketing department regarding their requirement. Before starting the design activities following things should be make clear with the customer.
The component related input from the customer may be in the form of
2D Component Drawing
3D Component Model
Existing Sample of Component
The Tool related input from the customer may be in the form of
Type of Mould / Die
No. of Cavities
Production Rate
The Material related input from the customer may be in the form of
Component Material
Shrinkage
Component weight
Die Set Material
Core/Cavity Material
Production Department
1 Customer LARSEN & TOUBRO LTD,MUMBAI
2 Drg. No/Component Name BOTTOM HOUSING(DCL50809)
3 Projected Area(mm²) 90 sq.cm4 Component material POLYCARBONATE PC
943R(LAXAN)5 Material shrinkage 0.6%6 Material co-efficient of friction of
plastics with steel µ 0.5
7 Bulk factor 1.758 Molding temperature 300 0C9 Component weight (single) 33 grms
10 Density of Polycarbonate 1.20 gm/cu.cm
15
DESIGN INPUT
PROJECT REPORTAesthetic & Functional Requirements of Component that should be discussed with the customer are as follows
Type of gate
Location of gate
Parting Line Constraints
Ejection mark constraints
Other inputs required from the customer are as follows
Reference Information
Standard Parts
Side Core Actuation Method
Machine Specification
Tool details…
Hot tip mould preferred when quantity of production is more and time is limited. The quality of the mouldings bring a sense of hot runner moulds as advanced one where the others might be considered as obsolete. We can still go for the obsolete methods with an economic projection towards it. But in the long run HOT RUNNER SYSTEM brings more money.
The two plate Hot tip mould has been designed for single cavity system, provided with Pin point gating for auto degating. The tool with 354mm shut height and gross weight of 180 kg with ejection stroke of 42 mm.
Materials for the plates are taken as M.S./C-45 and for inserts it is ORVAR SUPREME also, based on the property of EN-31 we have selected it for guide pillar and guide bush. the slide is made of o.s material to Resist wear and tear during functionng.
Push back pins has been provided with springs as to assure the self return provision of the ejector assembly. The ejector assembly including ejector plate and ejector back plate has been supported by
Production Department 16
PROJECT REPORTtwo ejector supports, it is also provided with two ejector guide pillar screwed with cavity back plate. Component has been feeded by point gate to assure minimum gate mark and self degating.
Sufficient cooling has been provide in tool to optimize cycle mark and to achive sound product. As the core in fixed half required cooling, to assure effective cooling we have provided cooling channel right from the bottom plate, the concept of cooling is not quite popular, provision of cooling has also been provided in moving half cavity insert.Every aspects and considerations of designing and manufacturing also has been taken in the tool to fulfill the requirement of the customer and fit to economy of the organization.
Component details…
Production Department 17
PROJECT REPORT
Component details…
Production Department 18
PROJECT REPORT
Material – Polycarbonate (PC)
Shrinkage – 0.6%
Density - 1.2 gm/cm3
Type of Polymer – Amorphous Thermoplastic
Injection Moulding Processing Conditions
Drying: Suggested drying conditions are 80-90 C (176-195 F) for a minimum for two hours. The material moisture content should be less than 0.1%.
Melt Temperature: 290-300 C Aim -300 C
Mould Temperature: 25-80 C (77-176 F). Mould temperature controls the gloss temperature; lower mould temperature produce lower gloss levels.
Material Injection Pressure: 50-100MPa
Injection Speed: Moderate-High
Project details…Production Department 19
PROJECT REPORT
Mould details
1 Moulding machine
SP80
2 Weight of feed system
0 grms.(approx.)
3 Total shot weight 33 grms.
4 Locating ring Dia 120f8 mm
5 Sprue bush Radius /Dia
R12/dia 5 mm
6 Minimum ejection stroke reqd. 42 mm
7 Type of ejection PIN & SLEEVE EJECTION.
8 Minimum day light
354 mm.
9 Total height 354 mm.
10 Overall mould size(HxLxW)
346x270x354
11 Total weight of mould 290 kg.
12 Weight of injection side 110 kg.
13 Weight of Ejection side 180 kg.
1.Weight Calculations :-
Production Department 20
PROJECT REPORT
Weight of Component = Volume X Density
= 27.5 X 1.2
= 33 grams
NO FEED SYSTEM DUE TO HOT TIP MOULD
(C) Shot Weight Required
Shot Weight = 33 grams
2. SHOT CAPACITY:-
The screw type machine is normally rated in terms of “Swept Volume”
of the injection cylinder (Cu. Cms).
Machine Available is SP 80. For SP 80 Swept Volume is 49 cm3
Shot capacity (g) = Swept Vol. (Cm3) x p x C
p = Density of plastic at normal temperature (g/cm3)
C = 0.93 for amorphous materials.
Shot capacity (g) = 49 X 1.2 X 0.93
= 54.68 grams
3. PLASTICISING CAPACITY:
Plasticizing rate of material B (g/hr) = plasticizing rate of
material A (g/hr) x QA/QB
Production Department 21
PROJECT REPORTA = Polystyrene
B = ABS (Material actually to be used)
Q = Thermal capacity of the material (cal/g) (Heat content)
QA = 239.4 KJ/Kg
QB = 302.4 KJ/Kg
Machine Available is SP 80, Plasticizing rate = 4.7 g/S
Plasticizing rate of material B (g/hr) = 4.7 X (3600/1000) X
(239.4/302.4)
PB= 13.395 Kg/hr
4. Locking Force Calculations:-
The clamping force required to keep the mould closed during injection must exceed the force given by the product of the opening pressure in the cavity and the total projected area of all impressions
Production Department 22
PROJECT REPORTand runners. Lower clamping values can be used with screw presses owing to the lower injection pressures possible with these machines.
Thin sections need a high injection pressure to fill and therefore require more clamping force. Easy flowing materials like high melt index polyethylene and polystyrene fill more readily and hence require a lower clamping force. In the case of screw injection 2/3 to 1/2 times of injection Pressure should be taken for Clamping purposes. Max. Injection pressure may be obtained from press manufacture’s data sheet.
(A) Projected Area of the component = 9000 mm
(E) Total Projected Area =9000 mm
(F) Clamping Force = {Total Projected Area
X 1/2 Injection pressure}
= 1250 X 0.5 X 900
= 40 KN
(G) Locking Force = 1.2 X clamping force
(20% safety)
= 48 KN
Determination of number of Cavities:
The number of cavities in injection moulds is determined in most cases by the machine performance, but some times by the moulding shape or the mould locking pressure.
Production Department 23
PROJECT REPORTDetermined by Shot Capacity:
(Based on 85% of rated shot capacity)
Ns = No. of cavities based on shot capacity
W = Rated shot capacity for particular polymer (g)
m = Moulding weight per cavity(g)
Ns = 0.85 X 54.68 / 33
= 1.4 Approx.2
Determined by plasticizing capacity:
(Based on 85% of rated plasticizing capacity)
Np = No. of cavities based on plasticizing capacity.
P = Rated plasticizing capacity for particular polymer (g/hr)
Tc = Over all cycle time (Sec.) = 4 seconds
Np = (0.85P X Tc) / 3600m
Np = (0.85 X 13.39 X 1000 X 13)/ (3600 X 33)
= 1.2 Approx. 2
Determined by clamping capacity:
Production Department 24
PROJECT REPORTNc = No. of cavities based on clamping capacity
C = Rated clamping capacity (KN)
Pc = Clamping pressure in KN.
Am = Projected area of moulding (Sq. Cm.) including runners.
FOR FIRST COMPONENT
Nc = 300 X 1000 / (90 X 40000)
= 0.8 Approx
2. MIN. WALL THICKNESS
t = 3 C. P. d4 E.Y.
t = Min. wall thickness (cm)
y = Max. Deflection of Side Wall = 0.003cm
Pc= Max. Cavity Pressure = 900 bar
d = Total Depth of Cavity Wall = 3.6 cm
E=Modulus of Elasticity = 2.1 X107 N/cm2
c = constant
Ratio of the length of Cavity wall to the depth of Cavity wall (L/d)
Value of C
1.0 0.044
1.5 0.084
2.0 0.111
3.0 0.134
Production Department 25
PROJECT REPORT
4.0 0.140
5.0 0.142
Ratio of length/depth=21/10.56 = 1.98
So value of c=0.111 from table
= 3 0.111 X 900 X 10 5 X (3.6) 4 2.1x107 x 0.003 x104
= 0.5 cm
= 5.00 mm
SPLIT CALCULATION:-
Production Department 26
PROJECT REPORT
M = (L x Sin Ø)-(c/cos Ø)
Where:
M = split movement in mm = 15.5 mm
Ø = angle of finger cam = 18º
L =working length of finger cam=?
C = clearance = 0.5
We have to find L
15.5 = (L x sin18º)-(0.5/cos18º)
=28 mm
So working length of finger cam taken as 30 mm
Project details…
Production Department 27
PROJECT REPORT
Machine Selection
Machine selection for making any plastic moulding should be based principally on max. shot capacity, max. die opening and die size, max. & min. die height, clamping force and operating stroke, length of shot stroke, tie bar distance, over-all size and cost.
The thumb rule for selection of plastic moulding machine is to use the smallest machine that will do the job. This will ensure fundamental economy of operation, since the larger the machine, the slower its cycle. Clamping force is not necessary the deciding factor in the selection of a plastic moulding machine. Die dimensions must be considered. The machine adequate tonnage for casting a part may have insufficient platen area or tie-rod spacing for the die, or the opening stroke may not be sufficient for removal of component.
Machine available for this case is SP 80.
Machine Specifications for SP 80
INJECTION UNIT
Production Department 28
PROJECT REPORT
CLOSING UNIT
Part details…
Production Department
1 Injection pressure 1800 bar2 Stroke volume 49m cu.cm 3 Max. Injection weight 98gms.4 Injection rate 100cc/s5 Plastering rate 4.7gm/s6 Screw L/D ratio 187 Screw diameter 25mm8 Screw stroke 100mm9 Screw speed (max.) 250rpm.
11 Locating ring diameter 120 mm
12 Nozzle type Round nozzle
11 No. of heating zones 4
12 Closing force 400 KN.13 Mould opening stroke 450 mm.14 Min. mould height 100mm.15 Max. daylight 470mm.16 Distance between Tie Bar
(h x v)395 x 395 mm.
17 Size of mould plate (h x v) 400 x 400 mm.18 Ejection force 24KN.19 Ejector stroke 65mm
29
PROJECT REPORT
Part details…
Production Department 30
CAVITY INSERTCAVITY INSERT
PROJECT REPORT
Assembly details…
ASSEMBLY DETAILS
Production Department 31
CORE INSERTCORE INSERT
PROJECT REPORT
Assembly details…
Production Department 32
ASSEMBLY OF TOOLASSEMBLY OF TOOL
PROJECT REPORT
Assembly details…
Production Department 33
MOVING HALF OF TOOLMOVING HALF OF TOOL
PROJECT REPORT
Hot tip details
Production Department 34
FIXED HALF OF TOOLFIXED HALF OF TOOL
PROJECT REPORT
Production Department 35
HOT TIP HOT TIP
PROJECT REPORT
Production Department 36
HOT TIP WITH SECTIONHOT TIP WITH SECTION
PROJECT REPORT
Assembly details…
Production Department 372D ASSEMBLY DRAWING2D ASSEMBLY DRAWING
PROJECT REPORT
WORK ORDER NO. 822098N
MATERIAL PR. NO. P.O. NO. COST
INSERTS O.S R-180 R-151 485/kg
MOULD BASE STD R-221 R-214 65,000 /-
Production Department 38
PROJECT REPORT
Part list…
PROCESS PLANNING
Production Department 39
PROJECT REPORT As work piece quantities and costs in press work are usually high, considerable
economy can be affected by choosing an appropriate sequence of operations and
the right type of tooling. The process plan should take into account the total cost:
material, tooling, labour (time). Process planning generally includes the following
considerations.
Quantity required – total and annual,
Work piece – shape and size,
Work piece – dimensional tolerances,
Work piece – material limitations,
Equipment available for manufacture.
In every tool, the process planning done a vital role and it is
followed by above mentioned points. To manufacture the parts of the tool, it is
necessary to follow the proper methodology of manufacturing, so that one can get
accurate dimensional stability for that particular part within appropriate time.
In Die casting dies also all the parts of the tool are
manufactured by considering all above mentioned sequence and choosing of
machining sequence. Below mentioned sheet expresses all the view of machining
sequence of the tool. Similarly all the parts of the tool are manufactured by the
same followed suit.
MANUFACTURING PROCESSES PLANNING FOR EACH PART
Production Department 40
PROJECT REPORT All the features of the part with dimensions & their references with respect to
the assembly.
The part is studies and the plans for sequence of process like conventional,
non-conventional & CNC machining, heat treatment in process & stage
inspection etc.
Special requirements for the tooling, electrode, and CAD/CAM support for the
programs required for the Core & Cavity inserts that are to be machined on
the CNC machines etc. are planned in advance to meet the process flow & to
maintain the delivery schedule.
Stage drawings of each parts coming & going out from process are made for
the convenience of the machine operator showing the references, tolerance
analysis, manufacturing allowances using the ordinate dimensioning and
inspection methodology.
A continuous follow up for the machine availability is made for the
completion of the job in the planned time period to maintain the delivery
date.
The above information is applied for all processes related to the part
indicating earliest start & finish date of each process with respect to material
planning, date of availability of special tooling, electrode, CAD/CAM data,
monthly priority list etc.The start & finish date can be taken from the job
cards the earliest finish date of assembly can be analyzed for the first trial
and is communicated to all the interface departments about planning and
their support
JOB CARDProduction Department 41
PROJECT REPORT
WORK ORDER NO.
822098 PART MATERIAL O.S
PART NO. 01 PART MATERIAL SIZE 61.80X181.5X147.5
PART NAME MAIN CORE INS PART QTY 61
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT 510 7/8 8/8 XX
XX
XX
B. REWORK DETAILS
Production Department
PLAN BY
DATE
42
PROJECT REPORT
WORK ORDER NO.
822098 PART MATERIAL O.S
PART NO. 62 PART MATERIAL SIZE
PART NAME CAVITY INSERT PART QTY 01
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT 510 7/8 8/8 XX
XX
XX
B. REWORK DETAILS
WORK 822098 PART MATERIAL OS
Production Department
PLAN BY
DATE
43
PROJECT REPORTORDER NO.PART NO. 63 PART MATERIAL SIZE
PART NAME LOCAL CORE-1 PART QTY 01
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT XX
XX
XX
B. REWORK DETAILS
Production Department
PLAN BY
DATE
44
PROJECT REPORTWORK ORDER NO.
822098 PART MATERIAL O.S
PART NO. 64 PART MATERIAL SIZE
PART NAME LOCAL CORE2 PART QTY 01
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT XX
XX
XX
B. REWORK DETAILS
WORK ORDER NO.
822098 PART MATERIAL O.S
Production Department
PLAN BY
DATE
45
PROJECT REPORTPART NO. 65 PART MATERIAL SIZE
PART NAME SIDE CORE PART QTY 01
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT XX
11 EDM XX
XX
B. REWORK DETAILS
WORK ORDER NO.
822098 PART MATERIAL OHNS
Production Department
PLAN BY
DATE
46
PROJECT REPORTPART NO. 01 PART MATERIAL SIZE
PART NAME GUIDE RAIL PART QTY 02
DATE FINISH SIZE
A. PROCESS FLOW
SR.NO.
PROCESS DESCRIPTION
M/C START DATE
COMP.DATE
QTYACC. REJ.
COMP.BY
SIGN
01 BLOCK MILLING VF2 16/6 16/6 XX
02 S/G NEW KENT
17/6 17/6 XX
03 SPOTTING & DRILLING
V33 20/6 20/6 XX
04 B/W B/W 22/6 23/6 XX
07 H/T 52-54 HRC PLANT 25/6 2/7 XX
08 S/G KENT 2/7 2/7 XX
09 CNC MILLING HAAS 4/7 4/7 XX
10 WIRE CUT XX
XX
XX
B. REWORK DETAILS
PART MATERIAL DETAIL
Production Department
PLAN BY
DATE
47
PROJECT REPORT
MATERIAL C% Mn% Si% S% P% Cr% Ni% Mo%
M.S. 0.25 0.6-
0.9
0.1-
0.35
0.055 0.55 0.2-
0.35
EN-8 0.35-
0.45
0.6-
1.0
0.05-
0.35
0.06 0.06
EN-31 0.9-
1.2
0.3-
0.75
0.1-
0.35
0.05 0.05 1.0-
1.6
OHNS 0.85-
0.95
1.0-
1.5
0.2-
0.4
0.3-
0.6
0.3
O.S 0.39 0.4 1.0 5.2 1.4
HEAT TREATMENT DETAIL
Heat Treatment of steel may be defined as an operation or combination
of operations involving the heating and cooling the steel in solid state;
Production Department 48
PROJECT REPORTso as to modify its properties and to make it suitable for a particular
uses.
Purposes of Heat Treatment –
The heat treatment is done for following purposes
1) To improve machinability.
2) To produce a hard surface on a ductile interior.
3) To refine grain size.
4) To relieve internal stress or eliminate the effect of cold working.
5) To increase mechanical properties.
6) To increase the resistance to wear, heat & corrosion.
7) To improve magnetic & electric properties.
8) To change chemical composition.
9) To increase cutting properties of steel.
10) To remove gases.
Hardening
It is a method of steel heating, 40 - 500C above the upper critical
temperature for hypo eutectoid steel or 40 - 500 above lower critical
temperature for hyper eutectoid steel, soaking for a specified time. The
hardness obtained by hardening process depends upon following –
1) Carbon content
2) Quenching rate
3) Work size
Quenching
Mark tempering – it is a process in which a steel is heated at the
hardening temperature soaked for a specified time & quenched in
Production Department 49
PROJECT REPORTisothermal bath having temperature 1800 to 3000C, kept just above the
martensite start line. The material is held there for a time just before
the nose of the bainite line. Afterwards it is cooled in air. The end
product it martensite.
Objective
1) Less distortions or warping
2) Less change in volume
3) Less change of quenching cracks & internal stresses
H.T. FOR
ORVAR SUPREME -
Hardening temperature - 1020 to 1050 deg. cel.
Quenching medium - air
Hardness after quenching - 46 to 52 HRC
Tempering temperature - 250 to 550 deg. Cel.
Hardness after tempering - 54 HRC
H.T. FOR
O.H.N.S -
Hardening temperature - 790 to 815 deg. cel.
Quenching medium - oil
Hardness after quenching - 63 to 65 HRC
Tempering temperature - 150 to 425 deg. Cel.
Hardness after tempering - 50 HRC
Cost estimation…
Production Department 50
PROJECT REPORT
Production Department 51
PROJECT REPORT
Cost estimation…
Costing of tool
Involves Designing cost of the tool.
Material cost.
Pre machining cost.
Precision machining cost.
Heat treatment cost.
Fitting & assembly ,bench work cost.
Inspection & trail cost.
Production Department 52
PROJECT REPORT
Cost estimation…
1) Designing cost The amount and cost of time spent in designing a product are
estimated either on the basis of similar jobs previously
manufactured or on the basis of good judgment of designer. For
new and complicated product the job estimator must consult the
designer.
It is always preferable that standard rates per hour be used to
calculate the cost of designer’s time, and actual rates which are
usually paid on a monthly or any other basis.
It required, 60hours - 2D designing 20 hours - 3D modeling
As, 2D designing cost = 300 per hours 3D modeling cost = 500 per hours
2D designing cost 60 x 300 = 18000 /- 3D designing cost 20 x 500 = 10000/- ---------------- 28000/-
TOTAL DESIGNING COST = 28,000 /-
Production Department 53
PROJECT REPORT
Cost estimation…
2) Material costs.
For estimating the material cost of the product, following steps
are followed.
Find out the volume of the material.
Multiply it with density of the material.
The drawings of the product to be manufactured are broken up
into smaller simpler parts and their volumes are calculated by
applying the formulae.
Volume of square or rectangular cube = L x B x H. Where, L = length of piece, B = breadth of piece, H = height of piece.
Volume of cylinder = 2π RH.Where, π = constant i.e. 3.14 or 22/7, R = radius of piece, H = height of piece.
Volume of pyramid =( L x B x H)/3Where, L = length of piece, B = breadth of piece,
H = height of piece.
Density of steel = 7.86 gm/cm³
Production Department 54
PROJECT REPORT
Cost estimation…
3) Pre machining cost Unit costs (in hours)
Th e tool requires, Lathe = 20 hours Milling = 60 hours Surface grinding = 48 hours Cylindrical grinding = 18 hours
Lathe operation cost = 0 x 290 = 0 Milling operation cost = 60 x 290 = 1740Surface grinding = 48 x 290 = 1392Cylindrical grinding = 0 x 290 = 0 --------------------- 3,132 /-
TOTAL PRE MACHINING COST = 3,132 /-
Cost estimation…Production Department
Lathe 290/-Milling 290/-Surface grinding 290/-Cylindrical grinding 290/-
55
PROJECT REPORT
4) Precision machining cost
Unit costs (in hours)
The tool requires,
Lathe = 00 hours Milling = 18 hours Wire cut = 30 hours EDM = 40 hours Lathe operation cost = 00 x 575 = 0000 Milling operation cost = 22 x1000 = 22,000Jig boring = 00 x 575 = 0000Wire cut = 30 x 750 = 22500EDM = 40 x 600 = 24000 ----------------- 68,500/-
TOTAL PRECISION MACHINING COST = 66,500/-
Cost estimation…
Production Department
CNC Lathe 575/-CNC Milling 1000/-CNC Wire cut 750/-CNC EDM 575/-
56
PROJECT REPORT
5) Heat treatment cost
Unit costs (in hours)
The tool requires, Conventional = 60 hours. Vacuum = 20 hours.
Conventional treatment cost = 60 x 80 = 4800 /- Vacuum = 20 x 300= 6000/-
TOTAL HEAT TREATMENT COST = 10,800/-
6) Fitting / assembly cost
Unit costs (in hours)
Fitting / assembly cost = 140 /-
The tool requires, Fitting / assembly time = 24 hours.
Fitting / assembly cost = 24 x 140 = 3,360/-.
TOTAL FITTING / ASSEMBLY COST = 3,360/-
Cost estimation…
Production Department
Conventional 80/-vacuum 300/-
57
PROJECT REPORT
6) Inspection cost
Unit costs (in hours)
Conventional = 200/- CMM = 1000/-
The tool requires, Conventional = 18 hours CMM = 06 hours
Conventional Inspection cost = 25 x 200 = 5,000 /-CMM Inspection cost = 08 x 1000 = 8,000/-
TOTAL INSPECTION COST = 13,000/-
Cost estimation…
Production Department 58
PROJECT REPORT
TOTAL COST OF TOOL
TOTAL DESIGNING COST = 28,000 /-
TOTAL MATERIAL COST = 22,500 /-
STANDARD MOULD BASE = 65,000 /-
TOTAL PRE MACHINING COST = 3,132 /-
TOTAL PRECISION MACHINING COST = 68,500/-
TOTAL HEAT TREATMENT COST = 10,800/-
TOTAL FITTING / ASSEMBLY COST = 3,600/-
TOTAL INSPECTION COST = 13,000/-
STANDARD PARTS COST = 25,000 /-
PACKING CHARGES = 4% OF NET VALUE.
SALES TAX = 12.5% AS APPLICABLE
EXCISE DUTY = 15% AS APPLICABL
MARGIN = 15 % of NET VALUE
---------------------- 3, 27,000 /-
TOTAL COST OF TOOL = 3, 27,000 /-TOTAL COST OF TOOL = 3, 27,000 /-
Trail report…
Production Department 59
PROJECT REPORT
INSPECTION
Due to the great advancement, the continuous improvements in
the production methods and increasing quality demands, the Industrial
Production Department 60
PROJECT REPORTInspection does not mean fulfilling of the specifications lay down by the
manufacturer. Rather the Inspection in real sense is concerned with the
checking of a product at various stages of manufacturing, right from the
raw material form to the finished products in the hands of the end
customer. That is what called as the CUSTOMER SATISFACTION.
Thus, the Inspection led to the development of the precise
Inspection instruments which helps to change over from the traditional
lesser accurate machines to better design and more precise machines.
It also led to the improvements in metallurgy and raw material
manufacturing due to high demand of accuracy and precision.
Ultimately it leads to the QUALITY IMPROVEMENT.
After manufacturing of all the parts they are transferred to Quality
Control department to check the accuracy of profile also it’s positioning
from the reference. Various geometrical features such as
perpendicularity, parallelism, circularity, run out, and etc if required.
Inspection of all the parts are carried out by trained personal and precisely working machines and it is followed by below mentioned path
FITTING & ASSEMBLY
ASSEMBLY - PROCESS PLANNING
Production Department 61
PROJECT REPORT First of all the assembly & sub-assembly is to be studied the
process is planned considering the functional requirement along
with fitment of mating parts showing indications & directions.
The detail record is maintained of each part required for the
assembly right from the material received to the final inspection
report.
The details of the process of each part can be obtained from the
job cards. While the dimensions with tolerances can be known
from the inspection reports.
The details of part reaching the assembly can be obtained from
the bar chart made before starting the actual manufacturing.
ASSEMBLY – PROCESS
While assembly of all parts and sub units first of all check the
following things.
Production Department 62
PROJECT REPORT Study the drawing.
Check the component thoroughly.
Collect and analyze the mating parts and its dimensions.
Check the deburring if not then deburr it.
Before final assembly, check the fault occurring between mating
parts.
The Pre-machining & assembly is done in the Assembly &
Fitting section. Then centre drilling done on the plates, on NC machine.
Then drilling operation, for cooling holes, tapping holes are performed
on the bench drilling machines. Then those holes get tapped. Then after
the manufacturing of all the parts, actual assembly gets starts. All
standard parts available like Allen screw, etc which is required during
assembly are collected.
After manufacturing of Core and Cavity inserts are
transferred to Quality Control department to check the accuracy of
profile also it’s positioning from the reference. Various geometrical
features such as perpendicularity, parallelism, circularity, run out, and
etc. if required. For assembly of tool various points which are to be
considered are as following.
Check all parts of standard die set and plate thickness for
further calculation.
Production Department 63
PROJECT REPORT Check all the standard parts which are being used in this tool.
All the inserts are maintained as per drawing for easy fitment.
Check the all alignments and fitments of all matting parts.
Identification marks are marked on each part to avoid further
confusion after disassembly.
Trail report…
INJECTION MOLDING DEPARTMENT
COMPONENT TRAIL REPORT Date: -
Work order no:-822098N Trail no:-
Production Department 64
TOOL INSPECTION REPORT
PROJECT REPORT
Mould description: - DESIGN OF SINGLE CAVITY HOT TIP MOULD FOR BOTTOM HOUSING
Component description :- Ref:-Component no:- Customer name: - L &T Mumbai
Material: - Inj.moulding machine:-SP80No. of shots:-Shot weight:- Component weight :-
REMARKS / OBSERVATIONS:-
Observation on component
1} 2}3)
Observation on mould functioning
1} 2)3)4}
PARAMETERS:-
ACHIEVEMENT
Production Department
Clamping pressure :- Injection Time :- Holding Time :- Cooling Time & Refilling Time:- Total Cycle Time :-
65
PROJECT REPORT The project was a medium for me to enhance my knowledge in the field of
tool & Die Making. It helped me lot in better understanding of the concepts of
Injection Mould manufacturing.
During the project I had to communicate with various departments and
authorities to solve the problems and difficulties around in between. It has
helped to improve my abilities to work as a team.
A Hot tip mould for Bottom housing was required to be completed in a
specific period of time for which I had to work to the best of my abilities to
complete the Hot tip mould.
In the project work I was given an opportunity to study the HOT TIP Mould
right from manufacturing to dispatch as per planned time period, which
stretched our limits to achieve the goal.
It was a nice opportunity for me to learn about such a tool, thus enhancing
my knowledge.
CONCLUSION
Production Department 66
PROJECT REPORTA complete mould designer must have a through
knowledge of the principles of the mould making as the design of the
various parts of the mold depends on the technique adopted for its
manufacturer. Case studies of the various moulds of same kind have
been conducted prior to the design process. Proper evaluation of the
previous designs were performed and created something even better
instead of simply keeping to what was done previously. The various
demands of the customer were considered while designing of the
tool. The final mould design is prepared after the part design has
been specified and all requirements affecting the design of mould
have been clarified. The outcome is a near perfect design and the
trail made on the mould just about confirms it.
Production Department 67