PROJECT REPORT

PROJECT REPORT
ON
SINGLE CAVITY HOT TIP MOULD
IN

WORKORDER NO.822098N
CUSTOMER-LARSEN &TOUBRO LTD.
MUMBAI

By
ADTDM-04
YOGESH V.NIKAM
ENROLL NO. =2004141

Production Department 1
 PROJECT REPORT
PROJECT REPORT

(A GOVERNMENT OF INDIA SOCIETY)

P-31, MIDC INDUSTRIAL AREA, CHIKALTHANA,
AURANGABAD- 431210.

CERTIFICATE OF APPROVAL OF PROJECT WORK

This is Certify to The Mr. YOGESH VISHNU NIKAM, S/O
Mr.VISHNU NIKAM of ADTDM 2004 BATCH, Enroll no: - 2004141 has
successfully completed his project work in the Production
Department as implant training, a part of there ADVANCE DIPLOMA
IN TOOL & DIE MAKING (4 yrs.) in the partial fulfillment of course
for the award of Advance diploma in tool & die making from INDO
GERMAN TOOL ROOM, Aurangabad during the period of 12TH JAN.
2008 TO 31ST JULY. 2008.
The project has been approved as it satisfies the academic
requirements in respect of project work prescribed for the trainees.

PROD . MANAGER COURSE CO’OR. PROJECT GUIDE By

(T.A.
KARANDE)

Production Department 2
 PROJECT REPORT

I am very thankful to Mr. H.D.KAPSE (General Manager. Indo-

German Tool Room).

Mr.D.SIVAIAH (Sr. Manager Training) for assigning me does the

live project in the Design Department.

I would like to express my sincere thanks to Mr. T.A.Karande,

Mr. Mahesh kande, Mr.Yogesh Dxit, Mr. Amit Gajbhiye & Mr.

S.M.Shreerame for their expert guidance and valuable time. Also

thanks for the valuable guidelines and help from Mr. Vishal Sabde

and Mr. Kailash Gaikwad.

At last I would like to thank all the members of IGTR and collogues

for their Co-operation.

Production Department 3
 PROJECT REPORT
This project reveals the effort taken during the implant training in

design department between the duration of 12th Jan 2008 to 31st

July 2008.

The project gives a brief introduction about the work accomplished

in design including the explored applications in ProE, Unigraphics &

other design related information.

This project is basically dependent upon different types of Moulds

such as Injection Mould; hot tip Mould & Compression Mould etc. It also

gives a view of design consideration involved in press tool, mould & die-

casting-dies. It gives the idea of the flow of design from the stage of

receive till dispatch of the tool.

Finally this project is an overview of the work in design department.

PAGE
Sr.no. DESCRIPTION
NO.
Production Department 4
 PROJECT REPORT

INTRODUCTION
01 6-13
DESIGN CONSIDERATION
02 14
PROCESS
Design & PROJECT details
03 15-17

COMPONENT DETAILS
04 17-19

COMPONENT MATERIAL
05 20-21
DETAIL

06 MOULD CAL.& m/c detail 22-28

PART DETAIL & assembly

07 detail 29-39

08 PART LIST 40-41

09 process sheet 42-44

10 JOB CARD 45-49

11
cost estimation 50-62

12
tool inspection report 63-68

13 achievement & CONCLUSION 69-70

Production Department 5
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1 BASICS
The single most important component in the moulding process is
the Mould. Some times cost of the mould overtakes machine cost and
always plays a vital role in deciding the product cost.
Almost 70% of the plastic products are produced by Injection Moulding
method among all the plastics processing techniques available so far.
So it is obvious that a large number of Injection moulds are made
everywhere. Accordingly a lot of developments in mould making
techniques have taken place. Hot Runner Mould is one of such great
achievements in mould making field.

1. E
VOLUTION OF HOT RUNNER MOULDS

Shaping of plastic materials in an Injection mould, particularly

in a multi-cavity one needs a well-laid feeding system.
The feeding system carries the plastic melt, under pressure, from
the nozzle of the injection moulding machine to the entry point of
the mould cavity and the continuity of the pressure helps the melt to
reach the extreme end of the impression. The receiving end of the
melt is known as Sprue. The Sprue delivers the melt on the main
feeding channel known as Runner and further branching of it is known
as sub-runners. The narrow bridge between cavity and the runner or
sub-runner is known as Gate. In general the combination of sprue,
runner and sub-runners is regarded as RUNNER SYSTEM.

In conventional moulding process the runner system is always

moulded and ejected along with the moulded article in every cycle.
This moulded runner is use less and forcibly produced as waste
because of the technological barrier. But elimination of the runner
system in the conventional moulding process is not possible. On the
other hand the total volume of the runners and sprue exceeds that of
the mouldings in case of multi-impression moulds quite often. More
volume means more cycle time, more manpower loss and there by

Production Department 6
 PROJECT REPORT

more wastage. One can argue of reusing the scrap as seconds and
mixing to virgin material, but, still the process is uneconomical.

Paying a constructive attention to eliminating moulding and ejection of

the runner system is worth the effort. Evolution of HOT RUNNER
SYSTEM is the right result of such progressive thought. Incorporation
of the Hot Runner System in the conventional mould makes it a HOT
RUNNER MOULD.
The Hot Runner Mould consists of a runner system, which remain hot
and keeps the plastics in molten condition right up to the gate point all
along the production cycle. So the runner system is never moulded
and ejected unlike conventional mould in every cycle. On injection
only the cavities are filled to form the moulding. During ejection
stroke the moulding is degated and ejected out of the mould. Perhaps
this is the reason the hot runner mould is often called as runner less
mould.

1. TYPES OF HOT RUNNER SYSTEM

Hot Runner System gives an opportunity to make either hot runner

mould or semi-hot runner mould. Hot runner moulds eliminate the
entire runner system where the Semi hot runner moulds eliminate a
part of the runner system. choice for fabrication of such types of
moulds is left to user’s economic consideration as well as geometry
and aesthetic of the product.

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The classification of Hot Runner Systems is subject to the kind of
heating provision available with it. They are two types in general, i.e.

i. Externally Heated Hot Runner Systems

In this case the melt is heated from out side while passing through
the feeding channel. Electrical heaters supply the heat.

ii. Internally Heated Hot Runner Systems

In this case the heater is placed inside the feeding channel and the
melt is supplied with heat from inside.
A third variety of system is also available, known as Combination
System. In this type the runner system contains a mixture of both
externally and internally heated hot runner systems.Indirect heating
system.

This kind of heating system is limited to Hot Nozzles only. The

indirectly heated nozzles do not have any dedicated heater. It receives
the required heat from the manifold to which it is attached. This is why
the nozzles for indirect heating should be made from good heat
conducting materials like BeCu, Cu or other such alloys. The main
advantage of this type is simplification of design. However their
temperature can not be controlled directly and independently.

1. HOT RUNNER ELEMENTS

Various elements used in hot runner systems are broadly divided into
two types as per their function. These are Path Elements and
Heating System Elements.

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Path Elements consists of the followings

i. Hot Sprue Bushing
ii. Manifold
iii. Injection Nozzles

Heating System Elements consists of the followings

i. Heaters
ii. Temperature Sensors
iii. Temperature Controller

Hot Sprue Bushing

The hot sprue bushings are designated to remove the superfluous direct
gate on single mouldings. Also this is used to carry plastic melt up to
main runner in case of multiple gate design.

Manifold

The heart of the hot runner system is the ‘MANIFOLD’. Manifold is a

heated block, which houses the runner system. Distribution of the melt
to every gate points takes place in this heated block. Leading standard
mould base and components’ manufacturers have standardized various
types of manifolds and these are readily available. Apart from this,
customized mould bases can be easily manufactured with respect to the
runner system design.

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 PROJECT REPORT
Injection Nozzles

Injection nozzle also some times called as Secondary nozzles is a part

of the hot runner system which provides as connecting flow path from
the manifold block to the cavity entry point. There are a number of
possible designs of these nozzles available in the market. Most
commonly used are cylindrical in shape and usually incorporate a
threaded section which screws into the manifold block. A leak free joint
between nozzle and manifold is essential.

Heaters

In practice electrical heaters are normally used for heating. Different

types of heaters are engaged to supply heat to different sections of the
hot runner system. Catridge heater, Tubular heater, Band heater and
Coil heater etc. are most commonly used one.

1. Catridge heaters
Most Common method of manifold heating is done with catridge
heaters. They are placed inside accurately drilled and reamed holes
parallel to the runner. The advantage lies with easy replacement of the
heaters. Catridge heaters are commercially available as standard part
in various diameters, lengths and wattage.

2. Tabular heaters

3. Band heater

4. Coil heater

Temperature Sensors

The hot runner system remains hot during its entire operation.
Temperature sensor is essential to keep track of the temperature of the
manifold and other components. Different types of thermocouples are
used to sense the temperature and give feed back to the controlling
unit.

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Temperature Controller

Hot runner moulds are extremely sensitive to temperature variation in

nozzle and gate area. Even a change of a few degrees in temperature
can interrupt the moulding process. Many times a high volume of
rejections result because of temperature variation. Exact temperature
control is, there fore, an important precondition for a good and
automatically operating hot runner mould. Temperature controllers
receive feed back from the heaters with the help of thermocouples and
regulate the temperature of by varying the current supply. In principle
each nozzle should be controlled individually for easy and smooth flow
of the melt. Dedicated controllers are now available which houses a
number of controllers to control multiple zones of the hot runner
system.
1. ADVANTAGES AND DISADVANTAGES
2. ADVANTAGES
BENEFITS
REASONS
1. Savings in material

COMMERCIAL
2. Savings in cost for
regrind
3. No investment for
grinder
4. No Investment for
robotized runner picker No sprue or runner is produced
5. Savings in storage cost
for scrap
6. Shorter cycle Moulding of the sprue and
7. Shot size is reduced by
runner is eliminated
volume
8. Larger shot volume is
available for filling
larger number of
cavities
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 PROJECT REPORT
9. Cooling timeis reduced
1 Smaller opening stroke
0. than for a three plate
mould
1 Ease of manufacturing Standard parts for hot runner
1. system are easily available, i.e.
Sprue bushings
Manifolds
Nozzles
Heaters
Thermocouples
1 Less moving parts Hot runner system become
2. compared to three integral and remain fixed to the
plate mould injection half

1. Simpler Automation of Omission of the moulding of the

the moulding process runner.
Abolition of the three plate
mould construction.
2. Increased flow length Runner network acts as an
for impression extension to the machine TECH.
barrel, thus length of flow is not
accountable.
3. Longer holding Ideal positioning of the gate
pressure allows it
4. Less pressure drop Diameter of the sprue and
runner is machined to bigger
size
5. Dimensional
repeatability
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 PROJECT REPORT
6. Increased mechanical Injection is possible right on the
strength component which improves
more homogenious feeding.

DISADVANTAGES

FLAWS REASONS
1. More work is Experienced designers are
necessary in mould required
design
2. Higher mould cost Incorporation of auxiliary

COMMERCIAL
3. Unit cost goes up
equipment’s like Nozzles, Heaters,
incase of low
Temperature sensors,
production
Temperatures etc.
requirement
4. Costly maintenance Careful handling is essential. Also
repair due to wear & tear and
damage costs more

1. Hazardous Thermal degradation of some

TEC
sensitive material.

DESIGN CONSIDERATION
Moulds:-
✖ Material used for the component, its applications.
✖ Shrinkage of the material.
✖ Calculate the weight of the component.
✖ Study the detail of the component.
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 PROJECT REPORT
✖ Type of mould required for the component to be produced.
✖ Machine available for the component.
✖ Injection pressure required.
✖ Type of runner system & gate required.
✖ Type of ejection system weather blade, stripper etc.
✖ Split and side core consideration if the component is having
any groove or notch on its sides.
✖ Cycle time required for the component for complete fill.
✖ Effective cooling in a short duration is necessary.
✖ Cooling channels must be lick proof.
✖ Selection of the material for core & cavity.
✖ Adding of shrinkage to core & cavity dimensions.
✖ Parts in the assembly must not foul with each other in
operation.
The layout of the tool must not be oversized

SINGLE CAVITY HOT TIP MOULD

FOR BOTTOM HOUSING

Component detail

Production Department 14
 PROJECT REPORT

1 Customer LARSEN & TOUBRO

LTD,MUMBAI
2 Drg. No/Component Name BOTTOM HOUSING(DCL50809)
3 Projected Area(mm²) 90 sq.cm
4 Component material POLYCARBONATE PC
943R(LAXAN)
5 Material shrinkage 0.6%
6 Material co-efficient of friction of 0.5
plastics with steel µ
7 Bulk factor 1.75
8 Molding temperature 300 0C
9 Component weight (single) 33 grms
10 Density of Polycarbonate 1.20 gm/cu.cm

DESIGN input

Customer gives information to the marketing department regarding

their requirement. Before starting the design activities following things
should be make clear with the customer.
The component related input from the customer may be in the form of
2D Component Drawing
3D Component Model

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 PROJECT REPORT
Existing Sample of Component
The Tool related input from the customer may be in the form of
Type of Mould / Die
No. of Cavities
Production Rate
The Material related input from the customer may be in the form of
Component Material
Shrinkage
Component weight
Die Set Material
Core/Cavity Material
Aesthetic & Functional Requirements of Component that should be
discussed with the customer are as follows
Type of gate
Location of gate
Parting Line Constraints
Ejection mark constraints
Other inputs required from the customer are as follows
Reference Information
Standard Parts
Side Core Actuation Method
Machine Specification

Tool details…

Hot tip mould preferred when quantity of production is more and

time is limited. The quality of the mouldings bring a sense of hot
runner moulds as advanced one where the others might be
Production Department 16
 PROJECT REPORT
considered as obsolete. We can still go for the obsolete methods
with an economic projection towards it. But in the long run HOT
RUNNER SYSTEM brings more money.

The two plate Hot tip mould has been designed for single cavity
system, provided with Pin point gating for auto degating. The tool
with 354mm shut height and gross weight of 180 kg with ejection
stroke of 42 mm.

Materials for the plates are taken as M.S./C-45 and for inserts it is
ORVAR SUPREME also, based on the property of EN-31 we have
selected it for guide pillar and guide bush. the slide is made of o.s
material to Resist wear and tear during functionng.

Push back pins has been provided with springs as to assure the self
return provision of the ejector assembly. The ejector assembly
including ejector plate and ejector back plate has been supported by
two ejector supports, it is also provided with two ejector guide pillar
screwed with cavity back plate. Component has been feeded by point
gate to assure minimum gate mark and self degating.

Sufficient cooling has been provide in tool to optimize cycle mark and
to achive sound product. As the core in fixed half required cooling, to
assure effective cooling we have provided cooling channel right from
the bottom plate, the concept of cooling is not quite popular,
provision of cooling has also been provided in moving half cavity
insert.
Every aspects and considerations of designing and manufacturing
also has been taken in the tool to fulfill the requirement of the
customer and fit to economy of the organization.

Component details…

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 PROJECT REPORT

Component details…

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 PROJECT REPORT

Material – Polycarbonate (PC)

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 PROJECT REPORT

Shrinkage – 0.6%
Density - 1.2 gm/cm3
Type of Polymer – Amorphous Thermoplastic

Injection Moulding Processing Conditions

Drying: Suggested drying conditions are 80-90 C (176-195 F) for a

minimum for two hours. The material moisture content should be less
than 0.1%.

Melt Temperature: 290-300 C Aim -300 C

Mould Temperature: 25-80 C (77-176 F). Mould temperature

controls the gloss temperature; lower mould temperature produce
lower gloss levels.

Material Injection Pressure: 50-100MPa

Injection Speed: Moderate-High

Project details…
Mould details

1 Moulding machine SP80

2 Weight of feed system 0 grms.(approx.)

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 PROJECT REPORT
3 Total shot weight 33 grms.

4 Locating ring Dia

120f8 mm
5 Sprue bush Radius /Dia R12/dia 5 mm

6 Minimum ejection stroke reqd. 42 mm

7 Type of ejection PIN & SLEEVE EJECTION.

8 Minimum day light 354 mm.

9 Total height 354 mm.

10 Overall mould size(HxLxW) 346x270x354

11 Total weight of mould 290 kg.

12 Weight of injection side 110 kg.

13 Weight of Ejection side 180 kg.

1. Weight Calculations :-

Weight of Component = Volume X Density

= 27.5 X 1.2
= 33 grams

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 PROJECT REPORT

NO FEED SYSTEM DUE TO HOT TIP MOULD

(C) Shot Weight Required

Shot Weight = 33 grams

2. SHOT CAPACITY:-
The screw type machine is normally rated in terms of “Swept Volume”
of the injection cylinder (Cu. Cms).

Machine Available is SP 80. For SP 80 Swept Volume is 49 cm3

Shot capacity (g) = Swept Vol. (Cm3) x p x C

p = Density of plastic at normal temperature (g/cm3)

C = 0.93 for amorphous materials.

Shot capacity (g) = 49 X 1.2 X 0.93

= 54.68 grams

3. PLASTICISING CAPACITY:
Plasticizing rate of material B (g/hr) = plasticizing rate of
material A (g/hr) x QA/QB
A = Polystyrene
B = ABS (Material actually to be used)

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 PROJECT REPORT
Q = Thermal capacity of the material (cal/g) (Heat content)
QA = 239.4 KJ/Kg
QB = 302.4 KJ/Kg

Machine Available is SP 80, Plasticizing rate = 4.7 g/S

Plasticizing rate of material B (g/hr) = 4.7 X (3600/1000) X

(239.4/302.4)

PB= 13.395 Kg/hr

4. Locking Force Calculations:-

The clamping force required to keep the mould closed during

injection must exceed the force given by the product of the opening
pressure in the cavity and the total projected area of all impressions
and runners. Lower clamping values can be used with screw presses
owing to the lower injection pressures possible with these machines.
Production Department 23
 PROJECT REPORT

Thin sections need a high injection pressure to fill and therefore

require more clamping force. Easy flowing materials like high melt index
polyethylene and polystyrene fill more readily and hence require a lower
clamping force. In the case of screw injection 2/3 to 1/2 times of
injection Pressure should be taken for Clamping purposes. Max.
Injection pressure may be obtained from press manufacture’s data
sheet.

(A) Projected Area of the component = 9000 mm

(E) Total Projected Area =9000 mm

(F) Clamping Force = {Total Projected Area

X 1/2 Injection pressure}

= 1250 X 0.5 X 900

= 40 KN

(G) Locking Force = 1.2 X clamping force

(20% safety)

= 48 KN

Determination of number of Cavities:

The number of cavities in injection moulds is determined in most

cases by the machine performance, but some times by the moulding
shape or the mould locking pressure.

Determined by Shot Capacity:

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 PROJECT REPORT

(Based on 85% of rated shot capacity)

0.85 W
Ns =
m

Ns = No. of cavities based on shot capacity

W = Rated shot capacity for particular polymer (g)
m = Moulding weight per cavity(g)

Ns = 0.85 X 54.68 / 33
= 1.4 Approx.2

Determined by plasticizing capacity:

(Based on 85% of rated plasticizing capacity)

0.85 P / TC
Np =
3600 m

Np = No. of cavities based on plasticizing capacity.

P = Rated plasticizing capacity for particular polymer (g/hr)
Tc = Over all cycle time (Sec.) = 4 seconds

Np = (0.85P X Tc) / 3600m

Np = (0.85 X 13.39 X 1000 X 13)/ (3600 X 33)

= 1.2 Approx. 2

Determined by clamping capacity:

C
NC =
Pc x Am

Nc = No. of cavities based on clamping capacity

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 PROJECT REPORT
C = Rated clamping capacity (KN)
Pc = Clamping pressure in KN.
Am = Projected area of moulding (Sq. Cm.) including runners.

FOR FIRST COMPONENT

C
NC =
Pc x Am

Nc = 300 X 1000 / (90 X 40000)

= 0.8 Approx

2. MIN. WALL THICKNESS

t= 3 C. P. d4
E.Y.
t = Min. wall thickness (cm)
y = Max. Deflection of Side Wall = 0.003cm
Pc= Max. Cavity Pressure = 900 bar
d = Total Depth of Cavity Wall = 3.6 cm

E=Modulus of Elasticity = 2.1 X107 N/cm2

c = constant
Ratio of the length of Value of C
Cavity wall to the depth
of Cavity wall (L/d)
1.0 0.044
1.5 0.084
2.0 0.111
3.0 0.134

Production Department 26
 PROJECT REPORT
4.0 0.140
5.0 0.142

Ratio of length/depth=21/10.56 = 1.98

So value of c=0.111 from table

= 3 0.111 X 900 X 105X (3.6)4

2.1x107 x 0.003 x104

= 0.5 cm
= 5.00 mm

SPLIT CALCULATION:-

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 PROJECT REPORT

M = (L x Sin Ø)-(c/cos Ø)
Where:
M = split movement in mm = 15.5 mm
Ø = angle of finger cam = 18º
L =working length of finger cam=?
C = clearance = 0.5
We have to find L
15.5 = (L x sin18º)-(0.5/cos18º)
=28 mm
So working length of finger cam taken as 30 mm

Project details…

Production Department 28
 PROJECT REPORT
Machine Selection

Machine selection for making any plastic moulding

should be based principally on max. shot capacity, max. die opening
and die size, max. & min. die height, clamping force and operating
stroke, length of shot stroke, tie bar distance, over-all size and cost.

The thumb rule for selection of plastic moulding machine is to

use the smallest machine that will do the job. This will ensure
fundamental economy of operation, since the larger the machine, the
slower its cycle. Clamping force is not necessary the deciding factor in
the selection of a plastic moulding machine. Die dimensions must be
considered. The machine adequate tonnage for casting a part may have
insufficient platen area or tie-rod spacing for the die, or the opening
stroke may not be sufficient for removal of component.

Machine available for this case is SP 80.

Machine Specifications for SP 80

INJECTION UNIT

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 PROJECT REPORT

1 Injection pressure 1800 bar

2 Stroke volume 49m cu.cm
3 Max. Injection weight 98gms.
4 Injection rate 100cc/s
5 Plastering rate 4.7gm/s
6 Screw L/D ratio 18
7 Screw diameter 25mm
8 Screw stroke 100mm
9 Screw speed (max.) 250rpm.
11 Locating ring diameter 120 mm
12 Nozzle type Round nozzle
11 No. of heating zones 4

CLOSING UNIT

12 Closing force 400 KN.

13 Mould opening stroke 450 mm.
14 Min. mould height 100mm.
15 Max. daylight 470mm.
16 Distance between Tie Bar 395 x 395 mm.
(h x v)
17 Size of mould plate (h x v) 400 x 400 mm.
18 Ejection force 24KN.
19 Ejector stroke 65mm

Production Department 30
 PROJECT REPORT

Part details…

CAVITY INSERT

Part details…

Production Department 31
 PROJECT REPORT

CORE INSERT

Assembly details…
ASSEMBLY DETAILS

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 PROJECT REPORT

ASSEMBLY OF TOOL

Assembly details…

Production Department 33
 PROJECT REPORT

MOVING HALF OF TOOL

Assembly details…

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 PROJECT REPORT

FIXED HALF OF TOOL

Hot tip details

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 PROJECT REPORT

HOT TIP

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 PROJECT REPORT

HOT TIP WITH SECTION

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 PROJECT REPORT

Assembly details…

2D ASSEMBLY DRAWING
Production Department 38
 PROJECT REPORT

WORK ORDER NO. 822098N

MATERIAL PR. NO. P.O. NO. COST

INSERTS O.S R-180 R-151 485/kg
MOULD BASE STD R-221 R-214 65,000 /-

Production Department 39
 PROJECT REPORT

Part list…

PROCESS PLANNING

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 PROJECT REPORT
As work piece quantities and costs in press work are usually high, considerable

economy can be affected by choosing an appropriate sequence of operations and

the right type of tooling. The process plan should take into account the total cost:

material, tooling, labour (time). Process planning generally includes the following

considerations.

⇒ Quantity required – total and annual,

⇒ Work piece – shape and size,

⇒ Work piece – dimensional tolerances,

⇒ Work piece – material limitations,

⇒ Equipment available for manufacture.

In every tool, the process planning done a vital role and it is

followed by above mentioned points. To manufacture the parts of the tool, it is

necessary to follow the proper methodology of manufacturing, so that one can get

accurate dimensional stability for that particular part within appropriate time.

In Die casting dies also all the parts of the tool are

manufactured by considering all above mentioned sequence and choosing of

machining sequence. Below mentioned sheet expresses all the view of machining

sequence of the tool. Similarly all the parts of the tool are manufactured by the

same followed suit.

MANUFACTURING PROCESSES PLANNING FOR EACH PART

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 PROJECT REPORT
⇒ All the features of the part with dimensions & their references with respect to

the assembly.

⇒ The part is studies and the plans for sequence of process like conventional,

non-conventional & CNC machining, heat treatment in process & stage

inspection etc.

⇒ Special requirements for the tooling, electrode, and CAD/CAM support for the

programs required for the Core & Cavity inserts that are to be machined on

the CNC machines etc. are planned in advance to meet the process flow & to

maintain the delivery schedule.

⇒ Stage drawings of each parts coming & going out from process are made for

the convenience of the machine operator showing the references, tolerance

analysis, manufacturing allowances using the ordinate dimensioning and

inspection methodology.

⇒ A continuous follow up for the machine availability is made for the

completion of the job in the planned time period to maintain the delivery

date.

⇒ The above information is applied for all processes related to the part

indicating earliest start & finish date of each process with respect to material

planning, date of availability of special tooling, electrode, CAD/CAM data,

monthly priority list etc.The start & finish date can be taken from the job

cards the earliest finish date of assembly can be analyzed for the first trial

and is communicated to all the interface departments about planning and

their support

Production Department 42
 PROJECT REPORT
JOB CARD
WORK 822098 PART MATERIAL O.S
ORDER NO.
PART NO. 01 PART MATERIAL SIZE 61.80X181.5X147.5
PART NAME MAIN CORE INS PART QTY 61
DATE FINISH SIZE

A. PROCESS FLOW

SR. PROCESS M/C START COMP. QTY COMP. SIGN

NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK VF2 16/6 16/6 XX
MILLING
02 S/G NEW 17/6 17/6 XX
KENT
03 SPOTTING & V33 20/6 20/6 XX
DRILLING
04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT 510 7/8 8/8 XX

XX

XX

B. REWORK DETAILS

PLAN BY

DATE

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 PROJECT REPORT

WORK 822098 PART MATERIAL O.S

ORDER NO.
PART NO. 62 PART MATERIAL SIZE
PART NAME CAVITY INSERT PART QTY 01
DATE FINISH SIZE

A. PROCESS FLOW

SR. PROCESS M/C START COMP. QTY COMP. SIGN

NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK VF2 16/6 16/6 XX
MILLING
02 S/G NEW 17/6 17/6 XX
KENT
03 SPOTTING & V33 20/6 20/6 XX
DRILLING
04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT 510 7/8 8/8 XX

XX

XX

B. REWORK DETAILS

PLAN BY

DATE

Production Department 44
 PROJECT REPORT
WORK 822098 PART MATERIAL OS
ORDER NO.
PART NO. 63 PART MATERIAL SIZE
PART NAME LOCAL CORE-1 PART QTY 01
DATE FINISH SIZE

A. PROCESS FLOW

SR. PROCESS M/C START COMP. QTY COMP. SIGN

NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK VF2 16/6 16/6 XX
MILLING
02 S/G NEW 17/6 17/6 XX
KENT
03 SPOTTING & V33 20/6 20/6 XX
DRILLING
04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT XX

XX

XX

B. REWORK DETAILS

PLAN BY

DATE

Production Department 45
 PROJECT REPORT
WORK 822098 PART MATERIAL O.S
ORDER NO.
PART NO. 64 PART MATERIAL SIZE
PART NAME LOCAL CORE2 PART QTY 01
DATE FINISH SIZE

A. PROCESS FLOW

SR. PROCESS M/C START COMP. QTY COMP. SIGN

NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK VF2 16/6 16/6 XX
MILLING
02 S/G NEW 17/6 17/6 XX
KENT
03 SPOTTING & V33 20/6 20/6 XX
DRILLING
04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT XX

XX

XX

B. REWORK DETAILS

PLAN BY

DATE

WORK 822098 PART MATERIAL O.S

ORDER NO.
Production Department 46
 PROJECT REPORT
PART NO. 65 PART MATERIAL SIZE
PART NAME SIDE CORE PART QTY 01
DATE FINISH SIZE

A. PROCESS FLOW

SR. PROCESS M/C START COMP. QTY COMP. SIGN

NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK VF2 16/6 16/6 XX
MILLING
02 S/G NEW 17/6 17/6 XX
KENT
03 SPOTTING & V33 20/6 20/6 XX
DRILLING
04 B/W B/W 22/6 23/6 XX

07 H/T 52-54 HRC PLANT 25/6 2/7 XX

08 S/G KENT 2/7 2/7 XX

09 CNC MILLING HAAS 4/7 4/7 XX

10 WIRE CUT XX

11 EDM XX

XX

B. REWORK DETAILS

PLAN BY

DATE

WORK 822098 PART MATERIAL OHNS

ORDER NO.
Production Department 47
 PROJECT REPORT
PART NO. 01 PART MATERIAL SIZE
PART NAME GUIDE RAIL PART QTY 02
DATE FINISH SIZE

A. PROCESS FLOW

MATERIAL C%
SR. PROCESS Mn%
M/C Si%
START S%
COMP.P% QTY
Cr% Ni%
COMP.Mo%
SIGN
NO. DESCRIPTION DATE DATE ACC. REJ. BY
01 BLOCK 0.25
M.S. VF2
0.6- 16/6
0.1- 16/6 0.55 0.2-
0.055 XX
MILLING
02 S/G 0.
NEW 0.
17/6 17/6 0. XX
KENT
03 SPOTTING & 9
V33 35
20/6 20/6 35 XX
DRILLING
EN-8
04 B/W 0.35- 0.6-
B/W 0.05-
22/6 0.06
23/6 0.06 XX

07 0.
H/T 52-54 HRC 1. 25/6
PLANT 0. 2/7 XX
45 0 35
08 S/G KENT 2/7 2/7 XX
EN-31 0.9-
09 CNC MILLING 0.3-
HAAS 0.1-
4/7 0.05
4/7 0.05 1.0- XX
1. 0. 0. 1.
10 WIRE CUT XX
2 75 35 6
XX
OHNS 0.85- 1.0- 0.2- 0.3- 0.3
XX
0. 1. 0. 0.
B. REWORK DETAILS
95 5 4 6

O.S 0.39 0.4 1.0 5.2 1.4

PLAN BY

DATE

PART MATERIAL DETAIL

Production Department 48
 PROJECT REPORT

HEAT TREATMENT DETAIL

Heat Treatment of steel may be defined as an operation or combination

of operations involving the heating and cooling the steel in solid state;

so as to modify its properties and to make it suitable for a particular

uses.

Purposes of Heat Treatment –

The heat treatment is done for following purposes
1) To improve machinability.
2) To produce a hard surface on a ductile interior.
3) To refine grain size.
4) To relieve internal stress or eliminate the effect of cold working.
5) To increase mechanical properties.
6) To increase the resistance to wear, heat & corrosion.
7) To improve magnetic & electric properties.
8) To change chemical composition.
Production Department 49
 PROJECT REPORT
9) To increase cutting properties of steel.
10) To remove gases.

Hardening
It is a method of steel heating, 40 - 500C above the upper critical
temperature for hypo eutectoid steel or 40 - 500 above lower critical
temperature for hyper eutectoid steel, soaking for a specified time. The
hardness obtained by hardening process depends upon following –
1) Carbon content
2) Quenching rate
3) Work size
Quenching
Mark tempering – it is a process in which a steel is heated at the
hardening temperature soaked for a specified time & quenched in
isothermal bath having temperature 1800 to 3000C, kept just above the
martensite start line. The material is held there for a time just before
the nose of the bainite line. Afterwards it is cooled in air. The end
product it martensite.
Objective
1) Less distortions or warping
2) Less change in volume
3) Less change of quenching cracks & internal stresses
H.T. FOR
ORVAR SUPREME -
Hardening temperature - 1020 to 1050 deg. cel.
Quenching medium - air
Hardness after quenching - 46 to 52 HRC
Production Department 50
 PROJECT REPORT
Tempering temperature - 250 to 550 deg. Cel.
Hardness after tempering - 54 HRC
H.T. FOR
O.H.N.S -
Hardening temperature - 790 to 815 deg. cel.
Quenching medium - oil
Hardness after quenching - 63 to 65 HRC
Tempering temperature - 150 to 425 deg. Cel.
Hardness after tempering - 50 HRC

Cost estimation…

Production Department 51
 PROJECT REPORT

Production Department 52
 PROJECT REPORT
Cost estimation…
Costingof tool

Involves

 Designing cost of the tool.

 Material cost.
 Pre machining cost.
 Precision machining cost.
 Heat treatment cost.
 Fitting & assembly ,bench work cost.
 Inspection & trail cost.

Production Department 53
 PROJECT REPORT
Cost estimation…
1) Designing cost

 The amount and cost of time spent in designing a product are

estimated either on the basis of similar jobs previously

manufactured or on the basis of good judgment of designer. For
new and complicated product the job estimator must consult the
designer.

 It is always preferable that standard rates per hour be used to

calculate the cost of designer’s time, and actual rates which are
usually paid on a monthly or any other basis.

It required,
60hours - 2D designing
20 hours - 3D modeling

As, 2D designing cost = 300 per hours

3D modeling cost = 500 per hours

2D designing cost 60 x 300 = 18000 /-

3D designing cost 20 x 500 = 10000/-
----------------
28000/-

TOTAL DESIGNING COST = 28,000 /-

Production Department 54
 PROJECT REPORT
Cost estimation…

2) Material costs.

 For estimating the material cost of the product, following steps

are followed.
Find out the volume of the material.
Multiply it with density of the material.
 The drawings of the product to be manufactured are broken up
into smaller simpler parts and their volumes are calculated by
applying the formulae.
 Volume of square or rectangular cube = L x B x H.
Where, L = length of piece,
B = breadth of piece,
H = height of piece.

 Volume of cylinder = 2π RH.

Where, π = constant i.e. 3.14 or 22/7,
R = radius of piece,
H = height of piece.

 Volume of pyramid =( L x B x H)/3

Where, L = length of piece,
B = breadth of piece,

H = height of piece.

Density of steel = 7.86 gm/cm³

Production Department 55
 PROJECT REPORT
Cost estimation…

3) Pre machining cost

Unit costs (in hours)

Lathe 290/-
Milling 290/-
Surface grinding 290/-
Cylindrical grinding 290/-
The tool requires,

Lathe = 20 hours
Milling = 60 hours
Surface grinding = 48 hours
Cylindrical grinding = 18 hours

Lathe operation cost = 0 x 290 = 0

Milling operation cost = 60 x 290 = 1740
Surface grinding = 48 x 290 = 1392
Cylindrical grinding = 0 x 290 = 0
---------------------
3,132 /-

TOTAL PRE MACHINING COST = 3,132 /-

Production Department 56
 PROJECT REPORT
Cost estimation…
4) Precision machining cost

Unit costs (in hours)

CNC Lathe 575/-

CNC Milling 1000/-
CNC Wire cut 750/-
CNC EDM 575/-

The tool requires,

Lathe = 00 hours
Milling = 18 hours
Wire cut = 30 hours
EDM = 40 hours

Lathe operation cost = 00 x 575 = 0000

Milling operation cost = 22 x1000 = 22,000
Jig boring = 00 x 575 = 0000
Wire cut = 30 x 750 = 22500
EDM = 40 x 600 = 24000
-----------------
68,500/-

TOTAL PRECISION MACHINING COST = 66,500/-

Production Department 57
 PROJECT REPORT
Cost estimation…

5) Heat treatment cost

Unit costs (in hours)

Conventional 80/-
vacuum 300/-

The tool requires,

Conventional = 60 hours.
Vacuum = 20 hours.

Conventional treatment cost = 60 x 80 = 4800 /-

Vacuum = 20 x 300= 6000/-

TOTAL HEAT TREATMENT COST = 10,800/-

6) Fitting / assembly cost

Unit costs (in hours)

Fitting / assembly cost = 140 /-

The tool requires,

Fitting / assembly time = 24 hours.

Fitting / assembly cost = 24 x 140 = 3,360/-.

TOTAL FITTING / ASSEMBLY COST = 3,360/-

Production Department 58
 PROJECT REPORT
Cost estimation…

6) Inspection cost

Unit costs (in hours)

Conventional = 200/-
CMM = 1000/-

The tool requires,

Conventional = 18 hours
CMM = 06 hours

Conventional Inspection cost = 25 x 200 = 5,000 /-

CMM Inspection cost = 08 x 1000 = 8,000/-

TOTAL INSPECTION COST = 13,000/-

Production Department 59
 PROJECT REPORT
Cost estimation…

TOTAL COST OF TOOL

TOTAL DESIGNING COST = 28,000 /-

TOTAL MATERIAL COST = 22,500 /-

STANDARD MOULD BASE = 65,000 /-

TOTAL PRE MACHINING COST = 3,132 /-

TOTAL PRECISION MACHINING COST = 68,500/-

TOTAL HEAT TREATMENT COST = 10,800/-

TOTAL FITTING / ASSEMBLY COST = 3,600/-

TOTAL INSPECTION COST = 13,000/-

STANDARD PARTS COST = 25,000 /-

PACKING CHARGES = 4% OF NET VALUE.

SALES TAX = 12.5% AS APPLICABLE

EXCISE DUTY = 15% AS APPLICABL

MARGIN = 15 % of NET VALUE

----------------------
3, 27,000 /-

TOTAL COST OF TOOL = 3, 27,000 /-

Production Department 60
 PROJECT REPORT

Trail report…

Production Department 61
 PROJECT REPORT

INSPECTION
Due to the great advancement, the continuous improvements in

the production methods and increasing quality demands, the Industrial

Inspection does not mean fulfilling of the specifications lay down by the

manufacturer. Rather the Inspection in real sense is concerned with the

checking of a product at various stages of manufacturing, right from the

raw material form to the finished products in the hands of the end

customer. That is what called as the CUSTOMER SATISFACTION.

Thus, the Inspection led to the development of the precise

Inspection instruments which helps to change over from the traditional

lesser accurate machines to better design and more precise machines.

It also led to the improvements in metallurgy and raw material

manufacturing due to high demand of accuracy and precision.

Ultimately it leads to the QUALITY IMPROVEMENT.

After manufacturing of all the parts they are transferred to Quality

Control department to check the accuracy of profile also it’s positioning

from the reference. Various geometrical features such as

perpendicularity, parallelism, circularity, run out, and etc if required.

Inspection of all the parts are carried out by trained personal and
precisely working machines and it is followed by below mentioned path

Production Department 62
 PROJECT REPORT

FITTING & ASSEMBLY

ASSEMBLY - PROCESS PLANNING

⇒ First of all the assembly & sub-assembly is to be studied the

process is planned considering the functional requirement along

with fitment of mating parts showing indications & directions.

⇒ The detail record is maintained of each part required for the

assembly right from the material received to the final inspection

report.

⇒ The details of the process of each part can be obtained from the

job cards. While the dimensions with tolerances can be known

from the inspection reports.

⇒ The details of part reaching the assembly can be obtained from

the bar chart made before starting the actual manufacturing.

Production Department 63
 PROJECT REPORT
ASSEMBLY – PROCESS
While assembly of all parts and sub units first of all check the

following things.

⇒ Study the drawing.

⇒ Check the component thoroughly.

⇒ Collect and analyze the mating parts and its dimensions.

⇒ Check the deburring if not then deburr it.

⇒ Before final assembly, check the fault occurring between mating

parts.

The Pre-machining & assembly is done in the Assembly &

Fitting section. Then centre drilling done on the plates, on NC machine.

Then drilling operation, for cooling holes, tapping holes are performed

on the bench drilling machines. Then those holes get tapped. Then after

the manufacturing of all the parts, actual assembly gets starts. All

standard parts available like Allen screw, etc which is required during

assembly are collected.

After manufacturing of Core and Cavity inserts are

transferred to Quality Control department to check the accuracy of

profile also it’s positioning from the reference. Various geometrical

features such as perpendicularity, parallelism, circularity, run out, and

Production Department 64
 PROJECT REPORT
etc. if required. For assembly of tool various points which are to be

considered are as following.

⇒ Check all parts of standard die set and plate thickness for

further calculation.

⇒ Check all the standard parts which are being used in this tool.

⇒ All the inserts are maintained as per drawing for easy fitment.

⇒ Check the all alignments and fitments of all matting parts.

⇒ Identification marks are marked on each part to avoid further

confusion after disassembly.

Production Department 65
 PROJECT REPORT
Trail report…
TOOL INSPECTION REPORT
INJECTION MOLDING DEPARTMENT

COMPONENT TRAIL REPORT Date: -

Work order no:-822098N Trail no:-

Mould description: - DESIGN OF SINGLE CAVITY HOT TIP
MOULD FOR BOTTOM HOUSING

Component description :- Ref:-

Component no:-
Customer name: - L &T Mumbai

Material: -
Inj.moulding machine:-SP80
No. of shots:-
Shot weight:-
Component weight :-

REMARKS / OBSERVATIONS:-

Observation on component

1}
2}
3)

Observation on mould functioning

1}
2)
3)
4}

PARAMETERS:-
Clamping pressure :-
Injection Time :-
Holding Time :-
Cooling Time & Refilling Time:-
Total Cycle Time :-

Production Department 66
 PROJECT REPORT

ACHIEVEMENT

⇒ The project was a medium for me to enhance my knowledge in the field of

tool & Die Making. It helped me lot in better understanding of the concepts

of Injection Mould manufacturing.

⇒ During the project I had to communicate with various departments and

authorities to solve the problems and difficulties around in between. It has

helped to improve my abilities to work as a team.

⇒ A Hot tip mould for Bottom housing was required to be completed in a

specific period of time for which I had to work to the best of my abilities to

complete the Hot tip mould.

⇒ In the project work I was given an opportunity to study the HOT TIP Mould

right from manufacturing to dispatch as per planned time period, which

stretched our limits to achieve the goal.

⇒ It was a nice opportunity for me to learn about such a tool, thus enhancing

my knowledge.

Production Department 67
 PROJECT REPORT

CONCLUSION

A complete mould designer must have a through

knowledge of the principles of the mould making as the design of the

various parts of the mold depends on the technique adopted for its

manufacturer. Case studies of the various moulds of same kind have

been conducted prior to the design process. Proper evaluation of the

previous designs were performed and created something even better

instead of simply keeping to what was done previously. The various

demands of the customer were considered while designing of the

tool. The final mould design is prepared after the part design has

been specified and all requirements affecting the design of mould

have been clarified. The outcome is a near perfect design and the

trail made on the mould just about confirms it.

Production Department 68