plastic injection training report

8/17/2019 plastic injection training report

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PRACTICAL TRAINING

At

S.P. ENTERPRISESB-60, WARD NO.9, DABUA COLONY

NIT Faridabad-!00

Submitted in the partial fulfillment of

Bachelor of Technology Degree Of

Maharishi Dayanand University, Rohtak

SUB"ITTED TO # SUB"ITTED BY #

Department of MECH. Engg. RAJAN(12ME081)

D!"#RTM!$T O% M!&'#$() !$*($!!R($*

Maharishi Dayanand UNIVERSI!" Rohtak+'aryana


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D$%&arati'(

I #ere $% &e'are t#at t#e proe't *or+ ent,te& -In&/tr,a ra,n,ng Report

S$m,tte& to t#e S.P. ENTERPRISES ,/ a re'or& of an or,g,na or+ Done $%me n&er #e g,&an'e of Mr. Har,n&er /,r Mr. /re/# S#arma /,r . It #a/ not $een

atere& or 'orre'te& a/ a re/t of a//e//ment an& ,t ma% 'onta,n error/ an&

om,//,on/. #e 3,e*/ e4pre//e& ,n ,t toget#er *,t# an% Re'ommen&at,on/ $% me.

Raan


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A%)('*&$d+$$(t

A 5roe't ,/ a 'om$,nat,on of 3,e*/" ,&ea/" /gge/t,on an& 'om$,nat,on of man%

peope. #e report ,/ t#e opportn,t% to t#an+ t#o/e *#o 'ontr,$te& to*ar&/ ,t/ff,ment. 6efore *e get t#o/e of t#,ng/. I *o& ,+e to a&& a fe* #eartfet

*or&/ for t#e peope *#o *or+ part of t#,/ tra,n,ng ,n #mero/ *a% peope *#o

g,3e nen&,ng /pport/.

I *o& ,+e to e4ten& m% grat,t&e to*ar&/ Mr. AJI CHAUHAN for g,3,ng

'on/,&erate an& #ep,ng.

I a/o *,/# to t#an+ t#e '#,ef manager at &,fferent &epartment A+a/# 7mar

an*ar (Sr. Manager) *#o/e 'on/tant /pport #e& ong *a% earn,ng &r,ng m%

tra,n,ng.

I am ,mmen/e% t#an+f to a t#e empo%ee of goe pa/t,' ,n&/tr,e/ *#o g,3e t#e

pre',o/ t,me on pro3,&,ng t#e *,t# 3aa$e ,nformat,on an& rep%,ng to m% a

er,e/.


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PREFACE

#,/ ,/ a report $a/e& on m% e4per,en'e at S.5. ENER5ISES. 6e,ng a /t&ent of

me'#an,'a eng,neer,ng" I *,/#e& to ga,n e4po/re to t#e 3ar,o/ a/pe't/ of

*or+,ng ,n an ,n&/tr%. #,/ *a/ a perfa't opportn,t% for me . M% pr,mar% goa

*a/ to ga,n /ome ,n/,g#t ,nto met#o&/ of manfa'tr,ng an& &e/,gn" an& &r,ng m%

t,me at t#e /#op9foor" I #a3e a'#,e3e& ,t to /ome e4tent.

It *a/ a goo& earn,ng e4per,en'e an& *, /tan& me ,n goo& /tan& me ,n goo&

/tea& ,n ftre.


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Tab&$ O C'(t$(tC#apter 1.Intro&'t,on

1.1 Ser3,'e/ An& Maor :n't,on/

1.2 Var,o/ Department1.; C/tomer/ Ven&or/

C#apter 2 Mo&,ng 5ro'e//

2.1 %pe/


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C/at$r .I(tr'd1%ti'(

e are one of t#e ea&,ng manfa'trer/ of pro3en a,t% pa/t,' mo&/ 'omponent/ ,n

:ar,&a$a&" /,n'e 2008.#e fa',,t% 'ompr,/e/ of 2 *or+/#op/ of /,Be/ =00 /.mt/.

?00 /.mt/.. ,t# a 'ompete /tan&$% po*er for t#e ent,re prem,/e/. e are 'on/tant%

n&ergo,ng e4pan/,on an& ,ntro&',ng ne*er te'#noog,e/ an& e,pment. #e

Manfa'tr,ng pro'e//e/ are #an& mo&,ng of &,fferent /,Be/" atomat,' #or,Bonta pa/t,'

,ne't,on mo&,ng ma'#,ne/" atomat,' 3ert,'a pa/t,' ,ne't,on mo&,ng ma'#,ne/.a t#e

pro'e//e/ are 'arr,e& ot *,t# #%&ra,' po*er.

e a/o #a3e a


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. S$r2i%$ A(d "a3'r F1(%ti'(

#e ,nfra/tr'tre of t#e Eng,neer,ng or+/#op/ 'o& pro3,&e t#e foo*,ng ,/te&

/er3,'e/ to ,t/ 'on/mer/ $ot# ,n a'a&em,' an& non9a'a&em,' term/.

e pro&'e more t#an 1">0"000 a,t% a//re& pa/t,' ,tem/ a mont# . e are 'ert,f,e& to S

1?= a,t% /%/tem re,rement/" from UV.

oe pa/t,' ,n&/tr,e/ manfa'tre/ 'omponent/ 'ompr,/,ng of #9'onne'tor/" /nap" p3' 'ap" eft

r,g#t &oor o'+" ,n/at,on 'ap"*,re a//em$% mae femae part/ a t#e/e are /e& ,n a//em$% of

&,fferent part/.

.! 4ari'1 D$art$(t5S/'• F Ne* 5ro&'t,on De3eopment Department

• FVen&or Spp,e& Area G Ra* mater,a Storage

• FSCM &epartment

• F5r,mar% In/pe't,on Department

• FMa,ntenan'e Department

• F5ro&'t,on S#op

• FHeat reatment /#op

• F5re D,/pat'# In/pe't,on Department

• F:,na In/pe't,on (Dome/t,'GE4port)

. C1t'$r 7 4$(d'r

FC1t'$r#

• S,3an, o'+/

F

F4$(d'r#

• 5.7. Eng,neer,ng or+/

C8APTER !


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"OULDING PROCESS9 Mo&,ng ,/ t#e pro'e// of manfa'tr,ng $% /#ap,ng ,,&

or p,a$e ra* mater,a /,ng a r,g,& frame 'ae& a mo& or matr,4. #,/ ,t/ef ma% #a3e $een

ma&e /,ng a pattern or mo&e of t#e f,na o$e't.

A mo& ,/ a #oo*e&9ot $o'+ t#at ,/ f,e& *,t# a ,,& or p,a$e mater,a ,+e pa/t,'" ga//"

meta or 'eram,' ra* mater,a. #e ,,& #ar&en/ or /et/ ,n/,&e t#e mo&/"a&opt,ng ,t/ /#ape.a

mo& ,/ t#e 'onterpart to 'a/t. #e 3er% 'ommon $,3a3e mo&,ng pro'e// /e/ t*o mo&/" one

for ea'# #af of t#e o$e't. 5,e'e mo&,ng /e/ a nm$er of &,fferent mo&/" ea'# 'reat,ng a

/e't,on of a 'omp,'ate& o$e't.t#,/ ,/ genera% on% /e& for arger an& more 3aa$e o$e't/.

#e mfg *#o ma+e/ t#e mo&/ ,/ 'ae& t#e mo& ma+er. A reea/e agent ,/ t%p,'a% /e& to

ma+e remo3a of #ar&ene&G/et /$/tan'e from t#e mo& ea/,er.

%p,'a /e/ for mo&e& pa/t,'/ ,n'&e mo&e frn,tre" mo&e& #o/e#o& goo&/" mo&e&

'a/e/" an& /tr'tra mater,a/.

!.T$ ' '&di(+ i(%&1d$#-

6


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/#ape.


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mo3,ng pro'e//. Ho*e3er" ,t ,/ a 3er% e'onom,'a pro'e// for part,'ar app,'at,on/ an& 'an $e

'#eaper t#an ot#er t%pe/ of mo&,ng. Ver% ,tte mater,a ,/ *a/te& /,ng t#,/ pro'e//" an& e4'e//

mater,a 'an often $e re9/e&" ma+,ng ,t an e'onom,'a an& en3,ronmenta% 3,a$e

manfa'tr,ng pro'e//.

C/at$r Bri$ r'%$ $;&a(ati'(

. IN>ECTION "OULDING < IN>ECTION "OLDING IN T8E

USA= ,/ a manfa'tr,ng pro'e// for pro&',ng part/ $% ,ne't,ng mater,a ,nto a mo&.

Ine't,on mo&,ng 'an $e performe& *,t# a #o/t of mater,a/" ,n'&,ng meta/" ga//e/"


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ea/tomer/" 'onfe't,on/" an& mo/t 'ommon% t#ermopa/t,' an& t#ermo/ett,ng po%mer/. Mater,a

for t#e part ,/ fe& ,nto a #eate& $arre" m,4e&" an& for'e& ,nto a mo& 'a3,t%" *#ere ,t 'oo/ an&

#ar&en/ to t#e 'onf,grat,on of t#e 'a3,t%. After a pro&'t ,/ &e/,gne&" /a% $% an ,n&/tr,a

&e/,gner or an eng,neer " mo&/ are ma&e $% a mo&ma+er (or tooma+er) from meta" /a%

e,t#er /tee or am,nm" an& pre',/,on9 ma'#,ne& to form t#e featre/ of t#e &e/,re& part. Ine't,on

mo&,ng ,/ *,&e% /e& for manfa'tr,ng a 3ar,et% of part/" from t#e /mae/t 'omponent/ to

ent,re $o&% pane/ of 'ar/. A&3an'e/ ,n ;D pr,nt,ng te'#noog%" /,ng p#otopo%mer/ *#,'# &o not

met &r,ng t#e ,ne't,on mo&,ng of /ome o*er temperatre t#ermopa/t,'/" 'an $e /e& for

/ome /,mpe ,ne't,on mo&/.

5art/ to $e ,ne't,on mo&e& m/t $e 3er% 'aref% &e/,gne& to fa',,tate t#e mo&,ng pro'e//

t#e mater,a /e& for t#e part" t#e &e/,re& /#ape an& featre/ of t#e part" t#e mater,a of t#e

mo&" an& t#e propert,e/ of t#e mo&,ng ma'#,ne m/t a $e ta+en ,nto a''ont. #e 3er/at,,t%

of ,ne't,on mo&,ng ,/ fa',,tate& $% t#,/ $rea&t# of &e/,gn 'on/,&erat,on/ an& po//,$,,t,e/.

;.2 E?UIP"ENTS

https://en.wikipedia.org/wiki/Elastomerhttps://en.wikipedia.org/wiki/Thermoplastichttps://en.wikipedia.org/wiki/Thermoplastichttps://en.wikipedia.org/wiki/Thermosettinghttps://en.wikipedia.org/wiki/Thermosettinghttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Engineerhttps://en.wikipedia.org/wiki/Mouldmakerhttps://en.wikipedia.org/wiki/Steelhttps://en.wikipedia.org/wiki/Aluminumhttps://en.wikipedia.org/wiki/Aluminumhttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Body_panelhttps://en.wikipedia.org/wiki/Body_panelhttps://en.wikipedia.org/wiki/Body_panelhttps://en.wikipedia.org/wiki/Body_panelhttps://en.wikipedia.org/wiki/Automobilehttps://en.wikipedia.org/wiki/3D_printinghttps://en.wikipedia.org/wiki/3D_printinghttps://en.wikipedia.org/wiki/3D_printinghttps://en.wikipedia.org/wiki/3D_printinghttps://en.wikipedia.org/wiki/Thermoplastichttps://en.wikipedia.org/wiki/Thermosettinghttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Industrial_designhttps://en.wikipedia.org/wiki/Engineerhttps://en.wikipedia.org/wiki/Mouldmakerhttps://en.wikipedia.org/wiki/Steelhttps://en.wikipedia.org/wiki/Aluminumhttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Body_panelhttps://en.wikipedia.org/wiki/Automobilehttps://en.wikipedia.org/wiki/3D_printinghttps://en.wikipedia.org/wiki/Elastomer


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Main article- Ine't,on mo&,ng ma'#,ne

Ine't,on mo&,ng ma'#,ne/ 'on/,/t of a mater,a #opper" an ,ne't,on ram or /'re*9t%pe

pnger" an& a #eat,ng n,t. A/o +no*n a/ pre//e/" t#e% #o& t#e mo&/ ,n *#,'# t#e

'omponent/ are /#ape&. 5re//e/ are rate& $% tonnage" *#,'# e4pre//e/ t#e amont of 'amp,ng

for'e t#at t#e ma'#,ne 'an e4ert. #,/ for'e +eep/ t#e mo& 'o/e& &r,ng t#e ,ne't,on pro'e//.

onnage 'an 3ar% from e// t#an > ton/ to o3er "000 ton/" *,t# t#e #,g#er f,gre/ /e& ,n

'omparat,3e% fe* manfa'tr,ng operat,on/. #e tota 'amp for'e nee&e& ,/ &eterm,ne& $% t#e

proe'te& area of t#e part $e,ng mo&e&. #,/ proe'te& area ,/ mt,p,e& $% a 'amp for'e of

from 1.8 to @.2 ton/for ea'# /are 'ent,meter of t#e proe'te& area/. A/ a re of t#m$" = or >

ton/G,n2 'an $e /e& for mo/t pro&'t/. If t#e pa/t,' mater,a ,/ 3er% /t,ff" ,t *, re,re more

,ne't,on pre//re to f, t#e mo&" an& t#/ more 'amp tonnage to #o& t#e mo& 'o/e&. #e

re,re& for'e 'an a/o $e &eterm,ne& $% t#e mater,a /e& an& t#e /,Be of t#e part arger part/

re,re #,g#er 'amp,ng for'e.

. "OULD

"'1&d or di$ are t#e 'ommon term/ /e& to &e/'r,$e t#e too /e& to pro&'e pa/t,' part/ ,n

mo&,ng.

https://en.wikipedia.org/wiki/Injection_molding_machinehttps://en.wikipedia.org/wiki/Metric_tonhttps://en.wikipedia.org/wiki/Injection_molding_machinehttps://en.wikipedia.org/wiki/Metric_ton


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1. ,&e 5,n/ f,4e& to one #af of t#e mo& an& a,gn t#e t*o #a3e/ $% enter,ng t#e #oe/

,n t#e ot#er #af.

2. Rnner pa//age*a%/ ,n t#e mo& 'onne't,ng t#e 'a3,t,e/ to t#e /pre $/#.

;. ate :reent% t#e rnner narro*/ a/ ,t enter/ t#e mo& 'a3,t%. #,/ ,/ 'ae& a gate

an& pro&'e/ a *ea+ po,nt ena$,ng t#e mo&,ng to $e ea/,% $ro+en or 't from t#e

rnner.

=. Spre 6/# apere& #oe ,n t#e 'entre of t#e mo& ,nto *#,'# t#e moten pa/t,' ,/ f,r/t

,ne'te&.

>. o'at,ng R,ng 5o/,t,on/ t#e mo& on t#e f,4e& paten /o t#at t#e ,ne't,on noBBe ,ne/

p *,t# t#e /pre $/#.

?. Mo& Ca3,t% #e /pa'e ,n t#e mo& /#ape& to pro&'e t#e f,n,/#e& 'omponent(/).

@. Ee'tor 5,n/ #e/e p,n/ p/# t#e mo&,ng an& /preGrnner ot of t#e mo&.

8. #e S#ot ota amont of pa/t,' ,ne'te& ,nto mo&.

. Spre Mater,a *#,'# /et/ ,n t#e /pre $/#.


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S,n'e mo&/ #a3e $een e4pen/,3e to manfa'tre" t#e% *ere /a% on% /e& ,n ma//

pro&'t,on *#ere t#o/an&/ of part/ *ere $e,ng pro&'e&. %p,'a mo&/ are 'on/tr'te& from

#ar&ene& /tee" pre9#ar&ene& /tee" am,nm" an&Gor $er%,m 9 'opper ao%. #e '#o,'e of

mater,a to $,& a mo& from ,/ pr,mar,% one of e'onom,'/ ,n genera" /tee mo&/ 'o/t more

to 'on/tr't" $t t#e,r onger ,fe/pan *, off/et t#e #,g#er ,n,t,a 'o/t o3er a #,g#er nm$er of

part/ ma&e $efore *ear,ng ot. 5re9#ar&ene& /tee mo&/ are e// *ear9re/,/tant an& are /e& for

o*er 3ome re,rement/ or arger 'omponent/ t#e,r t%p,'a /tee #ar&ne// ,/ ;8=> on

t#e Ro'+*e 9 C /'ae. Har&ene& /tee mo&/ are #eat treate& after ma'#,n,ng t#e/e are $% far

/per,or ,n term/ of *ear re/,/tan'e an& ,fe/pan. %p,'a #ar&ne// range/ $et*een >0 an& ?0

Ro'+*e9C (HRC). Am,nm mo&/ 'an 'o/t /$/tant,a% e//" an& *#en &e/,gne& an&

ma'#,ne& *,t# mo&ern 'ompter,Be& e,pment 'an $e e'onom,'a for mo&,ng ten/ or e3en

#n&re&/ of t#o/an&/ of part/. 6er%,m 'opper ,/ /e& ,n area/ of t#e mo& t#at re,re fa/t

#eat remo3a or area/ t#at /ee t#e mo/t /#ear #eat generate&. #e mo&/ 'an $e manfa'tre&

e,t#er $% CNC ma'#,n,ng or $% /,ng ee'tr,'a &,/'#arge ma'#,n,ng pro'e//e/.

I(3$%ti'( '1&di(+ di$ *it/ ITS SA"PLE

https://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Electrical_discharge_machininghttps://en.wikipedia.org/wiki/Beryllium_copperhttps://en.wikipedia.org/wiki/Rockwell_scalehttps://en.wikipedia.org/wiki/Electrical_discharge_machining


15/31


16/31


17/31


18/31

.@ "OULD DESIGN

Stan&ar& t*o pate/ too,ng 'ore an& 'a3,t% are ,n/ert/ ,n a mo& $a/e Kfam,% mo&K of f,3e &,fferent part/

#e mo& 'on/,/t/ of t*o pr,mar% 'omponent/" t#e ,ne't,on mo& (A pate) an& t#e ee'tor

mo& (6 pate). #e/e 'omponent/ are a/o referre& to a/ moulder an& mouldmaker 5a/t,' re/,n

enter/ t#e mo& t#rog# a /pre or gate ,n t#e ,ne't,on mo& t#e /pre $/#,ng ,/ to /ea

t,g#t% aga,n/t t#e noBBe of t#e ,ne't,on $arre of t#e mo&,ng ma'#,ne an& to ao* moten

pa/t,' to fo* from t#e $arre ,nto t#e mo&" a/o +no*n a/ t#e 'a3,t%. #e /pre $/#,ng &,re't/

t#e moten pa/t,' to t#e 'a3,t% ,mage/ t#rog# '#anne/ t#at are ma'#,ne& ,nto t#e fa'e/ of t#e A

an& 6 pate/. #e/e '#anne/ ao* pa/t,' to rn aong t#em" /o t#e% are referre& to a/runners.

#e moten pa/t,' fo*/ t#rog# t#e rnner an& enter/ one or more /pe',a,Be& gate/ an& ,nto t#e

'a3,t% geometr% to form t#e &e/,re& part.

Spre" rnner an& gate/ ,n a'ta ,ne't,on mo&,ng pro&'t

https://en.wikipedia.org/wiki/Sprue_(manufacturing)https://en.wiktionary.org/wiki/cavityhttps://en.wiktionary.org/wiki/cavityhttps://en.wikipedia.org/wiki/Sprue_(manufacturing)https://en.wiktionary.org/wiki/cavity


19/31

#e amont of re/,n re,re& to f, t#e /pre" rnner an& 'a3,t,e/ of a mo& 'ompr,/e/ a K/#otK.

rappe& a,r ,n t#e mo& 'an e/'ape t#rog# a,r 3ent/ t#at are gron& ,nto t#e part,ng ,ne of t#e

mo&" or aron& ee'tor p,n/ an& /,&e/ t#at are /,g#t% /maer t#an t#e #oe/ reta,n,ng t#em. If

t#e trappe& a,r ,/ not ao*e& to e/'ape" ,t ,/ 'ompre//e& $% t#e pre//re of t#e ,n'om,ng mater,a

an& /eeBe& ,nto t#e 'orner/ of t#e 'a3,t%" *#ere ,t pre3ent/ f,,ng an& 'an a/o 'a/e ot#er

&efe't/. #e a,r 'an e3en $e'ome /o 'ompre//e& t#at ,t ,gn,te/ an& $rn/ t#e /rron&,ng pa/t,'

mater,a.

o ao* for remo3a of t#e mo&e& part from t#e mo&" t#e mo& featre/ m/t not o3er#ang

one anot#er ,n t#e &,re't,on t#at t#e mo& open/" ne// part/ of t#e mo& are &e/,gne& to mo3e

from $et*een /'# o3er#ang/ *#en t#e mo& open/ (/,ng 'omponent/ 'ae& ,fter/).

S,&e/ of t#e part t#at appear parae *,t# t#e &,re't,on of &ra* (t#e a4,/ of t#e 'ore& po/,t,on

(#oe) or ,n/ert ,/ parae to t#e p an& &o*n mo3ement of t#e mo& a/ ,t open/ an& 'o/e/) are

t%p,'a% ange& /,g#t%" 'ae& &raft" to ea/e reea/e of t#e part from t#e mo&. In/ff,',ent &raft

'an 'a/e &eformat,on or &amage. #e &raft re,re& for mo& reea/e ,/ pr,mar,% &epen&ent on

t#e &ept# of t#e 'a3,t% t#e &eeper t#e 'a3,t%" t#e more &raft ne'e//ar%. S#r,n+age m/t a/o $e

ta+en ,nto a''ont *#en &eterm,n,ng t#e &raft re,re&. If t#e /+,n ,/ too t#,n" t#en t#e mo&e&

part *, ten& to /#r,n+ onto t#e 'ore/ t#at form *#,e 'oo,ng an& ',ng to t#o/e 'ore/" or t#e part

ma% *arp" t*,/t" $,/ter or 'ra'+ *#en t#e 'a3,t% ,/ pe& a*a%.

A mo& ,/ /a% &e/,gne& /o t#at t#e mo&e& part re,a$% rema,n/ on t#e ee'tor (6) /,&e of

t#e mo& *#en ,t open/" an& &ra*/ t#e rnner an& t#e /pre ot of t#e (A) /,&e aong *,t# t#e

part/. #e part t#en fa/ free% *#en ee'te& from t#e (6) /,&e. nne gate/" a/o +no*n a/

/$mar,ne or mo& gate/" are o'ate& $eo* t#e part,ng ,ne or mo& /rfa'e. An open,ng ,/

ma'#,ne& ,nto t#e /rfa'e of t#e mo& on t#e part,ng ,ne. #e mo&e& part ,/ 't ($% t#e

mo&) from t#e rnner /%/tem on ee't,on from t#e mo&. L1>288 Ee'tor p,n/" a/o +no*n a/

+no'+ot p,n/" are ',r'ar p,n/ pa'e& ,n e,t#er #af of t#e mo& (/a% t#e ee'tor #af)"

*#,'# p/# t#e f,n,/#e& mo&e& pro&'t" or rnner /%/tem ot of a mo&. ;#e ee't,on of t#e

art,'e /,ng p,n/" /ee3e/" /tr,pper/" et'. ma% 'a/e n&e/,ra$e ,mpre//,on/ or &,/tort,on" /o 'are

m/t $e ta+en *#en &e/,gn,ng t#e mo&.

#e /tan&ar& met#o& of 'oo,ng ,/ pa//,ng a 'ooant (/a% *ater) t#rog# a /er,e/ of #oe/

&r,e& t#rog# t#e mo& pate/ an& 'onne'te& $% #o/e/ to form a 'ont,no/ pat#*a%. #e

https://en.wikipedia.org/wiki/Parting_linehttps://en.wikipedia.org/wiki/Parting_linehttps://en.wikipedia.org/wiki/Injection_moulding#cite_note-IMhand3-15https://en.wikipedia.org/wiki/Injection_moulding#cite_note-IMhand3-15https://en.wikipedia.org/wiki/Injection_moulding#cite_note-IMhand3-15https://en.wikipedia.org/wiki/Coolanthttps://en.wikipedia.org/wiki/Coolanthttps://en.wikipedia.org/wiki/Parting_linehttps://en.wikipedia.org/wiki/Injection_moulding#cite_note-IMhand3-15https://en.wikipedia.org/wiki/Coolant


20/31

'ooant a$/or$/ #eat from t#e mo& (*#,'# #a/ a$/or$e& #eat from t#e #ot pa/t,') an& +eep/

t#e mo& at a proper temperatre to /o,&,f% t#e pa/t,' at t#e mo/t eff,',ent rate.

o ea/e ma,ntenan'e an& 3ent,ng" 'a3,t,e/ an& 'ore/ are &,3,&e& ,nto p,e'e/" 'ae& inserts" an&

/$9a//em$,e/" a/o 'ae& inserts" blocks" or chase blocks. 6% /$/t,tt,ng ,nter'#angea$e,n/ert/" one mo& ma% ma+e /e3era 3ar,at,on/ of t#e /ame part.

More 'ompe4 part/ are forme& /,ng more 'ompe4 mo&/. #e/e ma% #a3e /e't,on/ 'ae&

/,&e/" t#at mo3e ,nto a 'a3,t% perpen&,'ar to t#e &ra* &,re't,on" to form o3er#ang,ng part

featre/. #en t#e mo& ,/ opene&" t#e /,&e/ are pe& a*a% from t#e pa/t,' part $% /,ng

/tat,onar% -ange p,n/ on t#e /tat,onar% mo& #af. #e/e p,n/ enter a /ot ,n t#e /,&e/ an&

'a/e t#e /,&e/ to mo3e $a'+*ar& *#en t#e mo3,ng #af of t#e mo& open/. #e part ,/ t#en

ee'te& an& t#e mo& 'o/e/. #e 'o/,ng a't,on of t#e mo& 'a/e/ t#e /,&e/ to mo3e for*ar&

aong t#e ange p,n/.

A mo& 'an pro&'e /e3era 'op,e/ of t#e /ame part/ ,n a /,nge K/#otK. #e nm$er of

K,mpre//,on/K ,n t#e mo& of t#at part ,/ often ,n'orre't% referre& to a/ 'a3,tat,on. A too *,t#

one ,mpre//,on *, often $e 'ae& a /,nge ,mpre//,on ('a3,t%) mo&. A mo& *,t# 2 or more

'a3,t,e/ of t#e /ame part/ *, ,+e% $e referre& to a/ mt,pe ,mpre//,on ('a3,t%) mo&. Some

e4treme% #,g# pro&'t,on 3ome mo&/ (,+e t#o/e for $otte 'ap/) 'an #a3e o3er 128 'a3,t,e/.

In /ome 'a/e/ mt,pe 'a3,t% too,ng *, mo& a /er,e/ of &,fferent part/ ,n t#e /ame too.Some tooma+er/ 'a t#e/e mo&/ fam,% mo&/ a/ a t#e part/ are reate&. E4ampe/ ,n'&e

pa/t,' mo&e +,t/.

. TOOL "ATERIALS

oo /tee or $er%,m9'opper are often /e&. M,& /tee" am,nm" n,'+e or epo4% are /,ta$e

on% for protot%pe or 3er% /#ort pro&'t,on rn/. Mo&ern #ar& am,nm (@0@> an& 202= ao%/)

*,t# proper mo& &e/,gn" 'an ea/,% ma+e mo&/ 'apa$e of 100"000 or more part ,fe *,t#

proper mo& ma,ntenan'e.

https://en.wikipedia.org/wiki/Beryllium-copperhttps://en.wikipedia.org/wiki/Beryllium-copperhttps://en.wikipedia.org/wiki/Beryllium-copper


21/31

.6 "AC8INING

Mo&/ are $,t t#rog# t*o ma,n met#o&/ /tan&ar& ma'#,n,ng an& EDM. Stan&ar& ma'#,n,ng"

,n ,t/ 'on3ent,ona form" #a/ #,/tor,'a% $een t#e met#o& of $,&,ng ,ne't,on mo&/. ,t#

te'#noog,'a &e3eopment" CNC ma'#,n,ng $e'ame t#e pre&om,nant mean/ of ma+,ng more

'ompe4 mo&/ *,t# more a''rate mo& &eta,/ ,n e// t,me t#an tra&,t,ona met#o&/.

#e ee'tr,'a &,/'#arge ma'#,n,ng9(EDM) or /par+ ero/,on pro'e// #a/ $e'ome *,&e% /e& ,n

mo& ma+,ng. A/ *e a/ ao*,ng t#e format,on of /#ape/ t#at are &,ff,'t to ma'#,ne" t#e

pro'e// ao*/ pre9#ar&ene& mo&/ to $e /#ape& /o t#at no #eat treatment ,/ re,re&. C#ange/

to a #ar&ene& mo& $% 'on3ent,ona &r,,ng an& m,,ng norma% re,re annea,ng to /often

t#e mo&" foo*e& $% #eat treatment to #ar&en ,t aga,n. EDM ,/ a /,mpe pro'e// ,n *#,'# a

/#ape& ee'tro&e" /a% ma&e of 'opper or grap#,te" ,/ 3er% /o*% o*ere& onto t#e mo&

/rfa'e (o3er a per,o& of man% #or/)" *#,'# ,/ ,mmer/e& ,n paraff,n o, (+ero/ene). A 3otage

app,e& $et*een too an& mo& 'a/e/ /par+ ero/,on of t#e mo& /rfa'e ,n t#e ,n3er/e /#ape

of t#e ee'tro&e.

. COST#e nm$er of 'a3,t,e/ ,n'orporate& ,nto a mo& *, &,re't% 'orreate ,n mo&,ng 'o/t/.

:e*er 'a3,t,e/ re,re far e// too,ng *or+" /o ,m,t,ng t#e nm$er of 'a3,t,e/ ,n9trn *, re/t

,n o*er ,n,t,a manfa'tr,ng 'o/t/ to $,& an ,ne't,on mo&.

A/ t#e nm$er of 'a3,t,e/ pa% a 3,ta roe ,n mo&,ng 'o/t/" /o &oe/ t#e 'ompe4,t% of t#e part/

&e/,gn. Compe4,t% 'an $e ,n'orporate& ,nto man% fa'tor/ /'# a/ /rfa'e f,n,/#,ng" toeran'e

re,rement/" ,nterna or e4terna t#rea&/" f,ne &eta,,ng or t#e nm$er of n&er't/ t#at ma% $e

,n'orporate&.

:rt#er &eta,/ /'# a/ n&er't/" or an% featre 'a/,ng a&&,t,ona too,ng *, ,n'rea/e t#e

mo& 'o/t. Srfa'e f,n,/# of t#e 'ore an& 'a3,t% of mo&/ *, frt#er ,nfen'e t#e 'o/t. R$$er

,ne't,on mo&,ng pro'e// pro&'e/ a #,g# %,e& of &ra$e pro&'t/" ma+,ng ,t t#e mo/t

https://en.wikipedia.org/wiki/Electrical_discharge_machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/CNChttps://en.wikipedia.org/wiki/CNChttps://en.wikipedia.org/wiki/CNChttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Spark_erosionhttps://en.wikipedia.org/wiki/Spark_erosionhttps://en.wikipedia.org/wiki/Electrical_discharge_machininghttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/CNChttps://en.wikipedia.org/wiki/Machininghttps://en.wikipedia.org/wiki/Spark_erosion


22/31

eff,',ent an& 'o/t9effe't,3e met#o& of mo&,ng. Con/,/tent 3'an,Bat,on pro'e//e/ ,n3o3,ng

pre',/e temperatre 'ontro /,gn,f,'ant% re&'e/ a *a/te mater,a

. IN>ECTION PROCESS

,t# ,ne't,on mo&,ng" granar pa/t,' ,/ fe& $% gra3,t% from a #opper ,nto a #eate& $arre. A/

t#e grane/ are /o*% mo3e& for*ar& $% a /'re*9t%pe pnger" t#e pa/t,' ,/ for'e& ,nto a

#eate& '#am$er" *#ere ,t ,/ mete&. A/ t#e pnger a&3an'e/" t#e mete& pa/t,' ,/ for'e& t#rog#

a noBBe t#at re/t/ aga,n/t t#e mo&" ao*,ng ,t to enter t#e mo& 'a3,t% t#rog# a gate an&

rnner /%/tem. #e mo& rema,n/ 'o& /o t#e pa/t,' /o,&,f,e/ amo/t a/ /oon a/ t#e mo& ,/

f,e& pro'e// t#en repeat/.

CLA"PING t#e mo3,ng an& f,4e& paten/ of t#e ,ne't,on mo&,ng ma'#,ne #o&/

t#e mo& too toget#er n&er pre//re.


23/31

IN>ECTION t#e moten pa/t,' t#at #a/ $een mete& from peet form ,n t#e $arre of

t#e mo&,ng ma'#,ne ,/ ,ne'te& n&er pre//re ,nto t#e mo&.

DWELLING after t#e moten pa/t,' #a/ $een ,ne'te& ,nto t#e mo& pre//re ,/ app,e& to

en/re a 'a3,t,e/ are f,e&.

COOLING t#e pa/t,' part/ are t#en ao*e& to /o,&,f% ,n t#e mo&.


24/31

OPENING 9 t#e mo3,ng paten mo3e/ a*a% from t#e f,4e& pate/ /eparat,ng t#e mo& too.

E>ECTION 9 A pate or a,r $a/t t#en a,&/ ee't,on of t#e 'ompete& pa/t,' mo&,ng from

t#e ,ne't,on mo& too.

.9 IN>ECTION "OULDING CYCLE

#e /een'e of e3ent/ &r,ng t#e ,ne't,on mo& of a pa/t,' part ,/ 'ae& t#e ,ne't,on

mo&,ng '%'e. #e '%'e $eg,n/ *#en t#e mo& 'o/e/" foo*e& $% t#e ,ne't,on of t#e

po%mer ,nto t#e mo& 'a3,t%.


25/31

C/at$r @ "at$ria& A(d P'*$r R$1ir$$(t

@. T8ER"OPLASTIC "ATERIALS A LS

#e ta$e $eo* pro3,&e/ /ome $r,ef &eta,/ on &,fferent t#ermopa/t,' mater,a/ /e& ,n

,ne't,on mo&,ng. #e ,/t ,/ $% no mean/ e4#a/t,3e an& t#ere are a nm$er of $en&/ of

&,fferent mater,a/" e.g. 5CGA6S" &e/,gne& to a'#,e3e t#e $e/t performan'e propert,e/ of t#e

t*o ,n&,3,&a 'omponent/. ,t#,n ea'# grop of pa/t,'/ mater,a/ &,fferent e3e/ of

performan'e are a3a,a$e. A&&,t,ona /trengt# ma% $e ga,ne& t#rog# t#e a&&,t,on of f,er/"

/'# a/ ta' or ga//" ,n man% 'a/e/. A/o a&&,t,3e/ to ,mpro3e UV /ta$,,t% or fame

retar&an'% or pro3,&e ant,m,'ro$,a propert,e/ ma% a/o $e /e&.

"at$ria& Abbr. Pr'$rti$ Ti%a& A&i%ati'(

5o%prop%ene 55 oo& '#em,'a re/,/tan'e 5a'+ag,ng" 'onta,ner/

55 H555 Sem, r,g,&" &ra$e Sma &ome/t,' app,an'e/

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26/31

Homopo%mer eg +ette/

5o%et#%ene 5E oo& '#em,'a re/,/tan'e"

fe4,$e or /em, r,g,& &epen&,ng

on gra&e. eat#erproof" goo&

o* temperatre performan'e.

Non to4,'. o* 'o/t

o* Den/,t% 5a'+ag,ng"

'onta,ner/. H,g# Den/,t%

'rate/" '#em,'a &rm/"

ga/G*ater p,pe an& f,tt,ng/"

+,t'#en*are

5E o* Den/,t% D5E GD5

E

5E H,g#

Den/,t%

HD5E

5o%/t%rene 5S 6r,tte" tran/parent. 5oor UV

/ta$,,t%. HI5S p to @4 ,mpa't

/trengt# of 55S

55S to%/" pa'+ag,ng"

'o/met,' pa'+ag,ng

HI5S V 'a$,net/"

refr,gerator ,n,ng/" to,et

/eat/

enera 5rpo/e 55S

H,g# Impa't HI5S

A'r%,' 5MMA R,g,&"'ear" go//%" goo&

*eat#er re/,/tan'e

en/e/" /,gn/" ,g#t

&,ff/er/" po,nt of pr'#a/e

&,/pa%/

A'r%on,tr,e

6ta&,ene

St%rene

A6S R,g,&" opae" tog#" goo&

go//" te4tre po//,$e

Dome/t,' app,an'e/" 'ar

fa/',a/" 'ompter #o/,ng/

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27/31

N%on

(5o%am,&e)

5A R,g,&" tog#" #ar&*ear,ng ear/" $ear,ng/"

atomot,3e n&er $onnet

part/

@.! "OULDING DEFECTS

Ine't,on mo&,ng ,/ a 'ompe4 te'#noog% *,t# po//,$e pro&'t,on pro$em/. #e% 'an $e

'a/e& e,t#er $% &efe't/ ,n t#e mo&/" or more often $% t#e mo&,ng pro'e// ,t/ef.

"'1&di(+

d$$%t

A&t$r(ati2$

(a$

D$%riti'( Ca1$

6,/ter 6,/ter,ng

Ra,/e& or a%ere&

Bone on /rfa'e of

t#e part

oo or mater,a ,/ too #ot" often

'a/e& $% a a'+ of 'oo,ng aron& t#e

too or a fat% #eater

6rn mar+/A,r $rnGga/

$rnG&,e/e,ng

6a'+ or $ro*n $rnt

area/ on t#e part

o'ate& at frt#e/t

po,nt/ from gate or

*#ere a,r ,/ trappe&

oo a'+/ 3ent,ng" ,ne't,on /pee& ,/

too #,g#

:a/# 6rr/ E4'e// mater,a ,n Mo& ,/ o3er pa'+e& or part,ng ,ne

http://www.rutlandplastics.co.uk/advice/nylon.htmlhttps://en.wikipedia.org/wiki/Molding_flashhttp://www.rutlandplastics.co.uk/advice/nylon.htmlhttps://en.wikipedia.org/wiki/Molding_flash


28/31

t#,n a%er e4'ee&,ng

norma part

geometr%

on t#e too ,/ &amage&" too m'#

,ne't,on /pee&Gmater,a ,ne'te&"

'amp,ng for'e too o*. Can a/o $e

'a/e& $% &,rt an& 'ontam,nant/

aron& too,ng /rfa'e/.

Em$e&&e&

'ontam,nate/

Em$e&&e&

part,'ate/

:ore,gn part,'e

($rnt mater,a or

ot#er) em$e&&e& ,n

t#e part

5art,'e/ on t#e too /rfa'e"

'ontam,nate& mater,a or fore,gn

&e$r,/ ,n t#e $arre" or too m'# /#ear

#eat $rn,ng t#e mater,a pr,or to

,ne't,on

Jett,ng

5art &eforme& $%

tr$ent fo* of

mater,a.

5oor too &e/,gn" gate po/,t,on or

rnner. Ine't,on /pee& /et too #,g#.

5oor &e/,gn of gate/ *#,'# 'a/e too

,tte &,e /*ean& re/t ett,ng.

7n,t ,ne/ e& ,ne/

Sma ,ne/ on t#e

$a'+/,&e of 'ore p,n/

or *,n&o*/ ,n part/

t#at oo+ ,+e /t

,ne/.

Ca/e& $% t#e met9front fo*,ngaron& an o$e't /tan&,ng pro& ,n a

pa/t,' part a/ *e a/ at t#e en& of f,

*#ere t#e met9front 'ome/ toget#er

aga,n. Can $e m,n,m,Be& or e,m,nate&

*,t# a mo&9fo* /t&% *#en t#e

mo& ,/ ,n &e/,gn p#a/e.


29/31

(In t#,'+er Bone/)

'oo,ng t,me too /#ort" *,t# /pree//

#ot rnner/ t#,/ 'an a/o $e 'a/e& $%

t#e gate temperatre $e,ng /et too

#,g#. E4'e//,3e mater,a or *a/ too

t#,'+.

S#ort /#ot Non9f, or

/#ort mo&5art,a part

a'+ of mater,a" ,ne't,on /pee& or

pre//re too o*" mo& too 'o&" a'+

of ga/ 3ent/

Met#o&/ /'# a/ ,n&/tr,a C /'ann,ng 'an #ep *,t# f,n&,ng t#e/e &efe't/ e4terna% a/ *e a/

,nterna%.

@. TOLERANCES AND SURFACES

Mo&,ng toeran'e ,/ a /pe',f,e& ao*an'e on t#e &e3,at,on ,n parameter/ /'# a/ &,men/,on/"

*e,g#t/" /#ape/" or ange/" et'. o ma4,m,Be 'ontro ,n /ett,ng toeran'e/ t#ere ,/ /a% a

m,n,mm an& ma4,mm ,m,t on t#,'+ne//" $a/e& on t#e pro'e// /e&. Ine't,on mo&,ng

t%p,'a% ,/ 'apa$e of toeran'e/ e,3aent to an I ra&e of a$ot 1=. #e po//,$e toeran'e

of a t#ermopa/t,' or a t#ermo/et ,/ O0.200 to O0.>00 m,,meter/ In /pe',a,/e& app,'at,on/

toeran'e/ a/ o* a/ O> Pm on $ot# &,ameter/ an& ,near featre/ are a'#,e3e& ,n ma//

pro&'t,on. Srfa'e f,n,/#e/ of 0.0>00 to 0.1000 Pm or $etter 'an $e o$ta,ne&. Rog# or pe$$e&

/rfa'e/ are a/o po//,$e.

"'1&di(+ T$ Ti%a& P'ib&$

https://en.wikipedia.org/w/index.php?title=Short_shot&action=edit&redlink=1https://en.wikipedia.org/wiki/Industrial_CT_scanninghttps://en.wikipedia.org/wiki/IT_Gradehttps://en.wikipedia.org/w/index.php?title=Short_shot&action=edit&redlink=1https://en.wikipedia.org/wiki/Industrial_CT_scanninghttps://en.wikipedia.org/wiki/IT_Grade


30/31

#ermopa/t,' O0.>00 O0.200

#ermo/et O0.>00 O0.200

@.@ POWER RE?UIRE"ENTS

#e po*er re,re& for t#,/ pro'e// of ,ne't,on mo&,ng &epen&/ on man% t#,ng/ an& 3ar,e/

$et*een mater,a/ /e&. Manufacturing "rocesses Reference *uide /tate/ t#at t#e po*er

re,rement/ &epen& on Ka mater,a/ /pe',f,' gra3,t%" met,ng po,nt" t#erma 'on&'t,3,t%" part

/,Be" an& mo&,ng rate.K 6eo* ,/ a ta$e from page 2=; of t#e /ame referen'e a/ pre3,o/%

ment,one& t#at $e/t ,/trate/ t#e '#ara'ter,/t,'/ ree3ant to t#e po*er re,re& for t#e mo/t

'ommon% /e& mater,a/.

"at$ria& Spe',f,' gra3,t% Met,ng po,nt


31/31

R$$r$(%$#

***.googe.'om

***.*,+,pe&,a.'om

***.fa&ooeng,neer/.'om
http://www.google.com/http://www.wikipedia.com/http://www.fadooengineers.com/http://www.google.com/http://www.wikipedia.com/http://www.fadooengineers.com/

plastic injection training report

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