ABSTRACT

This report consists of details about Blow Mould and procedure that are adopted in the

processing. The Report includes observations of conventional machines to CNC machines

their applications in the field of manufacturing system. The latest developments in the

field of laser manufacturing system are also discussed in the report.

In this report details about processing the blow moulds is mainly discussed along with the

cost estimation, types of machines used, machining hour’s calculations, different

complication involved and inspections done through out the completion of the process.

INTRODUCTION

The development of the specialized machines like CNC machines, Laser machines

rapidly improved the growth of the industrial production along with the quality products

with lesser time period. These machines produce accurate and precise works at lesser

cost. At the same time the development in the tool manufacturing side the introduction of

the new tool promise longer tool life, less cost and more machining capabilities. This

technological development improves the rate of production of the material and reduces

the overall cost of production this in turn reduces the price value in the market and helps

in business competitions with others.

Every industrial unit needs specialized system of management where it needs both

manufacturing and training units separately but under the same roof. The report brings out

the features they adopt in training and method they adopt in manufacturing of the material

from raw material stage to finish stage.

CONTENTS

ACKNOWLEDGEMENT

ABSTRACT

INTRODUCTION

CONTENTS

SL.NO: DESCRIPTION PAGE NO:

CHAPTER 1.0: MANUFACTURING DETAILS OF 1.5 LITERS

BLOW MOULD.

1.0 BLOW MOULD PROCESS DETAILS

1.1 PROCESS DETAILS

CHAPTER 2.0: ANALYSIS OF PROCESSING METHOD

2.0 DESIGN ANALYSIS

2.1 TIME STUDY

CHAPTER 3.0: IMPROVEMENT CASE STUDY

“COST REDUCTION USING CONDITION MONITORING OF TOOLS”

CHAPTER 4.0: LITERATRE SURVEY

CHAPTER 5.0: RESULTS & DISCUSSIONS

REFERENCES

CHAPTER 1.0

MANUFACTURING DETAILS OF 1.5 LITERS “BLOW MOULD”.

1.0 BLOW MOULD PROCESS DETAILS:

Fig no: 1

The above figures show the working of a blow mould. The first figure shows the pre

heating of the component that is in the form of test tube this pre heated component is

inserted into the core and cavity of the design required. The stretch rod which holds the

tube stretches up to the bottom.

Hot air is blown through the tube and the plastic tube enlarges and fit to the design

made. The shrinkage allowances and the cooling system given will automatically create

the required design of the part.

This is how the blow molding process is done the main components required for

these processes are

a) CORE/CAVITY

b) TOP PLATE

c) LOCATING RING

d) BOTTOM INSERT &

e) HEIGHT ADJUSTER

Fig no 2: mould core/cavity

In Mold companies these components are manufactured and assembled and supplied to

the customers. The processing of pet 1.5 liters blow mold starts from the marketing order,

which is given in the form of “work order instructions” to planning department. The

instructions given in the work order comprises of the following details.

TABLE 1: WORK ORDER INSTRUCTIONS

From: Marketing To: Planning

Order conformation number *******

Customer *******

Description 1500 ml shell mould painted & completed

Scope of work 04 cavity & assembly

Quantity 2 set

Drawing & specification Design & drawing from GTTC

Raw material specification AA2014 by customer

Date of delivery 20/09/04

Priority Normal

The products received from the Company were sent to inspection for flatness and right

angle perfection. The results obtained from the quality section are given below.

length Profile area to bottom Rework y/n

1f=299.997/300.039 0.04 Y

1m=300.018/300.051 0.05 Y

2f=299.94/299.96 0.09 N

2m=299.97/299.96 0.11 Y

The average length will be 299.90mm set as standard value to all the 4 body. After

completion of the inspection the planning department analyzes the sequence of procedure

that can be suitable for completion of the work and appoint a person specialized in

planning and processing of that job.

The main requirement for any process to be complete is the design drawings. The

skillful designer knowing the requirements of the job will create the design. The designer

uses the engineering drawing, which will be the communication language between the

technician and the designer.

After obtaining the design drawing for all these components the planner decides

the requirements of raw materials required along with the raw materials size with the aid

of marketing department.

1.1 PROCESS DETAILS

As the Raw material arrives the processing of the components starts. The planner

appointed will control the process along with allocation of machinery, tools and estimate

the time for completion. The job running will be stage inspected and after every finish

quality inspection will be done.

The processing of the job done by the planner consists of process sheet, job card and the

design drawing. The format for each record is as follows:

TABLE 2: JOB CARD FORMAT:

Company Name JOB CARD UNIT CODE:

OC number Description: Dept:

Drg/Part NO: Qty:

Planned date of loading Completion date:

Recommended Estimated time Actual time

Machine Section

Operation

Special instruction

Foreman / shift in charge remark

Date: Signature:

Job card prepared by: Section

Name: Date:

Production planning

This card specifies the needed information about the job. This is very important sheet that

represents the movement of the component through out the process.

TABLE 3: PROCESS SHEET LAYOUT:

Company

Name

Process sheet Sheet no:

Customer Date:

Part drawing number: Material specification:

Part description code: Raw material size:

Qty: OC no: Drawing SN/no:

Operation no Process details/ Drawings Machine Tools and gauges

Process

prepared by:

Process

approved by:

Co-ordinate

by:

Process sheet prepared by:

This process sheet describes the types of operation that has to be done and the machine,

tool combination along with the process detail drawings.

TABLE 4: OPERATION DRAWING SHEET:

Company Name OPERATION DRAWING

OC NO: PART NO: REFERENCE DRAWING NO:

MACHINE: SECTION: DATE: QTY:

DRAWING-------------------------

DRAWN NO: CHECKED BY:

These types of records are always supplied along with the work pieces. This gives the

benefits of easy understanding of the work to be done on the job in a machine. After all

these bio data ready for each work the processing of the job begins. The following table

arranged explains the different operations conducted on which type of machines and

components along with the machining parameters. For easy understanding the tables are

classified according to the type of parts processed and operations.

TABLE 5: PROCESS OPERATION DETAILS

Part

name

Machine

used

Oper:

done

Speed

[rpm]

Feed

[mm/rev]

D.O.C Tool

used

Time

Taken

Height

adjuster

NH-32 Rough

turning

260 0.1 0.2 Carbide

tip

3Hr/com

CNC-

turn

Finishing 800 0.025 0.8 Carbide

tip

3Hr/com

CNC-

milling

Finishing 1200 0.03 0.5 Spotting

Drilling

Reaming

2Hr/com

Locating

ring

NH-32 Rough

turning

260 0.1 0.2 Carbide

tip

2Hr/com

CNC-

turning

Finishing 800 0.025 0.8 Carbide

tip

2Hr/com

CNC-

milling

Finishing 1200 0.03 0.5 Spotting

Drilling

Reaming

2Hr/com

Top plate CNC-

mill

Finishing 1200 0.03 0.5 spotting

Reaming

Flat drill

Cot-bore

2Hr/com

CNC-

turn

Finishing 800 0.025 0.8 Boring

1/2Hr

Part name Machin

used

Oper:

done

Speed

[rpm]

Feed

[mm/rev]

D.O.C Tool

used

Time

taken

Bottom

insert

NH-32 Rough

turning

260 0.1 0.2 Carbide

tip

2Hr/com

CNC-

turning

Finishing

Grooving

Step cut

800 0.025 0.8 Carbide

tip

3Hr/com

CNC-

milling

Slotting

Profile

4000 0.02 0.5 Ball nose 18Hr/co

Core

/cavity

CNC-

Milling

Surfacing

Profile

Drilling

In 3 stage

Rough-

cut

Semi-

finish

finish

3000

3500

4000

0.04

0.034

0.025

0.1

0.1

0.1

16 dia

8 dia

6 dia

drill bits

24Hr/co

Bench

works

Hand

work

deburring ---- ---- ---- Deburr

tool

1 to 2Hr

per

required

com

Assembly Hand

tooling

Polishing

Buffing

Pressure

test

Leak test

grinding

---- ---- ---- Air gun

Emery

paper

Air/water

Pr.

Supply

6Hr/com

CHAPTER 2:0

ANALYSIS OF MANUFACTURING PROCESS

2.0 DESIGN ANALYSIS

CORE/CAVITY----fig no:4 LOCATING RING----fig no: 5

HEIGHT ADJUSTER----fig no: 6 TOP PLATE----fig no: 7

BOTTOM INSERT----fog no:8 GRINDING ALLOWENCES----fig no:9

These design features is the communication language between the designer and the

operator. The requirements of the product will be specified in the design drawing and the

features are explained as shown in the above figures. These features will denote the

specific type of operation, the accuracy limits and the surface finish needed to be

achieved.

2.1. TIME STUDY

Fig no: 15

MACHINING TIME

30%

24%3%6%

11%

9%

9%8%

CORE/CAVITY

BOTTOM INSERT

TOP PLATE

LOCATING PIN

HEIGHTADJUSTERBENCH WORKS

ASSEMBLY

INSPECTION

Fig no: 16

MACHINE USAGE

65%13%

10%3% 9%CNC MILL

CNC TURN

NH32

BENCH WORKS

ASSEMBLY

The following table explains the actual time taken for completion of the job and the

calculated estimated time for each job. The calculation includes machining time with

percentage addition of extra time, which is:

Tool setting time

Job setting time

Programming time

Etc.

TABLE 6: MACHINING TIME

name M/c

type

Operation

done

Calculated/estimated

M/c time

Actual time

taken

No. of setting

Height

adjuster

NH-32 Rough

turn

2.24hr + 0.4hr

setting

3.34hr 2

CNC-T Step turn

Face turn

Taper turn

Threading

Radius

turn

0.58hr + 0.25hr

programming

1.15hr 2

CNC-M Drill

Tapping

3.22 hr + 0.5 hr

setting

4.12hr 2

RDU NH-32 Rough

turn

ID/OD

1.33hr + 0.3hr

setting

1.73hr 2

CNC-T Face turn

bore

ID/OD

0.73hr + 0.25hr

programming

1.15hr 2

CNC-

M

Profile

Drill

0.85hr + 0.5hr

setting

1.43hr 2

Top ring CNC-

M

Profile

Drill

Counter

bore

1.25hr + 0.5 hr

programming & tool

change & setting

1.88hr 1

CNC-T ID/OD

turn

0.22hr + 0.16hr

programming

0.45hr 1

FOND NH-32 Rough 0.41hr + 0.15hr 0.66hr 2

turn setting

CNC-T OD turn

Facing

0.26hr + 0.2 hr

setting

0.55hr 2

CNC-

M

Profile

Drill

Tapping

engraving

14.22hr + 0.5hr

setting

7.4hr RC

/9.53hr

finishing

=16.93hr

2

BODY CNC-

M

Profile

Drill

Reaming

[roughing]

[semi-

finish]

[finish]

18.56hr + 0.5 setting 19.98hr 1

Assembly Table

work

Hand

instrum

ents

Polishing

Buffing

Pressure/

Leak test

Manual

6hr 7.5hr

[including

surface

grinding]

----

Bench

work

deburri

ng

Hand

tools

Manual

6hr total to all the

parts

---- ----

Inspectio

n hours

Gauges

CMM

Manual 5hr total to all parts ---- ----

Total

hours

--- --- 64.65hr 77.87hr

The table above shows the time taken for the completion of all the components required

for the Blow mould. The variation in the estimation time and the actual time exists due to

the excess setting time taken for job and tool, part programs editing, ideal time of

machines for time breaks & stage or quality inspections. These reasons are unavoidable.

CHAPTER 3.0

IMPROVEMENT CASE STUDIES

“COST REDUCTION USING CONDITION MONITORING OF TOOLS”

In-process tool condition monitoring was first introduced in the early 1980s and is

gaining acceptance as a necessary component of modern machining equipment by many

manufacturers. Tool condition monitors provide rapid detection of tool and process

failures such as collisions, tool breakage and tool wear. By detecting failures as they

occur, manufacturers are able to improve the quality of their products up to 60% while

realizing valuable savings.

Tool monitoring enables greater automation and faster, more aggressive machining. Tool

monitoring is so great that every manufacturer fit each machine in the plant with the latest

tool monitoring technology. Whether or not one can benefit from tool monitoring depends

on the particular manufacturing process. This article will discuss how to calculate the

potential benefits of tool monitoring and describe the type of manufacturers who can

benefit from this technology.

Detecting collisions immediately can prevent serious damage to the work piece, tool and

machine. Broken tools, if not detected, can lead to collisions. Tool monitoring can detect

broken tools immediately and minimize damage. Tool inserts are often replaced at fixed

intervals. Since normal insert life varies from 10 % to 80 50 %, fixed intervals must

usually be set at the low end of the tool life curve.

With this policy, inserts are often replaced well before they are 100 % worn. Detecting

wear with tool monitoring allows tools to be replaced only when they are worn to a

desired level, decreasing the cost of tools and the downtime associated with frequent tool

changes. Depending on the application, tool monitoring may provide savings in

* Tool cost

* Tool holder and fixture cost

* Scrap and rework

* Direct labour

* Machine downtime

* Productivity

In some cases, potential benefits may be measured not only in terms of direct savings, but

also in terms of the advanced machining technology that can be safely and effectively

employed when combined with tool monitoring as in the following example.

EXAMPLE: HIGH VOLUME AUTOMATION USING TOOL MONITORING

SYSTEM

A volume producer of cast iron parts doubled productivity through the use of sialon

ceramic inserts that allowed for a 200 % increase in feed rate. While ceramic inserts can

cut at very high speeds, they are more brittle than carbide inserts. Tool monitoring

ensures the safe use of higher speed machines and more brittle tool materials by reducing

the risk of damage to machine and parts from tool breakage and other tool or process

failures. Table 1 shows the performance improvements made with the addition of a

Montronix TS20OW tool monitoring system. Running eight-hour shifts, 750 shifts per

year, this manufacturer was able to produce 126,000 additional parts per year. In addition

to productivity improvements, direct cost savings were achieved with tool monitoring by

increasing tool usage, reducing tool holder damage and reducing machine downtime. For

example, prior to tool monitoring, the manufacturer-replaced tool inserts every 25 parts.

With tool monitoring, the average parts per insert were increased to 37, reducing the cost

of inserts and the downtime to change the tools. Tool monitoring allows high volume

manufacturers to achieve more aggressive machining rates while protecting the higher

cost machines used to achieve higher levels of automation. While tool monitoring always

provides benefits and insights into the machining process, some manufacturers may not

see sufficient benefits to economically justify tool monitoring for their operation. Tool

monitoring is often not suitable for manufacturers who meet most or all of the following

criteria:

1. Small lot sizes

2. Low-cost machines

3. Low-cost parts

4. Continuously supervised

5. Non-aggressive conditions

A job shop manually producing small lots of non-critical aluminum parts, for example,

probably could not cost justify tool monitoring.

TABLE 7: COMPARISON BETWEEN TOOLS AFTER MONITORING

Parameter

Speed

Feedrate

Material removal rate

Insert

Cycle

Time

Pieces per hour

Before tool monitoring

300m/min

0,5mm/rev

375cm3/min

Carbide

102sec

24

After tool

monitoring

900m/min

0,8mm/rev

1,800cm3/min

Sialon Ceramic

45sec

45

CHAPTER 4.0

LITERATURE SURVEY

“MIRROR FINISH BLOW MOLD TOOLING”

Patented in N.A., Germany and Japan

Mirror Finish Blow Molded Products are now possible using our Super Porous Nickel

Tooling. Super Porous Nickel should not be confused with our Porous Nickel Tooling.

The difference between the two is the initial 0.2~0.5 mm layer of nickel and straight bore

micro pores that are found on Super Porous Nickel. It is this initial layer that allows the

tooling surface to be polished to a mirror finish without increasing the micro pore

diameter.

Fig no: 17

A SUPER POROUS NICKEL SHELL IS CAPABLE OF:

1. Withstanding up to 2000Kg/c‡u

2. Polishing and etching is possible with this type of tooling.

3. Micro pores sizes can be made from 30µ200µ According to customer request.

MANUFACTURING A SUPER POROUS NICKEL BLOW MOLULD:

1. Manufacture a model.

2. Take a silicone relief of the model

3. Form an epoxy model (mandrel) from the silicone mold, this becomes the plating

mandrel.

4. Place the plating mandrel into the plating tank. After applying a layer of

approximately 0.2~0.5mm of nickel, the mandrel is removed from the tank.

5. Using a YAG laser, micro pores are drilled into the nickel shell. These Micro pores

vary in size anywhere from 30~150µ.

6. The nickel shell is then placed into a porous nickel plating tank and 3~5mm of nickel is

applied. The unique quality of the porous nickel bath prevents plugging of the micro

pores, and therefore leaving the straight bore micro pore. It is this straight bore design

that allows the surface of the nickel shell to be polished to a mirror finish. A straight bore

micro pore also provides increased strength to the nickel shell.

7. The plating mandrel is then removed from the nickel shell.

8. In order to provide sufficient strength to the nickel shell, a special back plate is

manufactured. The back plate serves four purposes:

1) Provides physical support for the shell

2) Allows entrapped gases to vent out from the tool

3) Provides a momentary thermal insulation barrier

CHAPTER 5.0

RESULTS & DISCUSSIONS

The precision engineering can be achiever using CNC-machines but cost will be high.

The market value should always be specified before under taking the job. The

competition for low cost high quality products can be achieved using some of the

following methods:

The machine change over can be done for maximum rough work and to maintain

the precision the CNC-machines can act as precision marking machine. Example

for set of 12 holes has to be done the CNC- machines can drill the central drill and

mark the set of position on PCD and the conventional machine can take over the

rest. This type of work can also be done on the profile work where the required

amount of rough work can be done on conventional milling. This type of machine

change over can result in 25% reduction in the cost of production.

The discontinuity of work during the breaks can be avoided which gives more

machine time, that is during the breaks and lunch hours the shifting of workers

can give more machining hours.

The ratio of actual machining time and the estimated time are greatly affected by

quality inspections therefore suitable gauges can be implemented next to the

machine and the operator himself be trained for quality inspection this gives more

knowledge to the operator about what he is doing and the inspection time gap can

be reduces. By this the stage inspections can also be reduces.

Implementation of special machines like electro chemical machines. Latest

versions of existing machines and constant up gradation of the software’s give

more knowledge and better results in quality production.

“Top Ten Tips for Tooling Productivity”

Ten general tips for tooling productivity. Some of these may be old hat, but one or two

may give a new insight that might lead to improved metalworking productivity where you

work.” Top Ten" tips are as follows:

1. Focus on minimizing the overall machining cost of the part, not just tooling cost.

Tooling represents only about 3 percent of total part cost, much less than machine

time or machine labor. Follow the real money. Focus on the 97 percent all about time

and not about tooling price tags.

2. When engineering a new process or troubleshooting an existing one target four main

areas and set clear and measurable goals for each. Those areas are cycle time, tool

life, part quality and surface finish. Rank these by priority. Also, share your goals

and priorities with your vendors so they can give you better answers sooner.

3. Understand the forces involved in cutting metal and use these forces to your

advantage. Cut in a direction that improves the rigidity of the setup. Consider

reducing the depth of cut to convert radial forces into axial forces. Then increase the

feed rate to take advantage of the higher axial rigidity.

4. Take advantage of tool geometry to improve throughput. For example, on lead-

angle cutters, increase the feed rate to achieve the maximum recommended chip

thickness.

5. When troubleshooting, determine whether you have a process problem or a tooling

problem. Don't be too quick to blame the tool. Instead, use the mode of tool failure as

a clue to the root problem. A chipped edge could indicate use of the wrong carbide

grade or excess "play" in the machine or fixture, which would wreck any tool. Look at

machine rigidity, feed, and speed, depth of cut, presentation angle, chip clearance and

coolant. If the problem lies with the tooling, changing the tool will fix it. If the

problem lies with the process, it probably won't matter what tool you use.

6. Question the process. Sometimes the right answer is an unconventional approach.

On larger holes in one-off or short-run work, milling a hole from solid with helical

milling often makes more sense than drilling it, because large-diameter drills are more

expensive and less versatile. Another example of an unusual approach that may be

worthwhile is plunge milling, which removes material four times faster than slab

milling on average.

7. Understand heat: Metal cutting will always generate heat, not all of it from friction.

When machining steel in particular, you want just enough heat to soften the work

piece material and form good chips. Avoid heat levels that can trigger hardening

reactions in the material, overheat the tool or de-carbonize (crater) the insert.

8. Match tool geometry to the material being cut. Especially in job shops handling a

variety of work piece materials, beware of "general purpose" tooling. Take the time to

change tools when you change materials. You'll get more throughputs and make more

money. Again, the price tag on the tooling is the least important part of the process-

economics equation.

9. Plan the cutter path to maximize rigidity and take advantage of higher feed rates.

10. Train the engineers. Companies who send the engineers and programmers to training

centers see a return on their investment each time. And that return comes fast, usually

within weeks of employees completing their class. Another reason to train to is to

keep up with what's new in tooling.

These ten tips are must to be noted in every industrial production. These tips may look

old lines but they are applicable in modern machining system also.

REFERENCE

1. Philippe Poizat, "Predictive Maintenance: Defect factor: A tool to Monitor Rolling Element

Bearings", Industrial products and news reporter, Vol. 9, April – June 1996, pp. 29 – 32.

2. Chen M. F. and Natsuake .M., "Preventive Monitoring System for Main Spindle of Machine

Tool", Journal of vibration, acoustics, stress and reliability in design, Vol. 106, July 1989, pp. 179

– 186.

3. Mathew J., Alfredson R. J., "The Condition Monitoring of Rolling Element Bearings using

Vibration Analysis", Journal of vibration, acoustics, stress and reliability in design, Vol. 106, July

1984, pp. 447 – 453.

4. Prashad .H, Malay Ghosh., "Diagnostic Monitoring of Rolling Element Bearings by High

Frequency resonance Technique”, ASME Transactions, Vol 28, April 1996, pp.439-448.

LIST OF TABLES

TABLE NO: DESCRIPTION PAGE NO:

Table 1 work order instructions

Table 2 job card format

Table 3 process sheet layout

Table 4 operational drawing sheet

Table 5 machining time

Table 6 comparison between tools after monitoring

LIST OF FIGURES

FIGURE NO: DESCRIPTIONS PAGE NO:

Fig no 1 blow mould process

Fig no 2 mould core and cavity

Fig no 3 assembly of blow mould

Fig no 4 core and cavity

Fig no 5 locating plate

Fig no 6 height adjuster

Fig no 7 top plate

Fig no 8 bottom insert

Fig no 9 grinding allowance

Fig no 10 fixture for core/cavity in milling m/c

Fig no 11 fixture for height adjuster in milling m/c

Fig no 12 fixture for height adjuster in milling m/c

Fig no 13 fixture for fond in milling m/c

Fig no 14 fixture for locating plate in milling

Fig no 15 machining time–graph

Fig no 16 machine usage

Fig no 17 super porous nickel