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Fabrication of Pneumatic Plastic Injection Moulding Machine Projects
Fabrication of Pneumatic Plastic Injection Moulding Machine Projects
INTRODUCTION
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1.1 Fabrication
The polymer material are converted into plastics and used as tubes, sheets,
foams, rods, adhesives, etc., The theological properties, softening, tempering,
stability, the size and shape are important in describing the method. These
methods are different kinds of plastics. Broadly speaking the method may be
discussed under the following headings,
a. Moulding Process
b. Foaming Process
1.1.1. Moulding process:
In this process the plastics are fabricated under the effect pressure and
heat and both thermoplastics and thermosetting plastics may be starting materials.
Thermoplastics are produced by this method. In this the material is softened by
heating and the hot softened plastic is forced under high pressure into the mold,
when it is set by cooling and the mold is.
This involves the blowing of a volatile organic liquid, which is entrapped into a
polymer network resulting in the formation of foamed plastics. Foamed
polystyrene are produced in this process.
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CHAPTER2
2.1 Components
The main components of the pneumatic injection moulding
machine are,
• Pneumatic Double acting Cylinder
• Hooper
• Barrel
• Heating Coil and regulator
• Direction control Valve
• Flow control valve
• L-Angle
• Nozzle
• Die and
• Hose connectors
This can only be done at the end positions of the piston stock. In all
intermediate position a separate externally mounted cushioning derive most be
provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end
of the stock is required. As a result the sit in the cushioning chamber is again
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compressed since it cannot escape but slowly according to the setting made on
reverses. The air freely enters the cylinder and the piston stokes in the other
direction at full force and velocity.
b. Hooper:
The hopper is used to pour the plastic raw materials in to the barrel.
c. Barrel:
The barrel is used to hold the molten and unmated plastic raw materials.
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f. Flow Control Valve:
These are used to control the rate of flow of a fluid through the valve.
A directional control valve on the receipt of some, external signal, which might be
mechanical, electrical or a fluid pilot signal, changes the direction of stops, or
starts the flow of fluid in some part of the pneumatic/hydraulic circuit. They can
be used to carry out such functions as:
1. Controlling the direction of motion of an actuator
2. Selecting alternative flow paths for a fluid.
3. Stopping and starting the flow of fluid
Purpose: This valve is used to speed up the piston movement and also it acts as a
one way restriction valve which means that the air can pass through only one way
and it can’t return back.
By using this valve the time consumption is reduced because of the faster
movement of the piston.
g. L-angle:
Mild steel ‘L’ type angle is used to fabricate the frame to mount
the all the parts of the injection molding unit.
h. Nozzle:
The nozzle is used to inject the molded plastic material into the die.
i. Die:
The die is used to produce the required product. By using different
Types of die different products can be formed.
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j. Hose connector:
In our pneumatic system there are two types of connectors used; one is
the hose connector and the other is the reducer.
Hose connectors normally comprise an adapter (connector) hose nipple and
cap nut. These types of connectors are made up of brass or Al or hardened steel.
Reducers are used to provide inter connection between two pipes or hoses of
different sizes. They may be fitted straight, tee, “V” or other configurations.
These reducers are made up of gunmetal or other materials like hardened steel etc.
Hoses used in this pneumatic system
are made up of polyurethane. These hoses can with stand at a maximum pressure
level of 10 kg/cm2.
Piston : EN – 8
Media : Air
Temperature : 0-80 º C
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2.2.2 Solenoid Valve
Size : 0.635 × 10 ¯² m
Part size : 0.635 × 10 ¯² m
Max pressure range : 10 × 10 ⁵ N/m²
Quantity : 2
2.2.4 Hoses
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2.3General Machine
Specifications
a. Drill unit
b. Clamping unit
c. Pneumatic unit
d. General unit
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2.4 Design Calculation
Pressure applied :
8 × 105N/m²
Max pressure applied
rodin(D)
the cylinder (p) :
Diameter of piston : 4 × 10-2 m
Area of cylinder (A) : 12.56 × 10⎯⁴ m²
= 10.48 × 102N
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2.5 DESIGN DRAWINGS
FIG 1
L-BEAM
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FIG 2
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BARREL
FIG 3
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SUPPROT FOR BARREL
FIG 4
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SUPPORT FOR VICE
FIG 5
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ROTATING HANDLE FOR FIXTURE
FIG 6
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PNUEMATIC CYLENDER
FIG 7
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ASSAMBLY VIEW
FIG 8
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LAYOUT DIAGRAM
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CHAPTER-3
a. Working Stress:
The internal resistance must be equal to the external load if the body is to be in
equilibrium. This internal resistance per unit area is called intensity of stress or simple
stress.
Stress = Internal resistance / Area of cross section.
b. Working Strain:
The deformation per unit length is called strain. Strain has no unit since it is only a
ratio. Strain = Change in length / Original length
c. Elasticity:
The property of a material body to regain its original condition on the removal
of the deformation forces is called elasticity.
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d . Hooke’s law:
It states that when a material is loaded with in its elastic limit the stress is proportion
to the strain.
e. Bulk modulus:
The ratio of the change in the volume to the original volume of the body is known
as the volume strain or the bulk strain.
The ratio of the bulk stress to the bulk strain of a body is called the bulk modulus.
f. Poisson’s ratio:
With in the elastic limit the lateral strain bears a constant ratio with the linear
strain. The ratio is called the Poisson’s ratio and is denoted by 1/m
g. Factor of Safety:
The ratio of ultimate stress to working stress is known as factor of safety.
Factor of safety = Ultimate stress / Working stress.
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CHAPTER4
INTRODUCTION TO POLYMERS
The term polymer denotes a molecule made up of the repetition of simple unit
monomers. Plastics are produced from the polymers by the combination of latter with
compounding of the plastics.
4.1.1 Polyethylene:
This polymer is obtained from ethylene, which is a by product in petroleum
industries. The imperial chemical industries produced polyethylene by polymerization of
ethylene.
There are two types they are,
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a. Low density
polyethylene.
b. High density
polyethylene.
4.1.2 Polypropylene:
The polymer is obtained from polymerization of propylene using co-ordination
catalyst with the press up to 5 atmospheres & at temperature range (40-110) yield
polypropylene.
4.1.3 PolymethylMethacrylate:
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CHAP
TER5
CLASSIFICATION OF POLYMERS
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5.2 Components of plastics
The following materials are thermosetting plastics:
5.2.1 Fillers:
They are added to the polymers to impart special properties and also to reduce the
cost of finished products.
5.2.2 Plasticizers:
They are added to the polymers to increase plastic property and induce more
flexibility to the plastics.
5.2.3 Colorants:
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They are added to provide pleasing colors to the plastics. These decorative
colors are provided by both organic dye stuff and inorganic salts.
5.2.4Lubricants:
These substances are used to get a good finishing. These are added to most of
the polymers to improve flow within processing machineries and to reduce friction.
5.2.5 Stabilizers:
The polymers may undergo degradation with the formation of conjugated double
bonds along the chain, which result in declaration of the polymer. To avoid this suitable
materials are added, called stabilizers.
5.2.6 Antioxidants:
Polymers are protected against oxidative degradation by incorporating certain
compounds called antioxidants.
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CHAPTER6
POLYMER PROCESSING
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CHAPTER7
PROCESSING TECHNIQUES
The very fact that polymeric materials are used in many forms such as rods, tubes,
sheets, foams, coatings or adhesives and also as moulded and fabricated articles implies
that there must be a variety of ways in which the compound resins can be processed and
converted in then finished products. A majority of the articles are either moulded or
fabricated, while many others are made by casting liquid pre polymers into a mould and
allowing them to cure of cross-link. Fibers are made by a process known as spinning.
Today, there are many processes and automatic machines for this purpose, the
important ones being calendaring, casting, compression moulding, injection moulding,
extrusion moulding, blow moulding, cold forming, thermoforming, foaming, reinforcing,
melt spinning, dry spinning and wet spinning.
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CHAPTER8
The injection moulding process is best suited for producing articles made of
thermoplastic materials. Here, the equipment cost is relatively high but the main
attraction is the amenability of the injection moulding process to a high production rate.
In injection molding, a definite quantity of molten thermoplastic material is injected
under pressure into a relatively cold mold where it solidifies to the shape of the mould.
The injection moulding machine is shown in the process consists of feeding the
compounded plastic material as granules, pellets or powder through the hopper at
definite time intervals into the hot horizontal cylinder where it gets softened. Pressure is
applied through a hydraulically driven piston to push the molten material through a
cylinder into a mould fitted at the end of the cylinder. The molten plastic material from
the cylinder is then injected through a nozzle material from the cylinder is then injected
through a nozzle into the mould cavity.
The mould used, in its simplest form, is a two-part system. One is a movable part
and the other stationary. The stationary part is fixed to the end of the cylinder while
the movable part can be opened or locked on to the stationary part. The locking device
has to be very skillfully designed in order to withstand high operating pressures.
Furthermore, a proper flow of the molten material to the interior regions of the mold is
achieved by preheating the mould to an appropriate temperature. Usually, this
temperature is slightly lower than the softening temperature of the plastic material
undergoing moulding.
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After the mould’s filled with the molten material under pressure, then it is either
cooled by cold water circulation or air and then opened so as to eject the molded article.
The whole cycle could be repeated several time either manually of in an automated mode.
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CHAPT
ER-9
WORKING PRINCIPLE
The Pneumatic injection moulding process is best suited for producing articles
made of thermoplastic materials. Here, the equipment cost is relatively high but the main
attraction is the amenability of the pneumatic injection moulding process to a high
production rate. In pneumatic injection molding, a definite quantity of molten
thermoplastic material is injected under pressure into a relatively cold mold where it
solidifies to the shape of the mould.
The pneumatic injection moulding machine is shown in the process consists of feeding
the compounded plastic material as granules, pellets or powder through the hopper at
definite time intervals into the hot molten plastics. Pressure is applied through a
pneumatically driven piston to push the molten material through a barrel into a mould
fitted at the bellow the nozzle. The molten plastic material from the Hooper is then
injected through a nozzle material. The mould used, in its simplest form, is a two-part
system. One is a movable part and the other stationary. The stationary part is fixed to the
end of the cylinder while the movable part can be opened or locked on to the stationary
part.
By using a mechanical locking device, the mould is proper held in position as the
molten plastic material is injected under a pressure as high as 15×10-2 N/m2. The
locking device has to be very skillfully designed in order to withstand high operating
pressures. Furthermore, a proper flow of the molten material to the interior regions of
the mold is achieved by preheating the mould to an appropriate temperature. Usually,
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this temperature is slightly lower than the softening temperature of the plastic material
undergoing moulding.
After the mould is filled with the molten material under pressure, then it is cooled
by cold water circulation and then opened so as to eject the molded article. The whole
cycle could be repeated several times by the same procedure. The double acting
pneumatic cylinder is used to inject the molten plastic material into the die.
The flow control valve is used to control the flow of air in to the cylinder. The
direction control valve is used to control the direction of piston movement. These all
valves are already explained in the above chapter.
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CHAPTER-10
FABRICATION OF MECHINE
The injection moulding is widely used in the modern age. The human beings
make use of one or other material made up of plastics in their routine life. The frame is
designed like a chassis frame with the help of L angle. The frame is finished accurately
& it has provisions to mount the components. There is also a provision to mount the
channels on which the die locking & Die setting system works
The threads are formed on the shafts. The two shafts are mounted on the either
side of the channel. On one side square thread is made & thread is made on another
side. The shafts are tightened by using of hardware. The two shafts hold two plates by
drilling & boring the plate according to the required size. The plates are fixed up and
down on the shafts. There is also two shafts to hold two plates rigidly. The upper plate
holds the Rack & pinion gear mechanism, Rotating wheel, plunger. The bottom plate
holds Hooper, spring, Barrel, nozzle, Heating Coil, Heating Coil Regulator is used to
regulate the temperature of Heating coil.
The rocker & pinion is the main part of the Injection system in injection molding.
The plastic cannot be injected without Rack & Pinion. The Rack & Pinion makes the
operation of Injecting system.
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10.1.1 Classification of
Gears:
a. Spur gear
b. bevel gear
c. worm and worm wheel
d, helical gear
10.1.2 Construction of
Gears:
a. Pitch Circle:
The pitch cycles are the outlines of the imaginary smooth rollers or discs.
c. Addendum Circle:
A circle passing through the tips of the teeth is called addendum circle.
d. Addendum:
The part of the tooth out side the pitch circle is called the addendum.
e. Dedendum Circle:
A circle passing through the roots of the teeth is called dedendum circle.
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f. Dedendum:
The distance between center to center of two teeth measured along the arc of the
pitch circle is called his circular pitch.
g. Module:
Module is the length of the pitch circle dia per tooth & is given by.
10.1.3 Working:
A gear whose pitch circle dia is infinity is called as rack. The small gear which
meshes with rock is called the pinion. Rock & pinion gear arrangement is used to
convert the linear motion into rotary one & vice versa.
Rotating wheel:
The rotating wheel is arranged with the pinion. The Bearings are attached on
either side of the pinion to give the support to the wheel rod. By rotating of the wheel.
The plunger moves up & down.
Plunger:
The plungers are attached with the rack. By making external threads on rack and internal
threads on plunger. The plunger is used to compress the molten plastic.
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a. Helical spring:
A Helical spring is formed by bending a wire around a mandrel in the form of a
helix. The coil in a helical spring is subjected to torsion and hence its known as Torsion
spring. Helical spring of two types.
10.3 Thread:
When the job is rotated the tool is automatically moved by the lead screw in the
longitudinal direction. The longitudinal feed should be equal to the pitch of the thread to
be cut per revolution of the work. The lead screw has a fixed pitch. So, a ratio between
the rotation of the head stock spindle and the longitudinal feed is found out. The lead
screw is connected by carriage by engaging the half nut lever. So, when the head stock
spindle rotates the lead screw rotates at same speed the pitch of the work will be equal to
the pitch of the lead screw. So far obtaining different pitches on the work, the speed of the
lead screw can be changed by fixing proper change gears between head stock spindle and
leadscrew.
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CHAPTER11
BILL OF MATERIALS
Table 1.Component
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CHAPTER12
COST ESTIMATION
12.1Material Cost:
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CHAPTER13
13.1 Advantages
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13.2Applications
13.3 Disadvantages
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CHAPTER14
CONCLUSION
Due to it’s low cost, this working model can be successfully inducted in small
scale moulding units and can be used to manufacture small plastic component at an
acceptable cycle rate within an effective cost component.
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As exhibited in the above tables, the newly fabricated machine has brought in a
considerable reduction in the cost component when compared to existing cheapest
machine available in the market
Thus we have successfully fabricated a machine which can remove the initial
starting cost hurdle and on basic standards cater to the needs of a small scale industry. After
the completion of fabrication the machine is tested with a wide variety of acrylic plastic
materials over a variable temperature range and plastic ring as the standard product from
the die is manufactured.
This prototype can be subjected to further improvement in product cycle time with
the compromise of the cost based component. A few of the changes which can be brought
about are:
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REFERE
NCES
4. McGraw Hill Book Company, Compressed Air Operations Manual, ISBN 0-07-
147526-5.
8. Society for Plastic Engineers, Journal of Injection Molding Technology, ISSN: 1533-
905X.