International Journal of Advance Engineering and Research Development

Size: px

Start display at page:

Download "International Journal of Advance Engineering and Research Development"

Merilyn Dorsey
5 years ago
Views:

1 Scientific Journal of Impact Factor (SJIF): 5.71 e-issn (O): p-issn (P): International Journal of Advance Engineering and Research Development International Conference on Creativity and Innovation in Technology Development Volume 5, Special Issue 05, March-2018 (UGC Approved) A Review on Modeling and manufacturing of Vertical Injection molding machine Prototype Parts M Shoeab Sheikh 1, Dr. Prashant Sharma 2 1 Department of Engineering, College of Dairy, Food Science & Technology ( MPUAT),Udaipur Rajasthan, India 2 Principal, SS College of Engineering, Udaipur Rajasthan, India Abstract - Injection Moulding is the one of the most common methods in producing plastic products for many purposes ranging from a daily product to high-tech equipments. This work is concerned with the design of parts and manufacturing, Prototype of Vertical Pneumatic Injection Moulding Machine. from analysis of design, manufacturing and production in Plastic materials from a long time, it was found that injection moulding system using Pneumatic pressure gives us better results than traditional approach. A simple experimental approach suggested the difference in quality of product cavity. The Experimental work is mainly concentrate on to observe the conditions for maximum use of Raw material with less material wastage The final Result shows by doing experimental analysis of output come from machine in the form of mould product, their quality as well as importance of machine & product economy specially designed with the concern of Small Scale Industries. Keywords : Prototype, Injection Moulding, Pro-E, Design, Plastics I INTRODUCTION Injection moulding is the most common method of part manufacturing. It is a manufacturing process for producing parts for both thermoplastic and thermosetting plastic materials. According to customer needs like less operating cost, user friendly, automatic temperature control, Better output in less time consuming and finished product the vertical pneumatic injection moulding machine is the best option created recently. In pneumatically operated plastic injection machine two pneumatic cylinders are used. One for injection of plastic and other for automatic opening of the die [1] There is no problem of oil leakage and fire hazards and the cost is very less as compared to hydraulic machine. In manual machine there is a problem of automatic removal of product. This problem is solved in pneumatic machine by using pneumatic cylinder [2].The main objectives for this project are Divided into mainly two Parts : In First Part Design & manufacturing description of Vertical Pneumatic Injection Moulding Machine as well as Design of Machine Component using Pro-E & CAD. In Second part Investigation of Experimental and Static analysis of Product variables like Injection Pressure, pressure drop, Flow front Temperature, quality prediction, Cost Estimation of Machine & Product etc. II LITRETURE REVIEW Sharifah Rafidah (2010) Study the Historical Invention in Moulding machine according to paper says Injection is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity. In 1868, American inventor John Wesley Hyatt developed a plastic material he named Celluloid, improving on Parkes' invention so that it could be processed into finished form. Together with his brother Isaiah, Hyatt patented the first injection moulding machine in This machine was relatively simple compared to machines in use today. The plastic injection moulding industry has evolved over the years from producing combs and buttons to producing a vast array of products for many industries including automotive, medical, aerospace and consumer products[4]. Karthikeyan L M, Sathiyavani K (2014) shows in their study about business augmentation of small Scale plastic Industries in India. The major supporting industries for plastic manufactures are machinery Suppliers, raw materials suppliers, chemical suppliers, mould and die makers. Chung Chih Lin, Wen Teng Wang (2014) have done study of melt viscosity in Injection moulding Process is important to understand the influence of setting parameters on the melt viscosity. An apparatus named as pressure sensor bushing (PSB) module that is used to evaluate the melt viscosity during injection process is developed in this work. Organized By SS College of Engineering, Udaipur 1

III PNEUMATICVERTICAL INJECTION MOULDING MACHINE III MACHINE COMPONENTS DESIGN In Pneumatically operated Vertical injection moulding machine the moulding operation is done with the help of compressed

2 III PNEUMATICVERTICAL INJECTION MOULDING MACHINE III MACHINE COMPONENTS DESIGN In Pneumatically operated Vertical injection moulding machine the moulding operation is done with the help of compressed air which is cheaper than and more efficient than manual machine. The advantages of this machine is the productivity increased as well as less wastage of material. The Pneumatically operated moulding machine fabricated using various components; these are the list of components- Cylinder, Flow control Valve, Direction control Valve, pressure regulator, Die assembly, Heater, mounting table [5]. Following points are needed to be considered while selecting a pneumatic cylinder- Cylinder thrust, Air consumption and type of mounting. Injection cylinder gives the require pressure of mould cavity into the barrel. A Cylinder Injection cylinder is composed of cylinder body, piston, and piston load.the upper cylinder is used for up and down motion of the plunger which injects the plastic material in to barrel. Lower cylinder is used for automatic opening of the die. Design of Cylinder consist of (a) Cylinder Thrust (b) Air Consumption (c ) Mounting. B Barrel Nitride Steel barrel are used for Iupilon /Novarex plastic resins is good. The Barrel consists of cooling water channel, heater bands, Thermocouple whose function is to note the temperature in various section of barrel. The air consumption data for cylinder is required in order to estimate the compressor capacity. The calculations include air consumption during forward as well as return stroke[6]. Barrel Length Outer Diameter Inner Diameter Table 1Specification of Barrel 300mm. 25 mm. 20 mm. C Heater The Plastic resins are moulded at high temperature. the heater with heat capacity can be heated to about C is used, and a band heater is usually used. D Nozzle Nozzle is the end part of the barrel which provides melt can leave barrel and enter into the mould. melt can be heated here by friction and conduction from a heater band before entering the relatively cold channels in the mould. The temperature of the nozzle should be set to the material's melt temperature or just below it, depending on the recommendation of the material supplier. When the barrel is in its full forward processing position, the radius of the nozzle should nest and seal in the concave radius in the sprue bushing with a locating ring. During purging of the barrel, the barrel backs out from the sprue, so the purging compounds can free fall from the nozzle. Organized By SS College of Engineering, Udaipur 2

Fig. II Nozzle Nozzle with Barrel in Processing Position (A) and Nozzle with Barrel backed out for purging (B) The Plastic resins are moulded at high

E Clamp Holder Clamping is used to keep the mould tightly closed under sufficient pressure to let the molten plastic fill in the cavity without leaking during

[6] Clamping is used to keep the mould tightly closed under sufficient pressure to let the molten plastic fill in the cavity without leaking during the

3 Fig. II Nozzle Nozzle with Barrel in Processing Position (A) and Nozzle with Barrel backed out for purging (B) The Plastic resins are moulded at high temperature, the heater with heat capacity can be heated to about C is used, and a band heater is usually used. E Clamp Holder Clamping is used to keep the mould tightly closed under sufficient pressure to let the molten plastic fill in the cavity without leaking during the injection process. Clamping system clamps the mould using a mechanical advantage developed through series of linkages.[6] Clamping is used to keep the mould tightly closed under sufficient pressure to let the molten plastic fill in the cavity without leaking during the injection process. F Collar or Sprue Collar or Sprue is the channel along with the molten plastic first enters the mould through the cylinder pipes. It delivers the melt from the nozzle to the runner system. Organized By SS College of Engineering, Udaipur 3

Figure IV Collar G Mould Plate Mould consists of two halves into which the impression of the part product to be moulded is cut.

Core is male portion of the mould forms the internal shape of the moulding. Cavity is the female portion of the mould, gives the moulding its external form of the part [6].

granules in the barrel from hopper. Heating coil is provided around the barrel which heats the plastic granules. The temperature of this heating coil can be control by dimmer of 1 amp (100 C) [5].

4 Figure IV Collar G Mould Plate Mould consists of two halves into which the impression of the part product to be moulded is cut. The mating surface of the mould halves are accurately machined so no leakage so plastic can occur at the parting line [3]. This die is made from mild steel using CNC fabrication on it. Core is male portion of the mould forms the internal shape of the moulding. Cavity is the female portion of the mould, gives the moulding its external form of the part [6]. (a) Cavity NC Check in Pro-E (b) Mould Die Core & Cavity (Single Cavity) Used in Machine IV WORKING OF PNEUMATIC MOULDING MACHINE Working of pneumatic machine is as follows: Insert the plastic granules in the barrel from hopper. Heating coil is provided around the barrel which heats the plastic granules. The temperature of this heating coil can be control by dimmer of 1 amp (100 C) [5]. The stopper is provided at the bottom of the barrel from its inner side to preventing molten material fall down. The stopper is attached in such a way that if pressure is provided due to the action of plunger molten material gets injected smoothly into the die. Spring is used to provide a clearance between barrel and the die. Compressor is attached to cylinder through 5/2 direction control valve which operate the cylinder [6] Organized By SS College of Engineering, Udaipur 4

Figure VI Pro E Design and Assembled Machine Compressor is attached to cylinder through 5/2 direction control valve which operate the cylinder. The direction control valve is hand lever type of valve.

5 Figure VI Pro E Design and Assembled Machine Compressor is attached to cylinder through 5/2 direction control valve which operate the cylinder. The direction control valve is hand lever type of valve. At first stroke compressed air having pressure of 3.2 bar passes into cylinder ( ) which pushes the plunger downward into barrel and molten material gets injected into the die V CONCLUSIONS From analysis of design, manufacturing and production in Plastic materials from a long time, it was found that injection moulding system using Pneumatic pressure gives us better results than traditional approach. A simple experimental approach suggested the difference in quality of product cavity. This design result can be used to pre-calculate the production & manufacturing process of machine in order to achieve faster breakeven point. Analysis/simulation provides an insight into the nature of processing and consequently offers valuable inputs towards the design of the Parts. This study is intended to be the stepping stone for incorporating more the use of Injection Moulding simulation software in the product design, mould design, and product development that involves the use of injection moulding process. REFERENCES [1] Eranna H, Development of Pneumatically operated compression Moulding Machine in International Journal of Engineering Research, Vol.2 Issue 4 oct. 2014, Pages [2] Moldflow, 2004, Injection Molding Automation: From Concept to Flawless Volume Production in One Go. [3] N Sreenivasulu, Dr. R Ravikanth, Injection Moulding Tool Design Manufacturing, Estimation and Comparison of L&T Power Box Side Panel Using Plastic Materials HDPE, ABS, PP and PC [4] T Sung -Yen Ling, Ming-Shyan Haung, Designing robust parameter for Injection Compression Moulding light guided Plates based on desirability function & Regression model in International Journal of Engineering & Technology IJET- IJENS, Vol.14, Issue 01,Feb. 2014,Pages [4] R. Surace, G. Trotta, V. Bellantone and I. Fassi, The Micro Injection Moulding Process forpolymeric Components Manufacturing, ITIA-CNR, Institute of Industrial Technology and Automation, National Research Council, Italy. [5] Poonam G Shukla, Gaurav p Shukla, Design & Fabrication of Pneumatically operated injection Moulding Machine, in International Journal of Engineering & innovative Technology (IJEIT), Vol. 2,Issue 7, January 2013, Pages [6] M Shoeab Sheikh, Dr. Prashant Sharma, Design analysis for components of Pneumatic Injection moulding machine using Pro-E,IJIERT Vol 2 issue7, July Organized By SS College of Engineering, Udaipur 5

PLASTIC INJECTION MOULDING MACHINE

PLASTIC INJECTION MOULDING MACHINE Gaikwad Mahesh Digamber 1, Sharif Mohiuddin Akbar 2, Dhomase Datta Govind 3, Ravale Shivshankar Ashokrao 4,Mr Bidve Mangesh Angadrao 5,Mr Devshette Ashish Rajkumar 6