FACULTY OF MECHANICAL ENGINEERING,

UNIVERSITI TECHNOLOGI MARA (UITM)

LABORATORY REPORT

Program : Bachelor of Mechanical Engineering (Hons) (EM220)

Course : Manufacturing Processes Laboratory
Course Code : MEM564
Laboratory Name : Advanced Manufacturing
Lecturer Name : MOHAMAD FIRHAD MORNI
Title of Experiment : Advanced Manufacturing (Product Quality)
Group : EMD5M15

No Student Name Student ID Number Signature

.
1. Muhd hadrami hamdan 2015135647

2. Muhd faridzwan bin rosli 2014439412

3. Mohd fadzil bin yaacob 2014246234

4. Muhd hariz bin rahmat 2015115263

5. Muhd ammar bin abdul rahman 2015166041

Date of Practical Session Staff Certification (Signature)

12-MAY-2017

Date of Report Submission Staff Certification (Signature)

19-MAY-2017

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 LABORATORY REPORT CONTENTS
General Guidelines:
LEVEL Lemah Sederhana Memuaskan Baik Cemerlang
(Weak) (Marginal) (Satisfactory) (Good) (Excellent)
Scale 1,2 3,4 5,6 7,8 9,10

Page No: Marks Marks CO Remarks

Allocated Obtained Achieveme
nt
FRONT COVER
GRADING FORM

CONTENTS Page 3

CO1
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1.0 Title Page 4 (Total
10
Marks:40)
Page 4
___ x 4
2.0 Objective(s)
10

3.0 Introduction (background and Page 4-7 ___ x 10

theory) 10

Page 7-8
___ x 7
4. 0 Apparatus
10
Page 9
___ x 3
4. 1 Industrial Apparatus
10

Page 10- ___ x 15

5.0 Experimental Procedure
11 10
CO4
___ x 17
6.0 Results & Data Analysis (Total
10
Marks:60)
Page 12
___ x 17
7.0 Discussion of Results
10

___ x 6
8.0 Conclusion
10

___ x 5
9.0 Recommendation
10

___ x 10
10.0 References
10

___ x 5
11.0 Overall Report
10

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TABLE OF CONTENT

NO CONTENT PAGE

1.0 TITLE 4

2.0 OBJECTIVE 4

3.0 INTRODUCTION 4

3.1 INJECTION MOLDING 4-5

BACKGROUND
6-7
3.2 INJECTION MOLDING THEORY

4.0 APPARATUS 7-8

4.1 INDUSTRIAL APPARATUS 9

5.0 PROCEDURE 10-11

6.0 DISCUSSION 12-8

8.0 REFERENCES 19

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1.0 TITLE
ADVANCED MANUFACTURING (injection molding)

2.0 OBJECTIVES
1) To learn processing techniques associated with injection molding.

3.0 INTRODUCTION

Injection molding is a process of shaping plastic by melting it and injecting it into a

predesigned mold. The process was first designed in the 1930s and was originally based on
metal die casting designs. It offers many advantages to alternative manufacturing methods,
including minimal losses from scrap (since scrap pieces can be melted and recycled), and
minimal finishing requirements. This process differs from metal die casting in that molten
metals can simply be poured; plastic resins must be injected with force. The process uses
large injection molding machines, which advance the resins through six major processes to
produce everything from computer parts to plastic Halloween spiders. Although this machine
is a complex piece of equipment, it consists of two basic elements: the injection unit and the
clamping unit. Injection molds themselves can be surprisingly expensive,. If the desired part
quantity is great enough, however, the mold cost becomes relatively insignificant, and the
resulting plastic parts are very reasonably priced. This method of molding can be used with a
variety of plastic resins. The most popular resins for this type of molding include
polypropylene (PP), polyethylene (PE), and ABS.

3.1 INJECTION MOLDING BACKGROUD

Plastic injection molding is the process of heating raw material (plastic resin in pellet
form, in our case) to its melting point, forcing the viscous material into a mold, and allowing
it to cool into a hardened shape.

Injection molding is one of the prime processes for producing plastics. It is a fast
process and is used to produce large numbers of identical items from high precision
engineering components to disposable consumer goods. Injection molding produce all
plastics products from micro parts to large components such as bumpers and wheelie bins.
The flexibility in size and shape possible through use of this process have consistently

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extended the boundaries of design in plastics and enabled significant replacement of
[3]
traditional materials thanks to light weighting and design freedom .

The machine works such that the material is introduced into the injection molding
machine via a hopper. The injection molding machine consists of a heated barrel equipped
with a reciprocating screw which driven by a hydraulic or electric motor and feeds the molten
polymer into a temperature controlled split mound via a channel system of gates and
runners .

A parting line, sprue, gate marks, and ejector pin marks are usually present on the
final part. None of these features are typically desired, but are unavoidable due to the nature
of the process. Gate marks occur at the gate which joins the melt-delivery channels (sprue
and runner) to the part of forming. In spite of the relatively expensive tooling cost, injection
molding remains the most popular manufacturing process for plastic materials in mass
production, thanks to its low operational cost, high throughput, and the flexibility to make
parts with complex shapes.Polymers commonly used for injection molding include

Polystyrene (PS)
Acrylonitrile Butadiene Styrene (ABS)
Polyamide (PA)
Polypropylene (PP)
Polyethylene (PE)
Polyvinylchloride (PVC)
Other short fiber reinforced plastics

Figure 3.1 : Injection moulding

Parting line and ejector pin marks result from minute misalignments, wear, gaseous
vents, clearances for adjacent parts in relative motion, and/or dimensional differences of the
mating surfaces contacting the injected polymer. Dimensional differences can be attributed to
non-uniform, pressure-induced deformation during injection, machining tolerances, and non-
uniform thermal expansion and contraction of mold components, which experience rapid

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cycling during the injection, packing, cooling, and ejection phases of the process. Mold
components are often designed with materials of various coefficients of thermal
[6 ]
expansion .

These factors cannot be simultaneously accounted for without astronomical increases

in the cost of design, fabrication, processing, and quality monitoring. The skillful mold and
part designer will position these aesthetic detriments in hidden areas if feasible. Injection
molding uses a ram or screw-type plunger to force molten plastic material into mold cavity
and it solidifies into a shape that has conformed to the contour of the mold. It is most
commonly used to process both thermoplastic and thermosetting polymers, with the former
being considerably more prolific in terms of annual material volumes processes

3.2 INJECTION MOLDING THEORY

As for the injection molding machine, several types such as plunger type, plunger
preplasticating type, screw preplasticating type and in-line screw type, etc. have been
developed so far, but presently the in-line screw type injection molding machine as shown in
Figure has become the main type.

Figure 3.2 : Theory of the in-line screw type injection molding machine

In injection moulding, a plastic is heated to a molten state and then forcefully pushed
through a nozzle into a heated mold, typically made of stainless steel (though the ones used in
this lab are aluminum). The plastic enters the mold through the sprue, then through runners
which distribute the molten plastic evenly to all cavities in the mold. The mold cavity is
connected to the runners via a gate .These extra pieces may be later removed, chopped up and
recycled back into the machine (called regrind). The mold is used to create the desired
resulting part shape and may consist of two or even three pieces.

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 The two types of injection molding typically used are screw plunger and plunger. In
either case, the plastic, usually in the form of pellets, is fed in through a hopper in the top of
the barrel and melted in the barrel. It is next forced into mold through the heated barrel.In the
screw plunger method, the faster of the two methods (Figure 4-a), a screw is used to evenly
distribute the heat to the plastic pellets, causing them to melt more quickly. The screw can
also be used to mix in any additives that could cause the polymer to change color.

4.0 Apparatus

1. Injection Molding Machine

2. Green Pigment.
3. Machine to recycle the green pigment.
4. Chamber for producing product .
5. Hopper.
6. Control Unit
7. Mold.

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Figure 4.1: Green Pigment Figure 4.2: Machine to recycle the green pigment

Figure 4. 3: Chamber for producing product Figure 4.4: Hopper

Figure 4.5: Control Unit Figure 4.6 : Mold

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 4.1 Industrial Apparatus

Figure 4.1.1: Injection Moulding Machine

Figure 4.1.2 : CW Engineering injection moulding machine

Advantage:

Automated injection molding

Automated, computer aided insert molding
Wide selection of materials such as nylon, polycarbonate, LCP, polyester.
Customized Designs

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5.0- EXPERIMENTAL PROCEDURE

1. The injection moulding machine is set up at the required temperature and pressure by
control unit.

Figure 5.1 Control Unit

2. Two cups of white beads were mixed together with the colour pigments.
3. The green pigments are used and weighed by 10% from the amount of high impact
polystyrene by using weighing scale.

4. The high impact of polystyrene and the green pigments are mixed and stirred.

5. After the temperature and pressure of the machine have reached at the desirable scale,
the excess materials that have been used before is removed.

6. All the mixture of the plastic pallet is poured into hopper.

7. The safety door is closed before starting the process.

Figure 5.2:Safety Door

8. The machine is ran the process of clamping, injection, cooling and ejection.

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 Figure 5.3: Molding

9. The safety door is opened as the final product taken.

Figure 5.4: Final product

Injection Molding Product:

Gate

Runn
er

Spru
e

Figure 5.5 : final product.

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GROUP 2 A
INDIVIDUAL
DISCUSSION

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 Discussion Muhd
Hadrami Hamdan

2015135647
1. Based on June 2016 manufacturing question number 4 (C,D).
c. With aid of sketches , describe the operation of making drinking plastic bottle?
1. plastic is forced into the mold is by inject injection molding into a parison,
2. blow molding filling the plastic with air then taking shape of mold . shape.

d.Select and state 4 defects and their causes that normally occurred during plastic injection
molding?

1. Flow Lines: commonly off-toned in color, caused by the varying speed at which the
molten plastic flows as it changes direction through the contours and bends inside the
mold tool.

2. Sink Marks: Rapid cooling of plastic into mold therefor plastic solidify rapidly and
not filling the mold shape

3. Vacuum Voids: are pockets of air trapped within or close to the surface of an injection
molded prototype.

4. Surface Delamination: pockets of air trapped within or close to the surface of an

injection molded prototype. Caused by uneven solidification between the surface and
the inner sections of the prototype.

5. Weld Lines : a line that appears in a part where molten plastics meet each other as
they flow from two different parts of the mold.

6. Short Shots

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 7. Warping

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MUHD HADRAMI HAMDAN
TYPE OF DEFECTS
Sink Marks
Sink marks
are small
craters or
depressions
that develop in thicker areas of
the injection molded prototype
when shrinkage occurs in the
inner portions of the finished
product.
Vacuum Voids
Vacuum
voids are pockets of air trapped
within or close to the surface of
an injection molded prototype.
Surface Delamination
Surface
delamination is a condition
where thin surface layers
appear on the part due to a
contaminant material.
Short Shot
a molding
shot falls
short. This means that the
molten plastic for some reason
does not fully occupy the mold
cavity or cavities, resulting in a
portion where there is no
plastic. The finished product
becomes deficient because it is
incomplete.
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2015135647
CAUSE OF DEFECT
when the cooling time or the
cooling mechanism is
insufficient for the plastic to
fully cool and cure while in the
mold. They can also be caused
by inadequate pressure in the
cavity, or by an excessive
temperature at the gate.
Vacuum voids are often caused
by uneven solidification
between the surface and the
inner sections of the prototype
Foreign materials that find
their way into the molten
plastic separate from the
finished product because the
contaminant and the plastic
cannot bond. The fact that they
cannot bond not only has an
affect on the appearance of the
prototype, but also on its
strength.
Incorrect calibration of the shot
or plasticizing capacities can
result in the plastic material
being inadequate to fill the
cavities. If the plastic is too
viscous, it may solidify before
fully occupying all the cavities
and result in a short shot.
Inadequate degassing or gas
venting techniques can also
result in short shots because air
is trapped and has no way to
escape.
OVERCOME
1.Mold temperatures should be
lowered, holding pressure
increased, and holding time
prolonged to allow for more
adequate cooling and curing.
2.Reducing the thickness of the
thickest wall sections will also
ensure faster cooling and help
reduce the likelihood of sink
marks.
1.Locate the gate at the thickest
part of the molding.
2.Switch to a less viscous
plastic. This will ensure that
less gas is trapped as air is able
to escape more rapidly.
3.Increase holding pressure as
well as holding time.
1.Pre-dry the plastic properly
before molding.
2.Increase the mold
temperature.
3.Smooth out the corners and
sharp turns in the mold design
to avoid sudden changes in
melt flow.
1.Select a less viscous plastic
with higher flowability. This
plastic will fill the hardest-to-
reach cavities.
2.Increase mold or melt
temperature so as to increase
flowability.
3.Account for gas generation
by designing the mold so that
gas is not trapped within the
mold and is properly vented.
2014246234
MOHD FADZIL BIN YAACOB
Discussion

a) Past Year Question of June 2013

Q: Identify two (2) common defects that would occur during plastic injection moulding
process and suggest how to avoid them.

A: Firstly, the common defect that would occur is the warping. Warping is the deformation
that occurs when there is uneven shrinkage in the different parts of the molded component.
The result is a twisted, uneven, or bent shape where one was not intended. Warping is usually
caused by non-uniform cooling of the mold material. Different cooling rates in different parts
of the mold cause the plastic to cool differently and thus create internal stresses. These
stresses, when released, lead to warping. The way how to avoid warping is firstly ensure that
the cooling time is sufficiently long and that it is slow enough to avoid the development of
residual stresses being locked into the part. Then, design the mold with uniform wall
thickness and so that the plastic flows in a single direction.Besides, select plastic materials
that are less likely to shrink and deform. Semi-crystalline materials are generally more prone
to warping.

Secondly, the common defect is flash. Flash is a molding defect that occurs when some
molten plastic escapes from the mold cavity. Typical routes for escape are through the parting
line or ejector pin locations. This extrusion cools and remains attached to the finished
product. Flash can occur when the mold is not clamped together with enough force (a force
strong enough to withstand the opposing forces generated by the molten plastic flowing
through the mold), which allows the plastic to seep through. The use of molds that have
exceeded their lifespan will be worn out and contribute to the possibility of flash.
Additionally, excessive injection pressure may force the plastic out through the route of least
resistance. The defect can be avoided by increasing the clamp pressure to ensure that the
mold parts remain shut during shots. Then, ensure that the mold is properly maintained and
cleaned (or replaced when it has reached the end of its useful lifespan). Besides, adopt
optimal molding conditions like injection speed, injection pressure, mold temperature, and
proper gas venting.

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MOHD FADZIL BIN YAACOB
2014246234

b) The part of injection units (Barrel)

The injection unit is much like an extruder. It consists of a barrel that is fed from one end
by a hopper containing a supply of plastic pellets. The barrel is the part of the injection
molding machine that heats the plastic material into a molten state. This allows the plastic to
flow through the barrel, where the screw inside the barrel injects the plastic into molds or
cavities in the Clamping Unit. The temperature in the barrel needs to be properly regulated to
maintain the appropriate temperature for different types of plastic material. For example, a
Nylon base plastic will require a higher temperature than an HDPE plastic. Finally, the
process reaches the Clamping Unit.

The screw inside the barrel which operation surpasses that of an extruder screw in the
following respect; in addition to turning for mixing and heating the polymer, it also acts as a
ram which rapidly moves forward to inject molten plastic into the mold. A nonreturn valve
mounted near the tip of the screw prevents the melt from flowing backward along the screw
threads. Later in the molding cycle the ram retracts to its former position. Because of its dual
action, it is called a reciprocating screw, which name also identifies the machine type. Older
injection molding machines used a simple ram (without screw flights), but the superiority of
the reciprocating screw design has led to its widespread adoption in todays molding plants.

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DISCUSSION(MUHAMAD AMMAR B. ABDUL RAHMAN) 2015166041

BINDERS

Binder is a materials that hold together other materials to form bonding between other
materials or being called cohesive. The cohesive can be form either mechanically or
chemically. When bind fibres,filler powder, and other particles added into it,binder will
harden by chemical or physical process. Binder can be classified as organic and
inorganic.The classification of binder can based on their field use such as non-
hydraulic,hydraulic,acid resistant and autoclave according to their chemical resistance.

Physical properties
Some binder such as cements has high comprssive strength but low tensile strength and need
to reinforced with fibrous materials. Resin is one example of binder that may be tough and
possibly elastic but cannot bear compressive and tensile force.

Uses
In art usually in painting it be use to hold together pigments and sometimes filling materials
to form paint,pastel and other materials. In building construction,cement being use to build
concrete. In explosive, wax or polymers are often use as binders for plastic explosives.In
cooking various edible thickening agent use as binder(tapioca flour,lactose,sucrose)

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FINAL QUESTION (JANUARY 2012)
MUHAMAD AMMAR B. ABDUL RAHMAN 2015166041

QUESTION 7
a) Plastics can be grouped into thermoplastics and thermosetting. Describe and
diffrentiate between thermoplastics and thermosetting plastics.

THERMOPLASTICS THERMOSETTING

Require heat to form and retain it Formed into permanent shape and
shape when cooled cured by chemical reaction.

Can be reheat and reform in new Cannot be remelted and reformed

shape a number of times without into another shape but decompose
significant change in their property being heated to too high temperature.

Most thermoplastic consist of very Cannot be recycled.

long main chain of carbon atom
covalently bonded together.

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8.0 REFERENCES

1. Jonathan Band; Masanobu Katoh (2011). Interfaces on Trial 2.0. MIT Press.
p. 136,.ISBN 978-0-262-29446-1.
2. Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994). Manufacturing Processes
Reference Guide. Industrial Press, Inc.
3. Chikofsky, E. J. & Cross, J. H., II (1990). "Reverse Engineering and Design
Recovery: A Taxonomy". IEEE Software 7 (1): 1317. doi:10.1109/52.43044.
4. Vinesh Raja; Kiran J. Fernandes (2007). Reverse Engineering: An Industrial
Perspective. Springer Science & Business Media. p. 3. ISBN 978-1-84628-856-2.
5. http://www.bpf.co.uk/plastipedia/processes/injection_moulding.aspx
6. https://www.xcentricmold.com/about-injection-molding.php
7. Serope Kalpakjian; Steven R. Schmid (2014). Manufacturing Engineering and
Technology, Seven Edition.
8. https://www.xcentricmold.com/about-injection-molding.php
9. http://www.nikonmetrology.com/en_EU/Products/Coordinate-Measuring-Machines
10. http://www.hexagonmi.com/products/coordinate-measuring-machines

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