ACKNOWLEDGEMENT

Here we take this opportunity to express our sincere thanks to those who have helped us to complete this project successfully. At first we like to express our gratitude to Mr. S.K.Sharma, H.O.D. of Design Department, for his kind encouragement, guidance, and support in completion of this project. It is our delight to express our sincere thanks to Mr. Jasram Yadav and Mr. M.S. Rana who were our project in charge for their good co-ordination and encouragement. We also express our sincere thanks to all the staff of our institute and our fellow trainee who have helped us in all stages of our project. Thanking You Yours truly Rohit Mittal

CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND TECHNOLOGY

(Ministry Of Chemical & Fertilizers, Govt. of India)

Prepared by: ROHIT MITTAL PD-PMD (2004-2005) CENTRE LUKNOW

CONTENTS

INTRODUCTION TO THE PROJECT INTRODUCTION TO MOULD INTRODUCTION TO PLASTIC MATERIAL SELECTION OF MOULD MATERIAL MODELLING & ASSEMBLY BY USING PRO-E MOULD DESIGN THEORY PROCESSING TECHNIQUES CONCLUSION BIBLIOGRAPHY

INTRODUCTION
TO

THE

PROJECT

INTRODUCTION TO THE PROJECT

This project introduced about Complete Manufacturing & Assembly of Automatic Injection Mould for Knob Gauge using Pro-E. Knob Gauge is used in Automobile Companies for measuring the level of oil in engine for four stroke bikes.

INTRODUCTION TO THE COMPONENT

The first responsibility of mould designer is to check over the product design very thoroughly and produce, when necessary, a compromise design that will be moldable by the production methods and equipment available. Some important point to be consider during designing the component, such as This component is used in Automobile companies. This component is used for measuring and checks the oil level. Component requires radius and threads. It requires good compression strength.

INTRODUCTION TO THE MOULD

A mould is tool intended to fabricate plastic components is of several types with different shapes and sizes. In general a mould consists of Core which forms the internal shape of the component and a Cavity which gives the internal shape for the component. Mould can be differentiated on basis of the molding techniques as well as their manufacturing on the basis of manufacturing method it can be 1. Two plate mould. 2. Three plate mould. On the basis of molding techniques:

Injection mould Compression mould Blow mould Transfer mould

INTRODUCTION
TO

THE

PLASTIC MATERIAL

INTRODUCTION TO THE PLASTIC MATERIAL

Plastic need no introduction in today world in every walk of life its indispensability, is felt by each and everyone.
[

For common understanding scientists have defined plastics as high molecular weight material formed by linked up of small building blocks called monomers and hence called Polymers.
[

For better understanding of the properties of plastics, it is essential to classify them plastics that can be repeatedly molded or shaped by the application of heating and cooling cycle under pressure are termed as Thermoplastics. Those plastics which once shaped by the application of heat and pressure and do not have the versatility of repeat process ability are termed as Thermo sets. Based on physical properties difference these plastics may be classified into

Commodity plastics Engineering plastics Specialty plastics.

PLASTIC MATERIAL SELECTION FOR MAKING KNOB GAUGE NYLON

Nylons are a group of thermoplastic polymers containing amide groups in the main chain. Nylons are manufacture other by polymerizing di-amines and di-carboxylic acids or polymerizing amino carboxylic acids. Nylon-66 is manufactured by polymerizing hexamethylene di-amine with adipic acid and Nylon-6 is manufacture by ring opening polymerization caprolactam. Nylon is used for making knob gauge because it have tensile strengths (up to 8000 to 11,000 psi in some grades), modulus (in flexure: 210,000 to 500,000 psi). Nylon resists polar solvents, including aromatic hydrocarbons, esters, essential oils. high high nonand

TABLE OF NYLON PROPERTIES WITH VALUE S.NO. 01 02 03 04 05 06 07 08 09 PROPERTIES SPECIFIC GRAVITY TENSILE STREGTH, MPa ELONGATION AT BREAK, % HARDNESS DEFLECTION TEMPERATION UNDER LOAD (1.82 MPa), *C WATER ABSORPTION, 24hr., % MELTING POINT *C GLASS TRANSITION TEMP. *C MOULD SHRINKAGE, % VALUES 1.14 90 20 M90 104 2.8 255 60 1.0-2.5

SELECTION
OF

MATERIAL
FOR

MOULD

MOULD MATERIAL AND ITS SELECTION

It is well known that without proper mould material proper tooling cannot be achieved. A wide range of mould material are used for fabrication of moulds for plastics which includes Mild steel, Alloy steel, Carbon steel, Case hardened steel etc. Essential requirements of steel for moulds: 1. Excellent machinability. 2. Excellent heat-treat ability. 3. Good polish ability. 4. Good compressive strength. 5. High wear resistance. 6. Sufficient corrosion resistance.

Product Designer - Surface finish - Photo etching - Tolerances - Production quantity

Mould Designer - Economy - Standard sizes - Shares others STEEL REQUIREMENT

Mould Maker - Free from defects - Easy to machine and polish Compressivestrength - Stable in heat treatment - Suitable for EDM/ etching

Molder - Wear resistance -

FIGURE SHOWS: - Mould material selection is important for

every one mainly for Product designer, Mould Designer, Mould Maker, Molder.

The material selected for mould base in EN2A which is also called as mild steel because of its easy machinability and comparatively economical then other grade of steel.

LIST OF MOULD PARTS AND CORRESPONDING STEELS TO BE USED

S.NO. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

MOULD PARTS Back plate (fixed half) Cavity plate Core plate Core backing plate Riser block or packing blocks Ejector carrier plate or ejector retainer Ejector back plate Back plate (moving half) Core Locating ring Sprue bush Guide pillar Guide bush Ejector pin Push back pin Ejector stop pads Stripper plate (if required)

MATERIAL Mild steel Tool steel Tool steel Mild steel Mild steel Mild steel Mild steel Mild steel Tool steel Mild steel Mild steel Cast hard & Grd steel Cast hard & Grd steel Carbon steel Carbon steel Carbon steel Mild steel

PRODUCT DESIGN

One of the earliest steps in product design is to establish the configuration of the parts that will form the basis on which strength calculation are made and a suitable material selected for requirements.
[

During the sketching and drawing of shape and cross section, there are certain design teachers with plastics material that has to be dept in mind in order to avoid degradation of data properties. Such teachers may be called as property detractors. UNIFORM WALL THICKNESS

Under favorable conditions, the design of wall thickness normally depends upon the selection of the material. The determination of wall thickness should be the result of an analysis of the following requirements: Requirements of Use 1. 2. 3. 4. 5. Structure Weight Strength Insulation Dimensional stability

Manufacturing Requirements

1. Molding (a) Flow (b) Setting (c) Ejection 2. Assembly (a) Strength (b) Precision Plastic parts should be designed with the minimum wall thickness that will provide the specific structural requirement. This thickness results in an economy of material and high production levels due to the rapid transfer of heat from the molten polymer to the cooler mold surfaces.

(a)

(b)

(a) Shows un-uniformity in the design. (b) Shows uniformity in the design. Suggested wall thickness for NYLON Thermoplastic materials Nylon Minimum Inches 0.015 Average Inches 0.062 Maximum Inches 0.125

SHARP OUTSIDE CORNERS

Sharp corners are required at the parting lines, but are usually undesirable at all other points. All outside corners should be radioed as much as possible to help material flow, reduce mould cost, and avoid the sharp molded corners that chip and break easily during finishing operations. A radius of 0.125 in. (3mm) to a 0.50 in. (12.7 mm.) wall is ideal. (a) (b)

(a) Shows sharp corner in the design. (b) Shows some radius in the design.

DRAFT Draft is produced for the removal of parts from the mould. It is possible, when absolutely necessary, to produce some surfaces without draft. In most jobs, however, failure to provide adequate draft will be the source of many difficult molding problems. A minimum of * taper per side is generally satisfactory although 1* per side is most desirable for production jobs.

FILLETS

Radii or fillets must be used in all inside corners to assist material flow and strengthen the part, as fractures start easily from sharp corners. DESIGN OF SECTION Section may define as protruding steels as the part that assist in the assembling of the plastic part with another piece. MOULD DESIGN

In practice, a mould drawing normally comprises three views thats: 2) A plan view of the moving half. 3) A plan view of the fixed half. 4) A side sectional view of both halves.

MODELLING, MANUFACTURING
(CORE & CAVITY) AND

ASSEMBLY
USING

PRO-ENGINEER

INTRODUCTION OF PRO-E
Pro/Engineer uses parametric design principles for solid modeling. Pro-Engineer provides mechanical engineers with

approach to mechanical design automation based on solid modeling technology and the following features. 3-D MODELLING The essential difference between Pro-E and traditional CAD systems are that models created in Pro-E exit as three-dimensional solids. Other 3-D Modelers represent only the surface boundaries of the model. Pro E models the complete solid. This not only facilities the creation of realistic geometry, but allows for accurate model calculations, such as those for mass properties. PARAMETRIC DESIGN PRO E is parametric i.e. it is driven by parameters or variable dimensions. Modifying dimensions can easily change geometry. Features are interrelated. Modifications of a single feature propagate changes in other features a well, thus preserving design intent. A relationship known as a parent/child relationship, is developed between features when one feature references another.

FEATURE-BASED MODELING PRO E is feature based. Geometry is composed of a series of easy to understand features. A feature is the smallest building block

in a part model. Pro E allows building a model incrementally, adding individual features one at a time. This means, as you construct your model feature you choose your building blocks as well as the order you create them in, thus capturing your design intent. Design intent is the motive, the all-driving force, behind every feature creation. Simple feature make your individual parts as well as the overall model flexible and reliable. ASSOCIATIVITY PRO E is a fully- associative system. This means that a change in the design model anytime in the development process is propagated throughout the design, automatically updating all engineering deliverables, including assemblies, drawings, and manufacturing data. Associatively makes concurrent engineering possible by encouraging change, without penalty, at any point in the development cycle.

PLANNING YOU DESIGN

You can immediately begin designing models in Pro-E, and with product deadlines, it is tempting to jump- in and start creating models. However, to build value in your designs, you need to create products that can keep up with the constant design changes driven

by market demands. You need to build flexibility in your designs. Flexibility is the key to a friendly robust product design while maintaining design intent, and you can accomplish it through planning. To plan your design, you need to have a basic understanding of your model from a broad perspective. In other words, understand the overall function, form, and fit of the product. This understanding includes the following points:

Overall size Basic model characteristics The way in which the model can be assembled Approximate amount of components the assembly would contain The way in which the model can be manufactured

THE MODELING PROCESS

The following graphic illustrates the modeling process and the role design intent plays:

Feature- Based Modeling Model solid parts by combining Intuitive engineering features.

Build parts by combining Features relative to each Other and in a logical order Pattern feature within a part. Capturing Design Intent Incorporate engineering know -ledge into the solid model using implied and pattern.

Drawing Analysis

Create new parts Based on assembly Dimensions and Clearances.

Machining Assembly parts relative to Each other and in a logical order- pattern parts within an assembly; create family tables of related assemblies. Application

Creating Assemblies Combine part into assemblies

Parametric Modeling Process

PRO / MOULD DESIGN

What you can do with PRO/ MOULD DESIGN?

Pro/ Mould design is an optional module for Pro/ Engineer that provides the tools to simulate the mold design process within Pro/ Engineer. This module lets you create, modify, and analyze the

mold components and assemblies and quickly update them to the changes in the design model.

Design Part Creation and Modification Create models in Pro/Engineer including features requiring Pro/SURFACE Import and repair geometry if necessary

The import functionality can be used with the following: Data Doctor Option and Interface for Pro/Engineer Analyze it a design part is moldable, using Draft Check and Thickness Check capabilities. Automatically create parting lines and detect undercuts using Silhouette Curve functionality Fix problem areas by creating draft, rounds, and other features as needed.

Cavity Creation Assemble and orient design model dynamically while checking draft and projected area Apply a shrinkage that corresponds t design part material, geometry, and molding conditions. Automatically create the work piece stock from which sore, cavity, and inserts will be split.

 Create parting geometry, including sliders, inserts, automatic parting lines, and automatic parting surfaces. Automatically split the work piece to create cores, cavity, and inserts as solid models. For casting, create and assembles and cores.

Mold Layout Creation Create top-level mold assembly. Placement and patterning of mold cavities, allow multicavity molding. Online selection and automatic assembly of standard mold bases. Modification of mold base plates to allow for assembly of mold cavity. Online selection and automatic assembly of ejector pins and other mold catalog items. Automated creation of runners. Automated creation of waterlines, including 3-D waterline interference checks. Define and simulate mold opening and check for interference between mold components.

Drawing Creation Create complete production drawings, including dimensions, tolerances, and automatic bill of materials (BOMs) with or without balloon notes. Use of drawing templates.

TO PERFORM A TYPICAL PRO/ MOULD DESIGN SESSION

The Pro/MOULD DESIGN process may consist of the following steps:

 Create a mold model. Assemble or create reference models and work pieces. Perform a draft check on the reference model to determine if it has sufficient draft to be ejected from the mold cleanly. Define additional draft features in the design model or reference model as required. Create shrinkage for your mold model. You can create isotropic scale shrinkage or shrink coefficients for some or all dimensions. You can apply shrinkage by dimension to your design model to leave the design model unchanged for use in other applications. Define volumes or parting surfaces to split the work piece into separate components. Extract mold volumes to produce mold components. Once extracted, the mold components are fully functional Pro/ENGINEER parts, which you can bring up in part mode, use in drawings, machine with Pro/NC, and so on. Add gates, runners, and waterlines as mold features. They will be considered when creating the molded part, as well as for interference checking during the mold opening process.

Fill the mold cavity to create the molding. The system creates the molding automatically by determining the volume remaining in the work piece after subtracting the extracts. Define steps for mold opening. Check interference with static parts for each step. Modify mold components if necessary. Perform mold-filling check using Plastic Adviser.

 Estimate the preliminary size of the mold and select an appropriate mold base. Assemble mold base components, if desire. The mold base components are in the mold base parts (for example, top clamping plate, support plate, ejectors, and so on). The system displays them along with the mold model, and they are useful for visualizing the process of mold opening. With the optional module Pro/LIBRARY and the optional MOLD BASE library, you can view and assemble many standard mold fixtures. Complete the detailed design, which includes laying out the ejection system, waterlines, and drawing. Bring the mold components into Pro/NC for machining. During the molding process, changes to the design model may occur. When these changes are made to the design model, they will propagate throughout all aspects or the design to engineering drawings, finite element models, and molding information. Because the mold design engineering references the parametric design model directly, changes are reflected throughout all the intermediate process steps and captured in the molding model.

CONCLUSION
This project report of injection mould for Knob Gauge carried out to give clear picture of mould manufacturing process involved core cavity generation of an injection mould using PROENGINEER.

This report tells us the importance of CAD/CAM application in mould making technology. This report is an ideal reference and refresher manual for normal procedure involved in mould making using PROENGINEER.

BIBILIOGRAPHY
BOOK 1. Plastic Material 2. Injection mould design AUTHOR J.A. Brydson R. G. W. Pye

3. Work Shop Technology 4. Application of Plastic 5. Costing and Estimation

Hajraj Chaudary Dr. J. S. Anand S.C. Banga Sharma

INTRODUCTION TO INJECTION MOLDING AND PROPLASTIC ADVISOR

Injection molding is a process that has been used in a wide variety of industries for many years. This process uses amorphous and crystalline thermoplastic resins that are heated to a stable temperature and compressed into a mould.

One of the main problems with injection molding is the set up cost; this includes the mould design, tooling required and the polymer used. This makes it suitable for high volume production where the cost of moulds can be amortized over a large number of products. To help to reduce the cost of setting up this process ProEngineer has designed a package called Pro Plastic Advisor. This is an optional package - there is no guarantee any system will include the software. This package can be used to analysis the molding process and increase confidence in the design before significant costs are incurred in mould manufacture.