Sree Siddaganga Education Society (R)

SIDDAGANGA INSTITUTE TECHNOLOGY

(An Autonomous institution Affiliated to Visvesvaraya Technological University-Belagavi, Approved by
AICTE, Programmes Accredited by NBA, New Delhi & ISO 9001:2008 Certified)
Tumakuru-572103, Karnataka India

TECHNICAL SEMINAR REPORT ON

“INJECTION MOULDING”

In partial fulfillment of the requirements for the VIII Semester of Bachelor of

Engineering
In Mechanical Engineering

Submitted By
“PUNITH G S [1SI15ME124]”

Under the Guidance Of

“Mr. EKANTAPPA J, M .Tech, Assistant professor”

DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC YEAR 2018-19
Sree Siddaganga Education Society (R)
 SIDDAGANGA INSTITUTE OF
TECHNOLOGY
(An Autonomous institution Affiliated to Visvesvaraya Technological University-Belagavi, Approved by
AICTE, Programmes Accredited by NBA, New Delhi & ISO 9001:2008 Certified)
Tumakuru-572103, Karnataka India
Department of Mechanical Engineering

CERTIFICATE
This is to certify that the Technical Seminar report entitled “INJECTION
MOULDING” is prepared and presented by PUNITH G S (1SI15ME124) in partial
fulfillment of the requirements for the Final year of Bachelor of Engineering in
Mechanical Engineering at Siddaganga Institute of Technology-Tumakuru, during the
academic year 2018-19. The report has been approved as it satisfies the academic
requirements for the Bachelor of Engineering Degree.

Signature of the Guide Signature of the HOD

Ekanthappa.J Dr.K.S.Shashishekar

M.Tech, Assistant Professor M.Tech.,Ph.D

Department of Mechanical Engineering Department of Mechanical Engineering

Name and signature of the Examiners

1. 2.
 CONTENTS
Chapter 1 : Introduction
Chapter 2 : Injection moulding Process
Chapter 3 : Injection moulding

Chapter 4 : Applications

Chapter 5 : Advantages and Disadvantages of injection moulding

Chapter 6 : Key supplier of raw materials
Chapter 7 :Conlusion
Chapter 8 :Reference
Chapter-1

INTRODUCTION
Injection molding is a manufacturing technique for making part from plastic
material. Molten plastic is injected at higher pressure into a mould which is inverse of the
desired shape. The mould is made by mould maker from metal, usually either steel or
aluminum, and precision machined to from the features of the desired part. Injection
molding is very widely used for manufacturing a variety of parts, like cosmetic,food &
medicine packaging etc.

Considerable thought is put into the design of molded parts & there moulds , the
ensure that the parts will not be trapped in the mould , that the moulds can be completely
filled before the molten resin solidities , & to minimize imperfection in the parts which
can occur due to peculiarities of the process.

Moulds separate in to at least two halves called the core & the cavity to permit the
part to be extracted ; in general the shape of a part to be extracted; in general the shape of
a part must be such that is will not be locked in to the mould . For example, sides of
objects typically can not be parallel with the direction of draw the direction in which the
core & cavity separate from each other. They are angled slightly; examination of must
house hold objects made from plastic will show this accept of design, known as draft.
Parts that are ˝ bucket – like ˝ tend to shrink on to the core while cooling & after the
cavity is pulled away are typically ejected using pins. More complex parts are formed
using more complex moulds , which may require moveable sections which are inserted in
to the mould to form particular features that can not be formed using only a core & a
cavity , but are than with drawn to allow the part to be released.

The resin, or raw material for injection molding, is usually in pellet from, and is
electrically melted shortly before being injected in to the mould . The channels through
which the plastic flow towards the chamber will also solidify, forming & attached frame.
This frame is composed of the sprue , which is the main channel from the reservoir of
molten resin, parallel with the direction of draw , & runners , which are perpendicular to
the direction of drawn , & the used to convey molten resin to the gates, or points of
injection. The sprue & runner system can be cut off & recycled . Some moulds are design
such that it is automatically stripped from the part through action of the mould .
The quality of the moulded part depend on the quality of mould , the care taken during the
moulding process, and upon details of the design of the parts it self . It is essential that the
molten resin be at just the right pressure and temp. , so that it flow easily to all part of the
mould . The part of the mould must also come together extremely precisely , otherwise
small leakages of molten plastic can from a phenomenon known as flash . When filling a
new or unfamiliar mould for the first time , where shot size for that particular mould is
unknown , a technician should reduce the nozzle pressure so that the mould fills , but dose
not flash . Then , using that now - known shot volume pressure can be raised with out fear
of damaging the mould .
Chapter-2

INJECTION MOLDING PROCESS

Injection moulding is the process of forcing melted plastic in to a mould cavity.
One injection moulding often used in mass production & prototyping injection mould.
The first injection moulding m/cs were built in the 1930 s.

There are six major steps in the injection moulding process:

1. Clamping: - In an injection moulding machine clamping is the important part.

Its main function to closing the mould adds the time of the injection.
2. Injection :- During the injection phase , plastic material , usually in the from of
pallets , are low pallets feed in to the cylinder where they are heated until they
reach molten form the heating cylinder there is a motorized screw that mixes the
molten pallets and material has accumulated in front of the screw , the injection
process being . The sprue, while the pressure and speed are controlled by the
screw.
3. Dwelling: - The dwelling phase consists of a pause in the injection process. The
molten plastic is applied to make sure all of the mould cavities are filled.
4. Cooling: - The plastic is allowed to cool to its solid form with in the mould.

5. Mould opening: - The clamping unit is opened, which separates the two halves
of the mould.
6. Ejection: - An ejecting rod and plate eject the finished piece of the mould. The
unused space future mould.
Chapter-3

INJECTION MOULDING
The process is used to produce large quantities of identical plastic items. One of
the most common types of thermoplastics used in injection moulding is polypropylene.

Injection moulding is the most important plastics manufacturing process. It

produces such small products as bottle top; sink plugs, cosmetic products,&
pharamaseutical products. It is also used to manufacturer larger items such as buckets &
milk crates. Familiar products manufactured by injection moulding include cosmatic
products ( like fair & lovely cap, gulabri container cap & base, veet spatulla,
himamiwashar cap & food packazing products like bornvita cap, horlicks cap, Jemsball
top & bottom etc.

The process can be even mould such large items as 1Kg Cap of Bouranvita &
medicines box.

Injection moulding used to be operated by people on the factory floor but these
days it is a form of highly automated from of production. The whole process is controlled
by a central processing unit.

Stage 1:-

Granulated or powdered thermoplastic is fed from a hopper in to the injection

moulding machine

Stage 2:-

The injection moulding machine consists of a hollow steel barrel, containing a

rotating screw. The screw carries the plastic along the barrel to the mould. Heaters
surround the barrel melt the plastic as it travels along the barrel.

Stage 3:-

The screw is forced back as the melted plastic collects at the end of the barrel
.once enough plastic has collected a hydraulic ram pushes the screw forward injecting the
plastic through a sprue in to a mould cavity . The mould is warmed before injecting and
the plastic is injected quickly to prevent it from hardening before the mould is full.
Stage 4:-

Pressure is maintained for a short time (dwell time) to prevent the material
creeping back during setting. This prevent shrinkage and hollows, therefore giving a
better quality product. The moulding is left to cool before removing (ejected) from the
mould. The moulding is takes on the shape of the mould cavity. The image below shows
an injection moulding machine.

A mould used for injection moulding may cost thousands of moulding can be
produced from a single mould. This results in the low cost of each moulding.

It used to be the case that when a new type of casting was needed a brand new die
heads to be made. Modern dies and moulds are made from a number of inter changeable
parts. This allows the shape of the mould to be altered.

The dies or moulds used in the process are made from ally stainless steel. These
special alloy steel moulds are made in a number of parts to allow the moldings to be
easily removed. Plastics that are used in injection moulding include low density
polyethylene (LDPE), high density polyethylene, Polypropylene (PP).
Chapter-4

APPLICATIONS
The injection molding process makes it possible to manufacture very complex plastic
parts of good quality. Examples of such parts include functional and housing parts for
automotive components, electronic and medical equipment and general consumer goods.
A general trend toward miniaturization can be recognized in connection with parts of this
type. The materials spectrum ranges from relatively hard plastics for housing parts to soft
plastics with rubber-like properties. The production areas of injection molding plants are
often highly automated and operated in four shifts. It therefore makes sense to automate
the inspection process as well by integrating robots and pallet systems in four-shift
operation in the production process.
One key aspect regarding the use of measuring machines in plastics processing is
the final inspection of products. Functional dimensions such as the distance of detents,
sealing grooves and connector latches with tolerances of only several tens of micrometers
and less are checked. Tactile measuring processes are often ruled out in such cases due to
the large dimensions of the stylus tips and the excessive probing forces involved. For this
reason, optical measurement is often the only possible way to check dimensional
accuracy. A combination of image processing and autofocus sensor technology is used
here. Problems are often caused by forms typical for plastic parts including mold release
slopes and rounded-off corners. Depending on the color involved, sufficient contrast is
sometimes difficult to achieve. An optimally flexible illuminating system is therefore a
precondition for successfully measuring such workpieces with optical sensors. Bright-
field/reflected-light illumination featuring adjustable-angle reflected light a good basis.
The Werth 3D-Patch or Foucault Laser Sensor function can also be used to ensure that
rounded corners are measured reliably. The functional dimensions are evaluated
according to ISO standards. Form and position tolerances often occur.
Housing and soft trim parts used in vehicles usually have surfaces designed
primarily along aesthetic lines. The tolerances of these relatively inexactly defined free-
form (or designer) surfaces usually lie between 50 µm and 100 µm. The measured values
are compared with the CAD data point by point. The required large number of measured
points can be acquired, for example, with laser distance sensors or 3-D sensors. If a 3-D
multisensor coordinate measuring machine is combined with a rotational axis, complex
plastic parts can be measured within a coordinate system from all sides, thus enabling
complete inspection of the workpiece.
 The second main area of application in the injection molding process is the
measurement of injection molding tools and the erosion electrodes required to
manufacture them. Due to the current trend favoring shorter product cycle times, it is
becoming increasingly important to perform these inspections before beginning
production. Once the injection molding process has been started, any subsequent
correction would take too much time. Due to shrinkage and other influences of the
injection molding process, the tool dimensions often do not agree exactly with the parts
dimensions. Moreover, a much higher accuracy is required. A part tolerance of several
tens of micrometers and a tool tolerance of several micrometers typically result in
maximum measuring uncertainty requirements as low as 1 µm and less for the coordinate
measuring machines used (according to the tolerance chain argument).
Tactile measurement is usually possible due to the stability of the metal materials
used. However, it often proves inadequate where small dimensions are involved.
Combination systems featuring touch trigger or (better yet) measuring probing systems,
fiber probes and laser sensors are therefore used. Where complex injection molding
processes are involved, it is advisable to measure production-related deviations from the
CAD model in the scanning mode. The CAD model for the tool is intentionally modified
either by the corresponding software functions or manually to compensate for process
influences. The modified CAD model can then be used either to manufacture electrodes
or to directly control the machine tools for tool correction.
In connection with the inspection of parts and the process-internal measurements
described above, a general distinction must be made between two basic methods of
workpiece alignment:
In the case of functional parts, the workpiece is often uniquely aligned with
respect to the functional surfaces. Any free-form surfaces the workpiece may have are
then checked within this coordinate system.
If any deviations are measured which are out of tolerance, it must then be
determined whether the reference surfaces are incorrect or the free-form surface itself has
a fault. The latter possibility can be checked by performing a 3-D best-fit of the free-form
surface in the CAD model followed by a graphic evaluation. It is then also possible to
change only the reference surfaces in the tool and thus avoid costly reworking of the free-
form surfaces.
Chapter-5

ADVANTAGES OF INJECTION MOULDING

1. High production rates
2. Low Power Consumption
3. Good Accuracy
4. Low Maintenance Charge
5. High tolerances are repeatable
6. Wide range of materials can be used
7. Low labour costs
8. Minimal scrap losses
9. Little need to finish parts after moulding

DISADVANTAGES OF INJECTION MOULDING

 Expensive equipments investment

 Running cost may be high
 Parts must be designed with moulding consideration

Chapter-6

KEY SUPPLIERS OF RAW MATERIAL

 Reliance India ltd. PP

 Haldia petro chemical HDPE

 Helene HDPE
 IPCL PP
 Indian Oil LDPE
 Chapter-7

Conclusion
Injection moulding machine has been available as a processing method for big
plastic products for about 40 years. With in last 10 to 15 years there has been dramatic
change.Engineers and designers are taking a fresh interest in the process because of the
scope it offers for the production of relatively inexpensive, complex shape with low
levels of molded in stress. Material suppliers are continually developing new grades of
plastics as well as a wider selection of material suited to the process. In addition,
machinery suppliers are producing more sophisticated moulding equipment so that the
molder now has control over the process that was thought impossible.

The article of bigger size is to be moulded the heating , cooling time will be rised
significantly. Heating little but more time will be while cooling time will be around 6-8
sec. The total time for full cycle will be nearly 18 sec.

Reference
 Injection moulding reference guide 4th Edition :Jay W Carender
 Plastic Injection Molding : Material Selection and Product Design : Douglas M Bryce
 Plastic injection molding : material selection and product design

https://searchworks.stanford.edu/view/11842492

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