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SHREE N.M.GOPANI POLYTECHNIC INSTITUTE KINARA, RANPUR 363-610, DIST. AHMEDABAD.
( AN ISO 9001 : 2008 CERTIFIED POLYTECHNIC)
PROJECT REPORT: METALLURGY (MET 2) BATCH
“ROTATIONAL MOULDING
WORKING MODEL OF
ROTATIONAL MOULDING (ROCK AND ROLL TYPE)
GUIDED BY:- N.A. RANPURA.
HELPED BY:- SANGHANI MAULIK (SANGHANI ENGG)
PREPARED BY:- PATEL MAYANK .B (S062506010)
GOHIL NIKUNJ.B (S062506019)
SHAH DHWANISH.N (S062506020).
We are very thankful to Shree:- H.H.JADAV SIR.
And the other staff members who have given us
proper guidance and advice in this project.
Also we are especially thankful to all classmate and
friends who encouraged and help us in this project.
CERTIFICATE
This is to certify that the below students
Reg no :- PATEL MAYANK(S062506010)
Of Diploma programme in Metallurgy
has satisfactorily completed their project with in four
walls of N.M.G.P during term 092.
Date of submission:-
Staff incharge:-
Head of department:-
Index
Acknowledgement
Aim of project
Selection of project
Process planning
Project introduction
Raw material
Types of rotational moulding
Material list
Construction
Machine tools use to do project work
Merits
Application
Unique features
Cost estimations
Product range obtain by this process
Acknowledgement
S-Met 602 project is incorporated in the syllabus of
diploma metallurgical engineering by technical education
board of Gujarat state. The real practical work is very
important for the engineering students with study which
shows the knowledgement and interest of them in
technical field. The same is done while performing the
activities to construct the project.
During making the project student get opportunity
to be connected with vast industrial field (material, m/c
tools, tools, equipments, measuring instruments) then
know how to face problems of at practical field.
The successful completion of this project has
required a lot of assistant advice and support we are
gratefull deeply indepted to all those who have assisted
and guided us always for completion of project this is not
only success but also achievement of collaborative effort
of so many people who guided and helped us through
out this project.
Also we are especially thankful to all classmate
and friends who encouraged and help us in this project.
Aim of project
To develop on altitude of inquiry
To work as a leader and member of a team.
To measure physical phenomena.
To develop ability of report writing.
To develop planning and decision making skill
To develop and store the records how to keep
SELECTION OF PROJECT
Before selecting the project brain storming and
discussion has to between the team member on various
technical or engineering machines, availability and their
requirement in routine and professional activities then
we think on a similar product whether it is available in
market or not by thinking on different kind of machines
we can manufacture
Product having more advantage at economic cost we have consider the feasibility as well As suitability for available resources and facilities to carry
out the project work.
PROCESS PLANNING
Process planning is the fundamental of industrial
activities an efficient economy planning leads the firm
and to success planning. We can know that problems
which cause actual production.
We know that for the manufacture of a part
there are many methods and process we should chose
cheaper and process theme consumed during this
process should be less and material westage should be
less .
Advantages of process planning.
1) It determines the most economical process from all
possible processes.
2) It determines the sequence of operation to be
performed.
3) It determines the raw material requirement and its
gross weight.
4) It helps in estimating and costing.
5) Process planning helps to prepare delivery schedule.
(1) OPERATION PLANNING
No operation sequence should be accepted blindly.
first of all we should make the list of all the operations,
which we have to perform during the project work.
Operation planning is section of the best of the
method manufacturing so wastage of materials
,manpower and machine power can be eliminated to get
more production with least wastage the best operation
sequence should be selected for each operation which
has to be manufacture.
Establishment of the operation sequence is
possible of the engineer is provided with the following
information.
1) List the available machine in workshop.
2) List of available general purpose tool.
3) Capacity of equipment.
4) Plan layout maybe product type or process type.
5) Manual operation of each machine.
6) Proper safety precaution .
7) Availability of different type of gauge for inspection of
Product.
PROJECT INTRODUCTION
Rotational Molding: -
Broadly the process is classified in to following sub processes.
1. Compounding to produce colored of Granules 2. Pulverizing to convert material in to Resin form 3. Rotational Molding to produce the final product
» First Process: Compounding by means of Extrusion
The LLDPE raw material with suitable masterbatch is being fed in to the barrel cylinder through storage hopper. The barrel is preheated by heating zones and suitable temperature control system to process the input material. The rotating screw pushes the material towards die end with uniform and homogenized plastics melt. The screw is rotated by suitable AC motor coupled with heavy duty gearbox.The plastics strands extruded from die are fed in to high speed Pelletiser unit after they get cooled and traveled through SS water cooling tank. Pelletiser cuts the strands in to desired size of pellets which can be collected in to storage silo.
» Second Process: Pulverizing
The compounded or colored granules are being fed in to Pulverizing machine as Input material. The granules are
fed in to Disc Mill via vibratory feeder which feeds the material as per rate of vibration of the device. The fed material is being crushed in to Mill at very high speed by one Rotating blade and one stationery blade. The crushed material is conveyed in to cyclone hopper at height via efficient suction system.
The Rotary Air lock devise separates the blown air and pulverized resin and allows the powder passes in to Screen Vibro unit. Vibro screen unit screens the powder as per mesh used and discharge the final product in to the storage silo. The course particles are fed again in to the Mill to repulverise the same.
Compounding by means of High speed Mixer (Incase the Extrusion process is not used to produce the colored Granules)
The pulverized resin is being mixed with other ingredients to prepare a ready formulation. This process is also being adopted by many processors instead of producing granules from Extrusion Plant.
In the process the polymers mixed with other ingredients is being loaded in to Mixer vessel. The mixer vessel is made from special double wall construction of SS and MS Plates. In which the material is being mixed by means of specially designed two nos blades running at very high speed. The mixing cycle is decided by the certain set temperature. Normally batch time is 10- 15 minutes depending upon grade, quantity and formulation of material to be mixed. After cycle time is over, the the material is being discharged and collected in to silo. The final material is uniformly and homogenized mixed which is ideal to use as for Rotomoulding process.
» Third Process: Rotational Moulding
In the other Plastics processes like Injection Moulding, Blow Moulding & Extrusion Process ,the plastics material is being melt at certain higher temperature and conveyed forward in to die or mould by special designed Screw. Unlike such processes ,Rotational Moulding is a very simple process. In which it is easy to produce hollow and seamless products of all the sizes and profiles. Since Rotational Moulding is a very simple and economical process along with low cost Moulds , it is very popular in India especially to produce the water storage tanks.
It comprises of mainly four steps as per following.
1. Material Loading : The polymer powder is being loaded in to two parts Rotational Mould as per size and shape of product. After loading material manually in to mould , the mould is closed. According to type and shape of Mould , some times the mould are also closed by insulating covers.
2. Rotational Moulding : The closed Moulds mounted on to Arm are swinged in to closed heating chamber where Hot and forced Air is circulating. The moulds are already rotating in two perpendicular axis at certain low speed as per size of the mould. The moulds are in Rotation in two axis so as to distribute the loaded powder uniformly inside surface of the moulds. The moulds are heated by forced hot air in to chamber up to certain heating time. The material in to moulds fuses after heating and it forms a uniform layer inside the mould.
3. Cooling: Now the moulds are taken out form heating chamber and swinged to cooling station. The moulds are cooled at cooling station by means of forced air or by spraying water where the moulds are in rotation mode in both axis. After certain cooling period, the raw material gets solidifies in to shape of the mould.
4. Unloading the finished product: The mould is taken to unloading/ loading part where the mould is opened to get the finished product. After getting the finished product, again fresh polymer powder is being charged in to mould so as to keep ready for next cycle.
Raw material
» Raw material for Rotational Moulding:
LLDPE (Liner Low density Polyethalene) is being used with density of 0.930 to 0.936 gms/ Cm cube and Melt Flow Index in the range of 3 to 6 gm per 10 minutes. To produce the good quality water tanks by Rotational Moulding, the material should have following properties.
Good mechanical strength. Good material stability over a wide range of
temperature and cycle time. Good resistance over wrapage. Consistency in Shrinkage at least 2.5 % or slightly
more. High ESCR ( Environmental stress crack resistance )
» Other Ingredients:
The original LLDPE granules are of natural colour which have to be converted in to either black, white, blue or other colours as per requirement of final product. To produce the coloured granules , basic LLDPE granules have to be mixed with colour concentrate which are called as master batches.
These master batches are readily available in market which are to be added along with LLDPE.
The master batch should be of grade which is LD based. The master batch with antioxidants are more preferred. Anti oxidants protects the material from oxidation during
the Moulding process which helps to avoid the pin holes on surface of finished product.
Incase of black master batch, carbon contents are very important. Carbon contents act as UV stabilizer. It helps to improve the life of tanks if tanks are exposed to sunlight for longer period and to avoid the crack on tanks.
Types of rotational moulding
Rotational Moulding machines
Types of Rotation Molding Machine
Bi-Axial type rotomolding Machine Independent arm rotomolding machine Rock n roll type rotomolding machine Shuttle machine
Rock N Roll Machine
Material list
Sr.No. Part Name Specification Qty.
01 Base Frame m.s. Rectangular pipe-
25mmx10mm
1 Nos.
02 Main Frame m.s.Sq.pipe- 20mm x 20mm 1 Nos.
03 Acceleration Shaft m.s.Round Dia10mm 1 Nos
04 Main Shaft m.s.round dia 10mm 2 Nos.
05 Rotating wheel Aluminum round,dia 45mm 4 Nos.
06 Coupling Aluminum round,dia-25mm 1 Nos.
07 Burner m.s round,pipe 3 Nos.
08 Acceleration wheel m.s.round 1 Nos.
09 Brg.Housing m.s. flate 4 Nos.
10 DC Geared Motor 12V, DC Geared Motor 1 Nos.
11 Springs,Nutbolts. 2Nos, 12 Nos
12 Mold Aluminum 1 Nos.
Construction
Base Frame is made from M.S. Square Pipe.
Main Frame is made from M.S. Square Pipe
The machine includes a fix shaft which is made
from EN-24
The machine includes 2 rotating shaft which is
made from EN-24
There are three burners for heating the mould are
prepared from M.S.
There are 4 rotating wheels prepared from
Aluminium.
The machine includes a mould which is prepared
with the help of aluminium..
The machine even includes the four bearing
housing which are prepared from En 8.
Machine tools used for project work
Lathe Machine
Drill Machine
Power hacksaw Machine
Welding Machine
Bench Grinder
Polishing machine
Merits
Economic Tooling Costs One-piece construction; virtually stress-free-totally
enclose parts or with openings Weight reduction - as compared to most metals
Uniform wall thickness - no thinning in the extremities
Thickness can be varied if required Variety of finishes and color Resistance to stress-cracking and corrosion Excellent load-bearing properties Variety of materials The ability to produce multi-wall mouldings Design flexibility - from small and intricate to large
and complex Metal inserts as integral parts Economical for short production runs and prototypes
as well as volume production Minor undercuts are possible - with no draft angles
required Short lead-time
Application
Household & Commercial
Water Tanks ( Vertical & Horizontal ) Refuse containers & Bins, Buckets, Barrels & Drums
Telephone Booths & Cabins Book cases and Recks Insulated Ice Boxes Show cases & Display stands Building Interior & Exterior Gadern & Pool Furniture Traffic barriers, Dividers Portable Toilet and Urinal Cabins Industrial
Oil tanks & Chemical tanks Containers & Waste Bins Septic tanks & Insulated tanks Oil Dispensing tanks Special pupose tanks Special pallets Material Handling Trolleys Crates, Baskets & Carts for storage Boxes & Bunkers for storage Sheltar Cabins Canes for Fuel, Oil & Milk Housing & Cases for Appliances
Construction & Transport
Unique features
Various thicknesses in the product are possible
Flexibility of different models to produce from 200 ltr to 25000 Ltr vertical tanks
Special article like Drainage Pipes, Boats, up to 6.5 Mtr. Can be produced in Rock n Roll comfortably
Sturdy Machine suitable for manufacturing large size hollow products. Up to 40000 Itrs / 10000 USG. Capacity
Speed variable drive for Rocking & Rolling for better control of the product
Low pressure Burners which are very simple & can be adjusted from outside
Microprocessor based machine control panel with digital display
Most economical with less investment Faster return of investment due to lesser production
cost even for wide range of products to produced.
Cost estimation Sr.
No.
Part Name Specification Qty. Wt.
Kg.
Rate/
Kg. Rs.
Total
Cost Rs.
01 Base Frame msRectangularpipe 1
Nos.
4 55 220
25x10x1650mm
02 Main Frame m.s.Sq.pipe-
20x20x1200mm
1
Nos.
3 55 165
03 Acceleratio
n Shaft
m.s.Round
Dia10mmx450LG
1 Nos 0.6 90 54
04 Main Shaft m.s.round
dia 10mmx370
2
Nos.
2.5 100 250
05 Rotating
wheel
Aluminum round,
dia 45mmx60mm
4
Nos.
0.4 300 480
06 Coupling Aluminum round,
dia-25mmx50mm
1
Nos.
1.5 280 420
07 Burner m.s 1set. 1200 1200
08 Acceleratio
n wheel
m.s.round 1
Nos.
1 250 250
09 Brg.Housing m.s. flate 4
Nos.
0.5 55 220
10 DC Geared
Motor
12V, DC
Geared Motor
1
Nos.
4000 4000
11 Springs,Nut
bolts.
2Nos, 12 Nos 150 150
12 Mold Aluminum 1
Nos.
5 350 1750
TOTAL 9159.00
Product range obtained by
“ROTATIONAL MOULDING”