Final Project Nithin KP

Project Report
GOVT. TOOL ROOM &TRAINING CENTRE

(An Indo-Danish Project)
ON
“MANUFACTURING OF TWO CAVITY
PLASTIC INJECTION MOULD”
ON
“CAP FILTER INTERMEDIATE SCMT+CB”
BY
NITHIN K.P.
28TH BATCH
UNDER THE GUIDANCE OF
Mr. ARAVIND.D. Sir
GOVT. TOOL ROOM AND TRAINING CENTRE
MYSURU-16
Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

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CARRIED OUT AT:
3D PRECISION
# 65/2, 3RD MAIN ROAD,KAVERIPURA, NEAR
RAMAMANDIRA ROAD,KAMASHIPALYA,MAGADI MAIN
ROAD BANGALORE – 560 079
SUBMITTED BY:
Mr. NITHIN K.P.
REG. NO: 1032835
GOVT. TOOL ROOM & TRAINING CENTRE
(AN INDO-DANISH PROJECT)
MYSORE
SUBMITTED TO:
GOVT. TOOL ROOM AND TRAINING CENTRE
(AN INDO-DANISH PROJECT)
PLOT NO. 93 &94, BELAGOLA INDUSTRIAL AREA, K.R.S. ROAD
MYSORE-570 016
For Partial Fulfillment Of Sessional Requirement For The Award Of
“Diploma in Tool and Die Making”

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This is to certify that the project titled

“MANUFACTURING OF TWO CAVITY INJECTION
MOULD”for“CAP FILTER INTERMEDIATE SCMT+CB”has
been successfully carried out by Mr.NITHIN.K.P. having Reg. No.
1032835 in partial fulfillment of the sessional requirement for the award
of “Diploma in Tool and Die Making”

at GOVT. TOOL ROOM& TRAINING CENTRE, MYSURU during the
year 2017- 2018
PROJECT GUIDE PRINCIPAL

Mr.ARAVIND.D. Sir Mr.VENKATESH.P.S.Sir

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EVALUATION SHEET
NAME : NITHIN.K.P. BATCH : 28TH BATCH
REG.NO :1032835 YEAR : IV YEAR
SL. MARKS MARKS

DESCRIPTION
No. ALLOTTED OBTAINED
01. COMPONENT ANALYSIS 30
02. TOOL DESIGN ANALYSIS 50

ESTIMATION AND
03. 40
COSTING
TOOL MANUFACTURING
04. 50
PROCESS
05. TRAILS 10
06. DEFECTS & REMEDIES 10
07. PRESENTATION 10
TOTAL 200
SIGNATURE OF THE EVALUTOR
REMARKS:

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My Sincere Heartfull thanks to our Sir Mr.YOGISH.C.S. Proprietor, for

providing opportunity to complete project work at 3D PRECISION
Bangalore.
I wish to express my deep sense of gratitude to

Mr.PRAKASH.K. Project guide from 3D PRECISION who gave their
constant encouragement and assistance during the project period for
completing this project.
My special thanks to Mr.SRINIVASA.J. Proprietor of 3D PRECISION,

for the help & guidance received from him in the execution of this project
work. I am thankful to all the management members and workers who co-
operated with me in completing this project successfully.
I wish to thank Mr. SRINIVAS BHAT.S. (Tool Room) whose timely

advice and suggestions were helpful towards the quick & successful
completion of the project work.
Lastly I thank one & all who had their contribution directly or indirectly for
period completing this project

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(A Govt. of Karnataka Society)

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GOVERNMENT TOOL ROOM &TRAINING CENTRE(An
INDO DANISH PROJECT) established was in the year of 1972, with
the assistance of “GOVT. OF DENMARK”.It has become one of the
Leading tool room in imparting and reaching international standards in
manufacturing processes.
Government Tool Room and Training Center is one of the

premier institutions in the state Karnataka, devoted to training and
technological excellence in the field of tooling.
 It has most up-to- date technology and training program to meet the need
of the present competitive world. It renders training in Diploma In Tool
& Die Making (DTDM), Diploma In Precision Manufacturing (DPM),
Diploma In Mechatronics, Post Diploma In Tool Design, B.E. In
Precision Manufacturing, B.E. In Tool Engineering, M.Tech. In Tool
Engineering and CAD/CAM etc….
GT&TC is equipped with product development and component

manufacturing facilities. It has also embarked upon Research and
Development activities in advanced tooling and machining techniques. It
also has been constantly working for the development of the component
and system for various R&D organizations with a view to faster self-
reliance and technological up gradation.
Apart from this other major activities of the centre are promotion of
purposeful technical education of the youth in India. By imparting the
highest degree of skill through job oriented training relevant fields. It is
also helping trainees to get exposure to the industries through In-plant
training. It has 20 sub centers.They are;

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GT&TC CENTRES IN KARNATAKA

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1972 Bangalore
1992 Mysore
1994 Hassan, Mangalore,Gulbarga
1995 Dandeli
1996 Hospet
1998 Belgaum, Hubli, Harihar
2000 Maddur, Kudalasangama
2005 Kanakapura, Lingasugur, Kolar
2007 Gundlupet, Humnabad, Kadur
2009 Tumkur
2010 Shimoga
Diploma in tool and die making is a job-oriented course in which you

become familiar with the later technological aspects by training. We are
trained in operation of the most sophisticated machines, designing and
manufacturing of injection moulds and press tools. We gain exposure in
CNC operation of milling, turning, jig boring, edm etc...
Using all the above mentioned resources, GT&TC has been providing Tool
Makers, Machinists and Tool Design Engineers to the tool industry from
the past two decades. Apart from providing tool makers to the industry, an
immense interest is also shown towards the customers, who approach and
their requirement is fulfilled.

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COMPANY PROFILE
3D PRECISION
(PLASTIC INJECTION MOULDS)
#65/2, 3RDMain Road Kaveripura,NearRammandira

Road, Magadi Main Road,Kamashiplaya
Bangalore – 560079
SRINIVASA .J.
YOGISH .C.S.
OFFICE PH : 080-23483719
E-mail: threed_precision@rediffmail.com
3dprecisions@gmail.com

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ABOUT 3D PRECISION
COMPANY LOGO
Introduction…
Provide the Paramount quality in precision Tooling, machining,

engineering & manufacturing “on-time”, “every-time”.
3D PRECISION established in March 2004 as a SSI Unit, we are one of

the leading names engaged in manufacturing, exporting and supplying a
wide range of Injection Moulds. Ever since our commencement, our
foremost motive is to attain maximum satisfaction of clients. For this
reason, we facilitate our clients with premium quality range of Products. By
understanding diverse requirements of various industries, we provide these
equipment in different specifications. We are capable of Product Modeling,
Mould Designing (3-D), Mould Manufacturing & Precision Components
supply. We can manufacture and deliver 5-6 injection moulds on an
average per month.

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We Have Become Foremost Choice Of Our Clients Due To Following
Reasons:
Dedicated set up to work for you round the clock.
Cost benefit due to less overhead and quality people.
One stop solution for Modeling, Designing, Manufacturing and
Production.
Good program managing capability.
Quick communication and updates from us.
We acquired huge base of clients in India due to ethical business practices,

quality range of products and competitive prices. Further, we have link-ups
with some of the reliable transport agencies, which enable us to deliver
products within committed time frame.
OUR VISION
Become Strategic Supplier To Customer By:
Create a stronger allegiance with our Customer & Project
Development.
Becoming a "Preferred Tooling Supplier" with all 1st & 2nd Tier
Suppliers.
Develop stronger relationships with all world leading industries with
unbeatable quality record and project timing.
COMPANY POLICIES
Our company policies are basically based on providing quality
products as mutually agreed to the satisfaction of the customer
irrespective of size of business.
Strive to enhance satisfaction by continuous improvement.
In pursuance with achieving quality standards the company has
recruited qualified and trained personal keen in achieving set quality
standards in work.

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OUR SERVICES
Plastic injection mould manufacturing we specialize in manufacture of
precision moulds for automotive, medical, white good products ranging
from small to medium size up to 350 ton. Custom moulding we take-up
manufacture of moulded parts in small and medium volume. Panel checker
our rich experience of 8 years enables us to build high precision cost
effective panel checkers, jigs and fixtures. Precision CNC machining State
of art machining centers, rich industrial experience and enthusiastic team
makes the best machined product customer expected
QUALITY POLICY….
All products and services provided by 3D PRECISION shall conform to
the requirements specified. Each employee is responsible for their output
procurement, production, support delivery service or management
provided. We are committed for continual improvement in all products
and services we deliver to maintain 3D PRECISION as the “Quality
leader in industry.”
MILE TONES
2004 -Added EDM with 3 axis
2005- Started mould manufacturing.
2006 - Added ZNC EDM with 3 axis
2006 -Added Grinding Machine
2006 -Added Milling(DRO) Machine
2007- Added Turning Machine
2011-Added CNC Milling Machine
2013 - Started bigger tool manufacturing up to 350 T moulds.
2017-Wanted Shifted to bigger area - 5500 sq feet as 2 units.

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TOOLING EQUIPMENT LIST
SL.NO MACHINES BRAND SPECIFICATION NO’S
01 Precision CNC BFW AGNI Table Size 650 x 1
BMV 45 TC 20 450x 500
02 Precision EDM ELECTRANICA Table Size 550 x 1
SMART ZNC 350x 350
03 Precision EDM ELECTRONICA Table Size 500 x 1
EMS 500x300 300x 300
04 Grinding JOHAN Table Size 150 x 1
Machine SHIPMAN 540 450x 200
05 Milling ARGO DRO Table Size 700 x 1
Machine MILLING 300x 350
06 Turning SEMSON Table Size 1M 1
Machine
07 Sensitive KMP Size 1/2 inch 1
Drilling
Machine
cOMPANY PHOTOS

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This project gives detailed knowledge of mould designing and

manufacturing, in step-by-step and difficulties involved in the same also
and skill of the toolmaker.
It is helpful to toolmaker, by providing basic knowledge about design

aspects, raw material selection, manufacturing processes, assembly etc. The
information present in this project tool can be asset not only to a toolmaker
but also to anyone concerned with tool making and production.
This project report gives ideas regarding the different factors to be

considered while starting off a new tool. It also helps a fresh toolmaker to
understand how to approach. It also gives a brief idea on the defects and
remedies after the components are moulded. It also gives information
about the estimation and costing, before and after manufacturing of tool.
The aim of project report is to explain the tool making processes from
foundation to the finish in a simpler and clear manner.

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Any products to be manufactured invariably require tools. Tool design and

development is a specialized and critical area. Since tool is an aid for mass
production, it should be accurate and economical for successful life of a
product. Tool making is combination of art and science. Moulds are used to
produce three-dimensional components. The economy and life of mould
reacts entirely on the designer and his role is very important.
The main objective of the project work is to have the detailed

knowledge of the mould making techniques, tool processing in properly
planned and projective manner.
The project work incorporates the details of studying the designs,

process planning and manufacturing of Injection mould, which this a
“TWO CAVITY INJECTION MOULD” of “CAP FILTER
INTERMEDIATE SCMT+CB”
This presents an idea of fundamental necessary for processing the tool

and to give a clear picture of manufacturing process, i.e., sequence of
machining operations involved during manufacturing and assembly of
moulds.

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SL.NO DESCRIPTION PAGE.NO
01 INTRODUCTION 18-30
02 COMPONENT ANALYSIS 31-40
03 TOOL DESIGN ANALYSIS 41-62
04 RAW MATERIAL SELECTION 63-71
05 ESTIMATION 72-79
06 TOOL TERMINOLOGY 80-84
07 PROCESS PLANNING 85-88
08 MANUFACTURING PROCESS 89-108
09 HEAT TREATMENT 109-112
10 POLISHING 113-117
11 INSPECTION 118-122
12 FINAL ASSEMBLY 123-130
13 TRY OUT 131-138
14 DEFECTS AND REMEDIES 139-143
15 COSTING 144-150
16 SAFETY RULES 151
17 CONCLUSION 152-153
18 BILOGRAPHY 154-155

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INTRODUCTION TO MOULD
Mould is a tool, designed to form the plastic component with desired shape
and size. The type of material to be moulded and the shape of the
component are the major factor, the choice of the material compresses of
forming of article to the desired shape by the process of applying heat and
pressure to the plastic material in a suitable mould and solidifying the
material in the mould.
The mould is an assembly of parts containing within it an impression into

which hot plasticized material is injected, and then maintained at certain
temperature and pressure, then cooled to get a commercially acceptable
shape. The impression may therefore as that part of the mould, which
imparts shape to the moulding.
WORKING PRINCIPLE:-
The impression of a mould is formed by two mould members, namely:
“The cavity portion of the mould, forms the external shape of the
moulding
The core portion of the mould, forms the internal form of the
moulding”
It consists of a core plate and a cavity plate. The temperature control

channels are present in both the plates of core plates and cavity plate. It also
consist of support pillars,ejectors,spruebush,sprue puller and a gate.

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INJECTION MOULDS ARE BROADLY CLASSIFIED
AS FOLLOWS
 2-Plate Moulds[Standard Mould].
 3- Plate Moulds.
 Runner Less Moulds.
 Insulated Runner Moulds.
 Stacked Moulds.
TWO PLATE MOULD:-
Two plate moulds are often referred to as cold runner moulds or
conventional moulds. This is to indicate their simple open and shut
setup with the molded part formed between two plates.
One section of the mould is called the stationary side or injection half.
This is the side of the mould that sits against the portion of the
moulding press that does not move and it is also normally the place
where the plastic enters (injected) into the mould.
The other section of the mould is called the moveable side or ejection
half. This is because it is retained on the portion of the moulding press
that moves back and fourth to open and shut the mould. Also included
with that movement of the press is a bar in the press that actuates the
ejection of the part from the mould.
Plastic pellets are melted by the injection moulding press in it's screw
and barrel area. The melting is caused both by external heating bands
around the barrel and by the screw turning within the barrel to causing
friction and there for sheer heat in the plastic.
The melted plastic that has moved down the length of the screw to an
area in front of the screw flights is pushed forward out or the barrel
(injected) and into the runner system of the mould.

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The plastic moves through the runner system in the mould and
through a gate area into the recess in the tool for the plastic part to be
formed.
CONCEPT DESIGN OF TWO PLATE MOULD

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INTRODUCTION OF INJECTION MOULDING

MACHINE
INJECTION MOULDING MACHINE:-

Injection is a process in which plastic material is heated and
softened in one part of machine, and then injected under high pressure into
the mould where it is cooled and hardened to form the component. In this
type repeatedly accurate components can be moulded. It is constant
process. Generally thermoplastics are used for injection.
An injection mould consists of two halves, namely top half and
bottom half. The top half consists of cavity, which gives the external
profile to the component. The bottom half consists of core, which gives
the internal profile of the component.
When the mould is closed in an injection machine, two halves
are aligned by the main guide pillars and bushes provided in the tool. The
melted plastic material is injected under pressure and speed from the
heated barrel by a feeding device. The injected material passes through the
sprue, runner and gate to fills the cavity. The material is converted to a
rigid state by the water or oil circulated through the cooling holes in tool.
Then mould is opened & ejector assembly is actuated to eject component.
COMMONLY USED MOULDING METHODS:

Compression Moulding
Transfer Moulding
Injection Moulding
Extrusion Moulding
Blow Moulding
Rotor Moulding
Calendering
Thermo forming

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VERTICAL INJECTION MOLDING MACHINE
ADVANTAGES OF INJECTION MOULDING MACHINE:-

1. Parts can be produced at high production rate.
2. Large volume of production is possible.
3. Parts can be achieved with good surface finish.
4. Relatively low labor cost per unit is obtained.
5. For many shape this process is more economical to fabricate.
6. Close dimensional can be maintained.
7. Parts can be moulded with metallic and non-metallic inserts.
8. Minimum scrap as runners, gates and sprue can be reground and used.
9. Different surface colors can be obtained.
10.Parts can be moulded in combination of plastics and fillers of glass,
asbestos, talc and carbon.

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DIS-ADVANTAGES OF INJECTION MOULDING MACHINE :-
1. Material wastage is high.
2. High tool cost.
3. Expensive equipments.
4. High maintenance cost.
5. High power consumption.
6. Skilled labour is required to manufacture the tool.
TYPE OF INJECTION MOULDING MACHINE

• Hand Injection Moulding M/C
• Plunger Type Injection Moulding M/C
• Reciprocating Screw Type Injection Moulding M/C
THE SEQUENCE OF OPERATIOIN IS AS FOLLOWS

The rotating screw transports the polymer granules from the hopper into the
injection cylinder, where they are heated, plasticized and vented. The screw
deposits the melt in infant itself moving backward to accommodate the
material as it builds up. To ensure optimum plasticization a counter-
pressure exerted on the screw usually shows this backward movement
down. As soon as sufficient polymer has been plasticized for one shot, the
screw stops its rotating movement and acting as a plunger, moves forward
forcing to supply the material into the mould.So Machines operating on this
principle are now most commonly used.

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These Are The Following Processes Which Occur During Injection:-
1. Plasticizing:-
Heating and melting of the granules of the plastics and venting of the
melt.
2. Injection:-
The melt is injected into the relatively cold mould under high pressure
while closed. Solidification of the polymer begins during the injection,
first at the cavity walls.
3. Cooling:-
Moulds are cooled in order to harden the material, which has been injected
into the mould, were the plastic material to be solidified to facilitate
ejection.
4. Mould Release:-
The mould will be opened, ejects the component & gets ready for the next
cycle.

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INTRODUCTION TO PLASTICS
Plastics are varied group of organic material having very high molecular
compounds and fillers plasticizers, hardness, strains and pigments,
lubricating and other substances which are derived from natural source like
Petroleum, coal, cellulose, salts, water, air and natural gas. They can be
easily fabricated and formed under the effect of pressure and heat. Plastic
differ from other material in a way that provide a combination of properties
rather than extremes of a single property. Plastics can be flexible light,
strong and transparent at the same time. Plastics have a wide range of
properties, and wide range of colors.
 Plastics – The unique class of wonder materials came into existence

by virtue of their superior performance and cost effectiveness over to
conventional materials.
 Over the years the applications spectrum of plastics have been
widened with the advent of new generation Polymers, blend alloys
and composites.
 Every day newer application are being promoted in all the key
sectors of Indian Economy , Automobiles, Agriculture, Aerospace,
Building & Construction, Infrastructure, Telecommunication, IT,
Medical & Bio Medical engineering, Packaging, etc.
 This in turn necessitates the need for different types processing
methods and machinery to produce quality plastics
products at affordable cost.

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PLASTIC ARE GROUPED INTO TWO CLASSES
 THERMO-PLASTICS
 THERMO SET-PLASTICS
THERMO-PLASTICS:-
Thermoplastics are the materials, which soften by the
application of heat and reharden when the heat is removed. Physical
changes can be seen but no chemical reaction takes places therefore these
plastics can be recycled any number of times.
TYPES OF THERMO-PLASTICS
HDPE - High density polyethylene
LDPE - Low density polyethylene
PA6 - Polyamide-6
PA66 - Polyamide-66
PC - Polycarbonate
PMMA - Polymethylmethacrylate
POM - Polyoxymethylene
PP - Polypropylene
PS - Polystyrene
PVC - Poly vinyl chloride

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SAN - Styrene acrylonitrile
ABS - Acrylonitrile butadiene styrene
THERMOSET-PLASTICS:-
Thermo set-plastics are the material that hardens by
the application of heat and further heating has no softening effect on it.
This plastics are strong hard and brittle. These materials cannot be
recycled.
TYPES OF THERMOSET-PLASTICS
Phenol pharmaldihide
Amino plastics
Melamine pharmaldihide
Polyester plastics
Silicon plastics
Epoxy plastics
Epoxy graphite
Poly butadiene glycol

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PLASTIC FLOWCHART

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CAP FILTER INTERMEDIATE

SCMT+CB

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COMPONENT ANALYSIS
The successful design of a component and the relevant tool to produce
such component largely depends on how we analysis it. That is both on
technical and commercial aspects. A brief analysis of the component
“CAP FILTER INTERMEDIATE SCMT+CB” is given below:
The Component Analysis Depends Upon:-

 Component Details
 Function of component
 Properties of component materials
 Critical dimensions of component

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COMPONENT DETAILS:-
 Name :CAP FILTER
INTERMEDIATE SCMT+CB
 Customer : A O SMITH
 Material : POLY PROPYLENE
 Grade Of Material : PP H110 MA
 Master Batch% : 2% (WHITE)
 Colour : NATURAL
 Shrinkage : 1-2.5%
 Melting Temprature : 130-171˚C
 Component Weight : 12gms
 Mould Temperature : 25-30 0C
 Finish :Textured
FUNCTIONS OF COMPONENT:-
The component ‘CAP FILTER INTERMEDIATE SCMT+CB’ is
a DOMESTICS products it is used for internal assembly. Since the
component is directly visible it has requirement of highly finished textured
surface.
The CAP FILTER INTERMEDIATE SCMT+CB is assembled in the
WATER FILTER for WATER PURIFIER.
IMPORTANT FACTORS OF THE COMPONENT:-

 The produced should be as per dimension specified and should be
within tolerance.
 The component should be free from flash, weld line, sink mark, short
shot, flow lines, etc.
 The engraved portion of the component should be mat finish.

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PROPERTIES OF THE COMPONENT

MATERIAL
Material Selected For The Component:-
Material selected for the component is an important factor as it
gives life and functional aspects of the component, plastic material
selected for this component is PP H110 MA.
The material of the product is PP (polypropylene). Flexural modulus

increases with added talc at the expense of tensile strength. Flexural
modulus should be around or above 1400MPa for a good product. In some
cases, impact modifiers are added to maintain the impact strength, but at
the expense of stiffness.
As Per The Customer Requirement:-
Plastic material selected for the “CAP FILTER” component is

recommended by customer is Polypropylene (PP) the grade is H110
MA”.
Polypropylene:-
Polypropylene is a thermoplastic resin, polypropylene does not have
environmental stress cracking problem. The MFR (Melt Flow Rate) of
polypropylene ranges from 1 to 40, lower MFR materials have better
impact strength but lower in tensile strength.

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PROPERTIES:-
The properties of Polypropylene include:-
 Semi-rigid
 Translucent
 Good chemical resistance
 Tough
 Good fatigue resistance
 Integral hinge property
 Good heat resistance
Physical Properties
Tensile Strength 0.95 - 1.30 N/mm²
Notched Impact Strength 3.0 - 30.0 Kg/m²
Thermal Coefficient of expansion 100 - 150 x 10-6
Maxmium Contsant Temperature 80 °C
Density 0.905 g/cm3
ADVANTAGES:-
 Homopolymer
 Good Processability
 Food Contact Acceptable
 Good Stiffness
 Good Impact Resistance
 Co-polymer
 High Flow
 High Impact Resistance
 Chemically Coupled

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DISADVANTAGES AND LIMITATIONS:-
 Degraded by UV
 Flammable, but retarded grades available
 Attacked by chlorinated solvents and aromatics
 Difficult to bond
 Several metals accelerate oxidative degrading
 Low temperature impact strength is poor
TYPICAL APPLICATIONS:-
 Automotive Applications
 Household Goods
 Film
 Containers
 Appliances
 Packaging
 Electrical/Electronic Applications
 Industrial Applications
 General Purpose
CRITICAL DIMENSIONS:-
• Component to be free from any surface imperfections, flashes gate tabs.

• Component to be free from sharp corners, fillets, radius to be unless
specified.
• Ejector marks to be under flush counter bored as per detail.
• Maximum moulding mis- alignment to be 0.1 mm
• The 8.3,10.5 the full round is important dimension.
• The 4*206 slot is the cut out for water flow is maintained
• Groove size is 1.0mm width & 1.0mm in depth and gap between the
grooves is 1.0mm

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BRIEF ABOUT THE COMPONENT

ANALYSIS
 Number of cavity : Two-Cavity

The number of cavity will be based on the rate of production, shot
capacity and size of the component.
 Material of the component : Poly Propylene (PP H110 MA)

The selection of material will be based on the life and function of the
component.
 Type of ejection : Pin Ejection, Plate Ejection

The type of ejection will be based on the profile of the component and
wall thickness.
 Type of runner : Full Round

The runner will be selected on flow rate of the material.
 Type of gate : Edge Gate

The gate will be selected on size and shape of the component and rate
of material fill.
 Type of cooling : Water Cooling (Rectangular type cooling)

The cooling will be selected on the mould temperature, material
temperature, type of tool.

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Product application
COMPONENT PRODUCTION FOR FILTER ASSEMBLY
FILTER FIT TO THE WATER PURIFIERS
This product is fitted to water purifier of AO SMITH company our

customer.
There are different another parts we manufacture for the filter they are,
1. Cap Filter Top SCMT+CB
2. Top Cap
3. Bottom Cap
4. Quick Connector
This four component will also assembled to the filter, which will be
manufactured in our company only.

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TOOLING
Tool can be defined as hardware necessary to produce any article in large
quantity. It can be a jig or a fixture used for rapid machining of parts or a
press tool used for producing sheet metal components & Gauges used for
rapid and repetitive inspection. Mould tool used to produce plastic
components or a die casting tool used to produce metal castings rapidly.

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Features Of Tool Design:
 The tool designer should know the different manufacturing process.
 The tool should be designed economically.
 Designer should provide a drawing to produce the work piece.
 The designer should be able to suggest any rectification to the problems
arising out while assembly and manufacturing process.
 The designs submitted for manufacturing should be clear completely
and easily understandable.
 The design may be termed as a complete plan for manufacturing of the
tool for the given component, it includes all the factors necessary for
machining and the drawing for assembly.
TOOL PHOTOS

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METHODOLOGY FOR DESIGN OF INJECTION
MOULD

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FACTORS FOR TOOL DESIGN CONSIDERATIONS
Factors to be considered before designing a tool to make the design
successful:
1. PRIMARY CONSIDERATIONS
2. SECONDARY CONSIDERATIONS
PRIMARYCONSIDERATIONS
1. PART QUALITY:-
It mainly depends upon functional requirement and customer
satisfaction. The prime cost consideration is given to the part quality
requirement, which decides the method and process of manufacturing.
2. ECONOMY OF PRODUCTION:-
The designer should design a mould in such a way that the part will be
produced at the most economical rate of production.
SECONDARY CONSIDERATIONS
1. TYPE OF TOOL:-
The type of tool will be always considered after going to through type of
moulding process, profile and shape of the component etc. The type of
this tool for this component is an “INJECTION MOULD”.
2. MATERIAL OF THE COMPONENT:-

The life of the component depends on the material selected. The shape of
the component should be such that it suits the assembly. For this
component PolyPropylene (PP H110 MA) plastic material is best suited
from cost and performance perspective.

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3. SELECTION OF MACHINE:-
The Injection moulding machine, in which the mould can be mounted for
production is selected prior to the designing of the mould. The machine
should meet all the required necessities for the mould.
The Machine Is Selected Before This These Points Are Consider:
 Size of the mould
 Component weight
 Injection pressure
Considering this machine ELECTRONICA FUTURA 90TON is

selected for this particular tool.
4. NUMBERS OF CAVITIES:-
The number of cavities will be based upon factor like rate of production,
shot capacity of the machine and size of the component.
This particular tool has been design with Two Cavity because of the
component size is small and easy for ejection and production will be fast.
5. MOULD RAW MATERIAL SELECTION:-

The mould insert material must be correct to produce parts economically
and tough to withstand the hard use to which it would be subjected. The
toolmaker must have basic understanding of the various type of materials
used in mould making.
6. SELECTION OF THE PARTING LINE:-

The first step of the designer is to choose the parting line. Parting line is the
line at which the two halves of mould meet and form a seal to prevent the
escape of plastic. The lines formed on the component at the parting surface
are called parting line. The parting line decides the placement of component
in core and cavity. The nature of parting surface depends on the shape of
the component. The parting surface must be so chosen that the can be easily
ejected from the mould. In this mould Profile Parting Plane is adopted for
easy ejection of the moulded part. And some the component area are not
found in parting line then we selected the moving core because we form
required profile, and easy ejection.

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7. TYPE OF FEED SYSTEM:-

In a Injection Mould, the elements of the feed system are Sprue,
nozzle, Sprue gate.
THERE ARE THREE WAYS OF FILLING THE MOULD:-

The first is by having a screw in full forward position. The screw
starts to rotate after the mould is closed and fills the mould, the
pressure is to the injection ram to apply the final injection pressure.
Secondly is to fill the previously plasticized material. The screw
acting as a ram comes forward slowly and when it reaches its full
forward position it starts to turn until the mould is filled. Then a small
cushion is maintained and hydraulic pressure is applied to complete
the cycle.
Lastly, is to start with a full barrel and continue until the point where
the screw comes forward and a small cushion is left behind. This
method allows for a rapid filling cycle.

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8. RUNNER SYSTEM:-
Runner is channel machined in the mould plate to connect the flow part
from machine nozzle to the gate.
Selection Runner Depends Upon Following Factor:-

1) The cross sectional shape of a runner.
2) The size of the runner.
3) The runner layout.
(a) The No. of impression
(b) The shape of component
(c) The type of mould & gate

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Types Of Runner:-
 Half round runner
 Full round runner
 Trapezoidal runner
 Modified trapezoidal runner
 Rectangle runner
This particular tool has been design with Full Round Runner. Because
the material flow in high in full round runner
CALUCULATION CONSIDER IN TOOL DESIGN

PROCESS OF RUNNER DIAMETER
FORMULA FOR RUNNER DIAMETER CALCULATION
D =√W X 4√L/3.7 D = vW x ªvL/3.7
=√27 X 4√15÷3.7
=5.1 X 15.49÷3.7 Where a=4
=√ 21.75 D=runner diameter
Where D = 5.0 L=height/length of runner
Runner diameter is Ø5.0 W=weight of Component
9. TYPE OF GATE:-
It is a channel connecting the runner with the impression. The plastic
material flows through to sprue to a runner & a small opening termed as
gate to the desired impression. The runner & gate acts as the carriers of
material to the impression.
The shape of gate designed for this component is Edge Gate.Wide edge
gate with variable thickness it permit rapid filling of large part or fragile
mould section through a large entry area. It is used to carried a uniform
flow into wide parts, where warpages and dimensional stability are main
concerns.

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The gate should be taper in the both width and thickness to be maintain a
constant cross section area.The melting velocity will be constant.As with
other manually trimmed gates the maximum thickness should be no more
than 75% of the part thickness.
Typical gate size are from 0.4 to 6.4mm thick. The gate width is typically
from 1.6 to 12.7mm.
This type of gate is used to feed long flat thin moulding such as trays,
boxes, scales, covers and strips.

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CALCULATION OF GATE DEPTH AND WIDTH
DEPTH OF THE GATE:-

H=NT
= 0.7 X 3
= 2.1mm
Depth Of The Gate Is 2.1mm. Per side is 1.05.
WIDTH OF THE GATE:-

Where,
W = Width of gate
A = surface area of cavity (mm2)
N = metric constant (0.66 – PE, PS,
. PC ) (0.7– PP) (0.8-Nylon,PA)
W=N√A÷30
= 0.7√52mm÷30
=2
Width Of The Gate Is 2mm

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10. TYPE OF EJECTION:-
Ejection is a part of moulding cycle, where ejector assembly is actuated to
eject the component, which shrinks and sticks on the core. For the ejection
to be easy and simple the core should be place on the moving half. Since
facility is provided on injection moulding machine for the automatic
actuation of the ejector system on moving half. Round Pin Ejectors Pins &
Plate Ejection System are used to eject the runner and component in this
mould.
In this ejector system the return pin is used to retract the ejector assembly.
And the ejector guide bush & pillar are used to the ejection assembly it
moves straight axis & it moves easy.
This particular tool has been design with PLATE & PIN EJECTION
This particular tool has the ejection stroke of 40mm
Length of the ejector pin is 150mm
11. TYPE OF COOLING:-

One fundamental principle of injection moulding is that hot material enters
the mould, where it cools rapidly to the temperature at which it solidifies
sufficiently to retain the shape of the impression. The temperature of the
mould is therefore important as it a portion of the overall moulding cycle.
While the material flows more freely in a hot mould a greater cooling
period is required before the solidified moulding can be ejected.
PURPOSE OF COOLING:-
The temperature has to be controlled for two purposes.
 To keep the mould temperature at a constant level during the operation
 To Cools the component to the working temperature for solidification
for production

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TYPE OF COOLING SYSTEMS:-
1. Drilled hole system(Angled hole system) (Stepped hole system)
2. Baffle hole system
3. Annular cooling system
4. The Bubbler cooling system
5. Helical cooling system
6. Heat Rods cooling system
7. Air cooling system
8. Deep Chamber cooling system
9. The Spiral Plug System
This particular tool has be designed for U-Circuit Cooling System, it cools
only side core because it is the component area .
In this system the holes are drilled through the sidewall of the core. Parallel
to the core face. These holes are carefully plugged and finished they form
parting line of the impression.
In this cooling system the rate of water flow is 110lit/h.

The diameter of the cooling holeØ7mm
12. AIR VENTS:-

Air Vents are the shallow slots of 0.025-0.035mm depth and 3mm width
machined on the parting surface for allowing the air to escape when the
plastic material enters the impression. If the air is not allowed to escape, it
results in defect like sink marks, burn mark, incomplete filling etc.

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The air vent should be provided at the point where the flow paths are likely
to meet, thus causing the air trap.
13. SPLITS CORES:-

For some types of tool employed with undercut and profile of the
component. The undercut & profile formed by the help of the side core.
The side core moves the help of the cam. This cam is called as finger cam.
The length of finger cam is decided based on length of undercut in part &
Function & location of the side core
Function:-It helps to need a side profile of the component and under cut of
the component.
Location:- The side core moves the help of finger cam & cylinder. The
final stage of the location is located by the help of the locking block.

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In this component the rib and under cut or profile is important because of
the profile are locking in assembly condition
The angle of the wedge or locking block is 25˚
The angle of the finger cam is 20˚
The diameter of the finger cam is Ø12H7mm
The relief hole in the side core is Ø14.0mm

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CALUCULATION CONSIDER IN TOOL DESIGN
PROCESS
FINGER CAM CALCULATION
L = M/Sinθ +2C/Sin20 Where;

=27/0.22+2x1/0.34 L = Length of finger cam
=122.72+5.88 M = Movement of side core
=127.00 θ = Angle of finger cam
C = Clearance
Length of finger cam is 127mm
PROJECTED AREA
Projected Area LH = L*W

= 35 X 120
=4200 sq.cm
=42.0 cm2
Projected Area is=42.0 cm
Total projected area = Projected Area + 10%safety x No of cavity.

= 42+1.0x1
=43.0
Total projected area is 43 cm2

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DETERMINATION OF CLAMPING FORCE
Cf = (AP + AR) n X (1/2 to 1/3 of IP) X fos
Where, Cf = Clamping force in tones

n = Number of cavities
=2
IP = Injection Pressure in Kgf/cm2
= 200Kgf/ cm2
Cavity pressure = ip/3 to ½ of P(I) = 1/3
Cavity pressure = 50 Kgf/cm2
Substituting these values in the above equation

Cf= A (per cavity X number of cavities) * Cavity pressure * fos
Cf= (1250X1) * 0.35 * 1.2
Cf= 85 Tons
WEIGHT OF THE COMPONENT

Actual weight of the component
Weight = * V
= 1.04 grams/cm3X 529 cm3
= 12.5 grams
Weight of the component 12.5gms
Where,
W Weight of the component (grams).
Density of the plastic material used (gm/cm3)
V Volume of the component (cm3).
The weight of sprue & runner related to the moulding generally must not be
neglected. This should be considered in the formula when determining the
moulding weight.The moulding weight should be substituted in the formula
& multiplied with the multiplication factor of shot weight.

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SHOT WEIGHT
Shot weight = Component weight x No of impression + Runner weight
= 12.5 x 2 + 2gms
= 27gms
Shot weight = 27 gms
PLASTICIZING CAPACITY
P C = Shot weight / Cycle time
= 27gms / 50sec
= 0.54gms/sec
Plasticizing capacity is 0.54gms/sec
WHILE CONSIDERING ALL THE ABOVE

FACTORS HE START DESIGNING
TOP VIEW
 First he study the component and based on that he starts designing the
tool.
 He design top view of the component placing the number of component
required.
 He start designing the two cavity mould because the component is big
and the tool is split cavity.
 Layout of the cavity is required to take care to achieve the best result
during the layout of cavities.
 For economically suit for the component since component is in round
shape optimum disposition of cavities to achieve minimum overall size
of the mould.
 While he designing he should put correct layout of cavities to obtain
balanced clamping.

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 We place the split cavities, it had increase total layout of mould. We
should also take care of opening of split cavity ,we use flat parting
surface. Because component have internal undercut and ribs.
 For efficient cooling is give to the core because it is close to the
component area. For this we select U-circuit for economically suit for
the component since component is in round shape. Dia. 7 drill is
drilled for cooling circuit economically suits and cooling nipple is
1/8bsp thread.
 After drawing the split cavity layout,then he start to draw the pillar
holes at 4 corner each in this dia.26. After that he start to draw the
core housing layout.
 And then he draw the ejection unit,to eject the component and draw
the essential diameters of the ejector pins to balanced the ejection of
the component. And also provide four return pins to push back the
ejector unit.
 Once he completed of the ejection unit, next he draw the layout of
spacer to the inwards because the ejector plate width is less. Spacer
provides the space to move the ejector unit for ejection of the
component before going to draw the spacer he calculate the spacer
height.
 Once the height of the spacer is calculated by adding the total height
of the component and ejector plate thickness and ejector back plate
thickness and 10mm extra for easy ejection of the component
 At last he draw the top plate layout is same as the core housing.Once
the top view is completed he take the section plain such way that all
the details should be covered which shows how the parts are been
placed .
 Then section plain is taken in such a way that it should understandable
manner to others.

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FRONT VIEW
 The designer start the drawing by the bottom plate as sectioned front
view to show the all necessary views based on the tool.
 And then he draw the centre line refering from top view of the
drawing.
 First he start with bottom plate because it is the base of the mould. He
select the thickness of 27mm for the good strength and for clamping
purpose.
 Then he start to draw the ejector back plate, it is used for the
supporting the ejector plate as well as the ejector pins and sprue
puller pin and pushback pin. The thickness of the plate is 22mm .
 Then we draw ejector plate for the ejection of the component. It is

used for clamping the collar of ejector pins and push back pin . The
thickness of the ejector plate is 17mm for the essential purpose .
 Then he draw the spacer,it provides the space to move the ejector unit.
Before going to draw the spacer calculate the spacer height
 Then he start drawing the sectional view of Core housing. This plate
is used for housing the core insert. And we clamp the wear plate,guide
rail, guide pillar and the core block. The core housing thickness is
38mm.
 Then he start drawing the Cavity housing in which cavity insert

should be fit. And shows how the finger cam is actuated and how
wedges is locks the split cavities . The thickness of the cavity housing
33mm
 And next is top plate and it is the final plate of the assembly which
clamp on the machine platen. In this we clamp locating ring and sprue
bush to flow the plastic material and guide bush is fitted for the
movement of the assembly the top plate thickness is 27mm.

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SIDE VIEW
 Designing the sectional side view is because we cannot show all the
parts in the front view.
 When we show the all parts in front view without a side view all the
parts we be overlaped on each other.
 The people who read the drawing cannot understand what is in it so
he draw the side view.
 The alignment of parts like side core,guide rails cannot be shown in
the front view so the designer will draw the side view for identifying
the parts correctly and the alignment of parts.
MOULD DESIGN CHECK LIST

TOOL
 The core and cavity should be designed in such a way that the machining
can be done on available equipment?
 All necessary parts are hardened?
 Will the tool dimensions produce moulding within component tolerance?
 Will the mould remain on ejections side when mould is opens?
 Have the ejector return mechanisms been provided to prevent sticking
cracking or distortion of moulding?
 Have adequate guide pin been provided between the two halves?
 Having adequate cooling channels been provided?
 Is the cooling too close or too distance from the mould surface?
 Are the runners of sufficient size?
 Side core action guiding length is optimum or not?
 Mould opening and closing sequence are ok or not?

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COMPONENT
 Is the flash line at the tool parting line position is usually acceptable on
the moulding?
 Will the position of any flow or weld line that may occur be acceptable
in appearance?
CHECK LIST OF COMPONENT

 Will any heavy section in the moulding causes unacceptable sink marks?
 Is the design free of any undercut areas that will prevent ejection?
 Is the function of the part clearly understood?
 Is the gate location correct and acceptable?
 Will the component stick on to injection slide?
MACHINE
 Is the weight of the moulding runners and sprue with in the shot capacity
of the machine?
 Is the external output well within the plasticizing capacity of the press?
 Is the clamping pressure of the moulding machine sufficient for the
project is of the molding and runners?
 Will the mould pass between machine tie bars?
 Do the clamping arrangements for the tool slide the plate bolt holes?
 Is the machine opening stroke sufficient for ejection and extraction of the
moulding?
 Is the ejection stroke of tool within the capacity of the machine ejector
stroke?
 Is the ejector mechanism suitable for the particular machine ejector
system?
 Do the spherical nose and orifice of the cylinder nozzle mate with the
spherical seating and bore of the sprue bush?
 On split tools can all ejectors be in the forward position with out
Interfering with the clouding of the spill?

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The steel used in the manufacture of a mould base varies depending on the
requirements of the application proper material selection and proper
combination of alloys in varying percentage is required for finished tools.
The ultimate basis for the proper selection of tool steel is the final cost or
unit part produce by the tool.
The material selection for core and cavity is an important aspect of
tool manufacturing, as it governs the accuracy of the moulding and the tool
life.

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CRITERIA FOR SELECTION OF

MATERIAL
The Primary Factors Influencing The Selection Of Material For Plastic
Moulds Are:
 Type of plastic to be moulded.
 Method of moulding.
 Design of the part to be moulded. (Size & complexity)
 No. of component produced.
Other Factors Interrelated With The Primary Factor Are Physical &
Chemical Properties Of Mould Materials:
Palatability is essentially important for transparent plastics.

Where a smooth surface on the final product.
Where high surface hardness is necessary for resistance to
identification polish ability and wear resistance.
Toughness
Raw material selected usually depends on the functional aspects of the
part that it serves. In general material selected should have the following
characteristics:
1. High wear resistance.

2. Sufficient toughness and hardness.
3. Good Dimensional stability.
4. Good polishing properties.
5. High thermal conductivity.

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SELECTION OF MATERIAL FOR MOULD
MANUFACTURING
Material Mould parts Reason for selection
C-45 Bottom plate,  It has a high compressive strength.
core plate, top  It has high density & tensile strength.
plate, ejector  Application: plain carbon steel is most
plate, ejector suitable for mechanical engineering &
back plate, automotive components.
spacers,  Having tensile strength of 63-71
locating ring, , kgf/mm². Enough strength to
Tie bar, cavity withstand forces of impact load.
plate, core Low cost.
block,core back  C0.45% Si0.30% Mn0.30%
plate
H-13 core insert, core
T35Cr5M sub insert,  Plastic mould steel pre-hardened to
oV1 cavity insert & 29-33 HRC.
cavity sub  Uniform hardness distributed evenly
insert,split side in large cross-sections.
core.  Excellent weld ability with least
hardness elevation.
 Good mirror polish ability & less
streak, texture making finishing easier.
 Excellent toughness & nitriding
properties.
 Good for plastic injection moulds.It is
pre-hardened plastic mould steel that
has very good polish ability and good
machinability.
 C0.55% Si0.2% Ni0.2%
Cr0.65%
Mo0.3%

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OHNS Wear plate,  It is nickel chromium molybdenum
T110W2C wear button,rest steel for hot and cold work. It has
r1 button guide excellent air hardening ability with
pillar & bush, very good deep hardening properties,
ejector pillar & toughness and compressive strength
bush,wedge,we  A 6% allowance should always be
dge wear plate, made for removal of surface defects
Guide rail, during machining
Hardness is 48-50 HRC.
 C0.45% Si0.25% Mn0.4% Cr1.35%
Mo0.25% V4.0%
EN31 Sprue bush  Having wear resistance property
 Hardenability, Wear resistance
property.
Hardness 40-42HRC
C0.37% Si1.0% Mn0.4% Cr5.2% Mo1.3%
V0.4%

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EFFECTS OF THE ALLOYING ELEMENTS

 Effects Of Carbon (C) :-
Carbon increases the hardness of the steel and makes it more wear
resistant Steel having less than 0.3% carbon content cannot be hardened
directly and those having more than 0.3% to 0.8% can be hardened easily.
Beyond this, there is no change in hardness but wear resistance increases.
 Effects Of Chromium (Cr) :-

Addition of chromium increases hardness but decreases ductility. It
increases harden ability.
 Effects Of Molybdenum (Mo) :-

It induces deep harden ability and reduces tool steel corrosion.
 Effects Of Vanadium (V) :-
Vanadium helps in obtaining a fine grain structure in steel, hence
increasing toughness. It increases red hardness property and also tensile
strength, yield strength and wear resistance.
 Effects Of Silicon (Si) :-

It prevents steel from becoming porous after tempering the steel
will possess high strength with good ductility and shock resistance.
 Effects Of Manganese (Mn) :-

Helps to make the steel sound while casting as in got (0.1 - 1.35%).
Addition of more manganese increases hardens ability.The depth of
penetration of hardness increases.
Material Compsition Chart
2.00
1.50
% 1.00
0.50
0.00
C Si Mn Cr P S Ni Mo V
COMPOSITION
P20 0.40 0.30 1.50 1.90 0.20
EN24 0.35 0.10 0.70 1.14 0.05 0.05 1.80 0.35
OHNS 1.1 0.35 0.40 1.30 1.4
C45 0.45 0.30 0.60
HDS 0.35 0.4 1 1

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THE BASIC RAW MATERIALS SELECTED

FOR THIS TOOL
H-13:-
The IS codification of H-13 steel is T35Cr5MoV1.
It is pre-hardened plastic mould steel that has very good polish ability and
good machinability.
Composition:
C Si Ni Cr Mo
0.55 0.2 0.2 0.65 0.3
 Plastic mould steel pre-hardened to 29-33 HRC.

 Uniform hardness distributed evenly in large cross-sections.
 Excellent weld ability with least hardness elevation.
 Good mirror polish ability & less streak, texture making finishing
easier.
 Excellent toughness & nitriding properties.
 Good for plastic injection moulds.
C- 45:-
The IS codification of C-45 steel is
Composition:
C Si Mn
0.45 0.30 0.30
 It has a high compressive strength.

 It has high density & tensile strength.
Application:- Plain carbon steel is most suitable for mechanical engineering

& automotive components.

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EN-36B:-
The IS codification EN-36B is T110W2Cr1.
It is nickel chromium molybdenum steel for hot and cold work. It has
excellent air hardening ability with very good deep hardening properties,
toughness and compressive strength.
Composition:
C Si Mn Cr Mo V
0.45 0.25 0.4 1.35 0.25 4.0
 Good machinability.
A 6% allowance should always be made for removal of surface defects
during machining.
EN-24:-
The IS codification of EN-24 steel is T35Cr5MoV30.
It is a Chromium molybdenum vanadium hot work steel. This material
having good resistance to thermal verification. During molding period, heat
& cools rapidly. This time the thermal stress is induced in the body. This
behavior of material leads to cracking of material.This material is having a
very good resistance to cracking of material and it is having a good
dimensional stability when mould is heated.
Composition:
C Si Mn Cr Mo V
0.37 1.0 0.4 5.2 1.3 0.4
COPPER:-
Used as electrodes for sparking purpose in core insert and cavity inserts.

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RAW MATERIAL SELECTION FOR THIS TOOL
SL.NO DESCRIPTION QTY MATERIAL HARDNESS
01 Top Plate 01 C-45 -
02 Bottom Plate 01 C-45 -
03 Core Plate 01 C-45 -
04 Core Back Plate 01 C-45 -
05 Core Block 02 C-45 -
06 Cavity Plate 01 C-45 -
07 Ejector Plate 01 C-45 -
08 Ejector Back Plate 01 C-45 -
09 Side Core 02 H13 50-52 HRC
10 Wedge 02 OHNS 50-52 HRC
11 Core Insert 02 H-13 50-52 HRC
12 Core Sub Insert 02 H-13 50-52 HRC
13 Core Sub Insert-2 02 H-13 50-52 HRC
14 Cavity Insert 02 H13 50-52 HRC
15 Cavity Sub Insert 02 H13 50-52 HRC
16 Cavity Sub Insert-2 02 HDS 50-52 HRC
17 Wear Plate 04 OHNS 48-50HRC
18 Wedge Wear Plate 02 OHNS 50-52 HRC
19 Guide Rail 02 OHNS 48-50HRC
20 Locating Ring 01 MS -
21 Guide Pillar 04 OHNS 50-52HRC
22 Guide Bush 08 OHNS 50-52HRC
23 Ejector Guide Pillar 04 OHNS 48-52HRC
24 Rest Button 04 OHNS 48-50HRC
25 Wear Button 04 OHNS 48-50 HRC
26 Sprue Bush 01 EN24 45-50 HRC
27 Spacer 02 C-45 -
28 Spring Holder 04 MS -
29 Tie Bar 01 MS BRITE -

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Estimation can be defined as an art of finding the cost, which is likely to be

incurred on the manufacture of an article, before it is actually
manufactured. Thus, it is the calculation of a probable cost of an article
before the manufacturing starts. It also includes predetermination of the
quantity and quality of material, labour required, etc.
AIMS OF ESTIMATION:
1. To help the factory owner in deciding the manufacturing.
2. To help in filling up tender enquiries.
3. To decide about the amount of overheads, this helps in comparing and
checking the actual overheads of the factory.
4. To decide about the wage rates of the workers after making “Time
Study”.
5. It helps to decide whether a particular material should be purchased
from the market or to be manufactured.

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THE GOALS FOR ESTIMATION OF A TOOL :
 To raise the certainty and accuracy of the tool cost calculation.
 To reduce the time consumption for the calculation.
 Make it possible to calculate cost of moulds, when there is no previous
experience.
ESTIMATING PROCEDURE:
• To collect the information and special of product.
• To collect the drawing sequence operation, machine used, labor rate
cost and overheads.
• To decide about the production of the component in house production
or to purchase from outside.
• To determine the material cost of operation, labor cost and overheads.
• To determine the prime cost including above all cost.
• To planning of delivery charges.
• To calculate for the total cost, discount allowed delivery time cost.
MISCELLANEOUS OVERHEADS :
1) Standard Items: 10-13% of Prime cost.
2) Design Charges: 10-15% of Prime cost.
3) Inspection Charges: 3-5% of Prime cost.
4) Profit Margin: 15% to 20% of Prime cost.

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PROCEDURE OF ESTIMATION
DIRECT MATERIAL COST
+
DIRECT LABAOR COST PRIME COST
+
DIRECT EXPENCES
PRIME COST
+ FACTORY COST
FACTORY EXPENCES
FACTORY COST
+
ADMINISTRATIVE COST OFFICE COST
+
DESIGN COST
OFFICE COST
+
DESTRIBUTIVE CHARGE TOTAL COST
+
SAFETY CHARGES
TOTAL COST
+ SELLING PRICE
PROFIT

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PROCEDURE OF ESTIMATION TOOL

COST
TOTAL TOOL COST:

PRIME COST= Raw Material Cost + Machining Cost + Standard Item
Cost +Heat Treatment + Mould Base Cost
TOTAL COST= Prime Cost + Risk Factors + Overheads +Design

charges +Inspection + Profit.
RAW MATERIAL COST
Sl. No Material Price/Kg Mass Cost (Rs)

1 C-45 85Rs/Kg 210Kg 17,850 Rs
2 H-13 230Rs/Kg 65Kg 14,950 Rs
3 En -24 60Rs/kg 5Kg 300 Rs
4 OHNS 80Rs/Kg 60Kg 4,800 Rs
5 COPPER 650Rs/Kg 45Kg 29,250 Rs
6 HDS 230Rs/Kg 4Kg 920 Rs
7 20mncr5 100Rs/kg 25Kg 2,500 Rs
8 MS Brite 60Rs/Kg 12Kg 720 Rs
TOTAL RAW MATERIAL CHARGES 71,290 Rs

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STANDARD ITEMS COST
Sl. No Material Quantity Price (Rs)
01 Screws 135 1,900 Rs
02 Dowels 08 350 Rs
03 Cooling Nipples 04 400 Rs
04 Return Pin 04 1,200 Rs
05 Ejector Pin 12 1,500 Rs
06 Spring 08 1,800 Rs
07 Eye Bolt 01 200 Rs
08 Finger Cam 04 1,200 Rs
09 Ball Guage Bush 04 3,800 Rs
10 Ball Catch 04 900 Rs
TOTAL STANDARD ITEMS CHARGES 13,250 Rs
MACHINING COST
WORK Rs/Hour
Milling 125
Turning 60
Cylindrical grinding 120
Grinding 150
Drilling 60
Bench work 80
Wire EDM 250
CNC milling 850
Sparking 200

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ESTIMATION OF MACHININING COST AND TIME
Sl. OPERATIONS RATE / M/C TOTAL COST IN

HR TIME (Rs)
No IN Rs IN Hrs
1 Milling 125 70 8,750 Rs
2 Turning 60 15 900 Rs
3 Cylindrical 120 15
grinding 1,800 Rs
4 Grinding 150 50 7,500 Rs
5 Drilling 60 80 4,800 Rs
6 Bench work 80 8 640 Rs
7 Wire EDM 250 18 4,500 Rs
8 CNC milling 850 50 42,500 Rs
9 Sparking 200 45 9,000 Rs
10 Polishing 120 15 1,800 Rs
11 Assembly 200 38 7600 Rs
TOTAL ESTIMATED MACHINING COST 89,790 Rs
ESTIMATED COST AS FOLLOWS
SL.NO ELEMENTS TOTAL COST (Rs)

1 RAW MATERIAL CHARGES 71,290 Rs
2 MACHINING CHARGES 89,790 Rs
3 STANDARD ITEM CHARGES 13,250 Rs
4 HEAT TREATMENT 4,500 Rs
TOTAL PRIME COST 1,78,830 Rs

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TOTAL ESTIMATED TOOL COST
SL.NO ELEMENTS TOTAL COST (Rs)

01 Prime cost 1,78,830 Rs
02 Risk factor( 6% of prime cost) 10,729 Rs
03 Overheads(10%of prime cost) 17,883 Rs
04 Design charges ( 15% of prime 26,824 Rs
cost)
05 Inspection ( 3% of prime cost) 5,364 Rs
06 Tryout(5%of prime cost) 8,941 Rs
07 Profit ( 20% of prime cost) 35,766 Rs
TOTAL ESTIMATED TOOL COST 2,84,337 Rs
TOTAL ESTIMATED TOOL COST = 2,84,337 Rs
PIE CHART FOR ESTIMATED COST
G20%
F5%
E3% A PRIME COST
D15% B RISK FACTOR
A41% C OVER HEAD COST

C10%
D DISIGN CHARGES
E INSPECTION
B6%
F TRY OUT
G PROFIT

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1. TOP PLATE:
This is the top most plate. The top position of the mould parts
are clamped by means of screws. This also used for clamping top
assembly on to the machine platen. This plate also act as back plate for
the cavity inserts.
2. BOTTOM PLATE:
This plate is incorporated bottom of the spacer. The bottom
position of the mould parts are clamped by means of screws. It gives a
cushioning effect to the die as well as provides enough room for the tool to
be clamped to the machine platen. It will be of more thickness to prevent
bending.

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3. CORE PLATE :
This is a plate where core inserts is fixed by wedges and spacers
in position or in alignment with the cavity. It also incorporates guide bush
and provision for push back pins. The side core unit is also fixed in this
plate.
4. CAVITY PLATE:
This plate is used for fixing the cavity inserts by wedges and
spacers in position. It incorporates guide pillars.
5. CAVITY & CORE INSERTS:

Basically consists of two parts cavity and core. The part in
cavity portion of the mould, forms the external shape of the moulding &
the core portion of the mould, forms the internal form of the moulding”
When the mould is closed the two inserts come together forming a space
between the cavity and core. The space is called “IMPRESSION”.
6. SIDE CORE:
Side core or a local core, which is normally mounted at right
angle to the die axis for forming holes or recess in the side face of a
component.
7. GUIDE RAIL:
Guide rails are used to guide the side core in mould, during front
and back movement of side core.
8. WEDGE:
This is the portion, which gives final locking for the side cores
when the mould is in closed condition.

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9. REGISTER RING:
This disk shaped part is seated in the top plate on the cavity half of
the tool. It locates the mould on the fixed platen. Being an accurate size
ensures the sprue bush aligns on the center line of the injection unit.
10. REST BUTTONS:

These are used between the ejector back plate and bottom plate for
following advantages.
11. PUSH BACK PINS:

These pins are fitted in the ejector plate at the ends in the mould
split line. This is only to retain the ejector assembly back into its position.
12. EJECTOR PINS:

These are cylindrical moving pins used for ejecting the component.
It is housed in the ejector plate.
13. EJECTOR PLATE:

Ejector plate houses the ejector pin, sprue puller pin and push back
pin. Ejector plate transmits ejector force from the actuating system of the
machine to the ejector system.
14. EJECTOR BACK PLATE:

This plate is used for locking all the pins with ejector plate. It is a
plate securely attached to the ejector plate and to the ejector rod to retain
the ejector assembly.
15. CORE BACK PLATE:

It is fixed behind the core inserts. It supports the core inserts and
prevents the inserts from moving down.

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16. SPACERS:
These blocks are used in the mould to facilitate the ejector
assembly to be positioned and actuated.
17. SCREWS & DOWELS:

Screws are used to hold the die parts together and dowels are used
to align the different parts.
18. GUIDE PILLAR & GUIDE BUSH:

Guide pillar and guide bush is used for the proper alignment of top
half and bottom half of the mould.
19. EJECTOR GUIDE PILLAR & GUIDE BUSH:

Ejector guide pillar and guide bush are used for the proper
alignment of ejector assembly with respect to core.
20. WEAR PLATE:

These are hardened plates provided for enabling the proper and
free movement of the side core, there by avoiding the wear of the core
plate.
20. CORE BLOCK:
Support block are judiciously positioned and clamped to core
plate by means of screws. It is used for extra support for side core
assembly.Its main use is to less use of material consumption.
21. SPRUE PULLER PIN:

Sprue puller pin positively ejects out the sprue from the sprue
puller bush.

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Before the actual manufacturing of the tool parts, the toolmaker has to
decide the process of manufacturing of each part from the raw material
stage to the finished product. This procedure is called process planning.
Process planning includes developing the method of manufacture the
tool, so that it can be provided economically at a competitive price. It
establishes the correct sequence of operations.
The process planning directly effects the tool cost i.e., an incorrectly
planned manufacturing process increases machining time, there by
increases the tool cost.
For the manufacturing of hardened parts extra care should be taken
while deciding the manufacturing process, because machining of the
hardened parts is relatively costly and tedious.

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REQUIREMENT IN PROCESS PLANNING
 A brief description of the job to be manufactured.
 Specification and standards to be adopted by the job.
 Drawing should facilitate all the specification of the job.
 Equipment data should include capacity of machines availability of
equipment in the job.
 Condition and location of existing plant.
 Existing man power and staff.
 Date of starting and date of dispatch of tool.
 Whether special accessories like jigs or fixture are needed.
PROCESS PLANNING FOR

MANUFACTURING OF CORE & CAVITY
Since these parts from the heart of the mould, top priority should be given:
 Make a detailed study of drawing and important dimensions.
 Go for economy as well as quality depending how best a particular
profile can be machined on a particular type of machine with less
cost.
 See that inserts are periodical stress relieved, so that no towards
cracks and stress develop into them.
 After each operation, clear the inserts for fool proof inspection.
 The machining operation of core, cavity can be bifurcated as:
PROCESS PLANNING INVOLVES FOLLOWING STEP :-
1. Planning
2. Routing
3. Scheduling
4. Dispatching
5. Follow up
6. Inspection

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STEPS IN PROCESS PLANNING
 Design review to make quality require manufacturability simpler.
 Study and critically analyze the manufacturing specification and
facilities available.
 Continuous follow up of each part from the raw material to the finished
part.
 Prepare a list of raw material of right quality and quantity.
 Determine the step up time and standard time for each operation.
 Finally determine the estimated cost of the product to see whether or not
it will compete in the sales market.
 Determine the most economic process for manufacturing the parts.
 Select the proper machine and best sequence of operation.
 Provide clear documentation of each operation.
 Determine the stage of inspection.
 Assembly all the parts of the mould with proper care.
 Tryout of the fabricated tool.
 Trouble shooting of the component.
 Determine the actual cost of the tool and component.
ESTIMATION OF TIME
WEEK NO. 1 2 3 4 5 6 7 8 9
DESCRIPTION
COMPONENT ANALYSIS X
DESIGNING X X
DRAWING RELEASE X
MANUFACTURE X X X X X X
ASSEMBLY X X
TRIALS X
COMPONENT INSPECTION X
TRY OUT (if reworked) X X
FINAL INSPECTION X

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Machining can be broadly classified into two groups:

 CONVENTIONAL MACHINING.
 NON-CONVENTIONAL MACHINING.
Conventional Machining Involves:

Shaping, Turning, Grinding, Drilling, and Boring etc.
Non-Conventional Machining Involves:
E.D.M , Profile Grinding, Finishing Grinding,Wire E.D.M and C.N.C
machining.
From manufacturing point of view mould can be classified into two parts;
 Core and Cavity.
 The remaining part of the moulding.

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MANUFACTURING OF ELECTRODES:-
Selection of electrodes mainly depends upon:
 Type of profile & it accuracy
 Life tool
 Cost of tool
ELECTRODES:-
Electrodes are generally made of copper, graphite, tungsten. These are
very useful in the tooling for opening complicated profiles which are highly
impossible to open in any other machining process.
It is the most vital part in processing of core and cavity for any tool, which
requires material removing by spark erosion.
The material used, as electrodes will have good electrical conductivity like
Graphite, Tungsten and Copper. In this tool,Copper is used for roughing
and finishing operations. The profiles of electrodes were made slightly less
than the required profile on the insert in overall dimensions, which are
known as spark gap.
For our tool we select copper is also more expensive than graphite but
intentional difference (gap) between the electrodes and the required profile
which will be sparking eroded in the insert later on. Spark gap is given in
mm/side.
 Pre-machining is carried out as per drawing.
 Thickness is ground for parallelism and screw holes are drilled and
tapped as per the required pitches.
 Profile is wire cut as per drawing.
 Finally electrodes are polished before spark erosion is carried out.

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In This Tool For Electrodes Spark Gap Was Considered As:
Roughing : 0.1.5mm/side
Semi finishing : 0.10mm/side
Finishing : 0.05mm/side
REASON FOR SELECTING THE COPPER:-

 It is easy to machine.
 It is very resistant to thermal shock.
 It has a high coefficient of thermal expansion (3 times Higher than
graphite) which guarantees stability of electrode geometry during
electro discharge machining.
 It is available in large blocks.
 Its density is 5 times higher than that of graphite, which results in
lighter electrodes.
 It provides a higher metal removal rate than graphite with less wear.
 It has the unique characteristic that the wear ratio tends to decrease as
the peak current increases.

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NON-CONVECTIONAL MACHINING PROCESS
1) CAVITY PLATE:
Manufacturing Of Cavity

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Firstly raw material was pre machined (with Milling &Grinding). In this
tool at the pre-machining stage lifting holes will be machined it come to our
tool room.Then we planned CNC machining.
MATERIAL: C-45
SIZE:310*260*38
1st setting
 After the completion of pre machining loaded for CNC milling
machine.
 Rough machining was completed.
 Tapping holes are spotted and then they are drilled.
 All cavity profile was carried out only with the CNC milling.
 Drilling the holes for cavity free holes and counter bore foe clamping.
 In cavity plate machined with wedges, for side core movements.
 Sprue bush hole of dia.13.
2nd Setting
 Drilling the holes for guide bush and finishing through CNC milling
(BORING).
 Drilling and tapping for clamping hole and lifting holes.
 Provide the chamfer to break the sharp edges.
 Drilling the relief hole and collar for wear button.
2) CORE PLATE:
Firstly raw material was pre machined (with Milling & Grinding). In this
tool at the pre machining stage lifting holes will be machined it come to our
tool room.Then we planned CNC machining.
MATERIAL: C-45
SIZE:310*260*45
1st setting
 Drill and tap the clamping holes and lifting holes.
 Total over all rough milling of pocket was carried.
 After the completion of rough machining finishing was carried out by
ball nose cutters [carbide] especially for finishing.

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 Return pin holes are drilled and reamed.
 Drilled and mill the relief holes for finger cam.
 Wear plate holes & guide rail holes done.
2nd Setting
 From second setting ejector pin relief holes are carried.
 Core sub inserts holes is done according to drawing.
 Core insert clamping holes are drilled.
 Guide bush holes are machined with given fit.
 Boring was carried out for guide pillar holes.
 Boring holes are inspected by bore gauge.
 Core block tap hole is drilled.
Manufacturing of Core

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3) SIDE CORE(SPLIT CAVITY):
 Raw material blocks will be per machined [milling] and ground to
required dimension.
 Single blocks will be machined by CNC milling and profile is
maintained dimension of sparking.
 Core profile, Steps,Pockets are carried out by CNC milling only
and giving the stock for Edm.
 Runner is done by giving the stock for Edm.
 MATERIAL: H-13
 SIZE:185*92*50
Manufacturing of Side Core

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4) CORE & CAVITY INSERTS:
Manufacturing of Core & Cavity insert
MATERIAL: H-13
CORE SIZE:180*110*35
CAVITY SIZE:180*70*22

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 All the core and cavity inserts are pre-machined considering the
allowance for the grinding.
 Radius is done for inserts edge is milled.
 Drill the holes for ejector pins with allowance.
 Profile surface of the inserts made by CNC milling with allowance.
 Tap holes is done for inserts clamping.
5) TOP PLATE:
The raw material size is generally 5mm more than the required plate size.
Firstly the raw material is milled in the pre-tooling department keeping
0.5mm excess material for grinding allowance. Then the clamping holes
and counter bores for Allen screws is drilled as per the required pitch from
the part design. Then all the necessary holes in the plate including sprue
bush, recess for seating of locating ring etc, are drilled accurately. The top
and bottom surface is accurately ground before the assembly.
MATERIAL: C-45
SIZE:310*310*32
SL. Operation Machine Remarks

No.
1. Milling Milling For sizing.
M/c
2. Drilling Drilling M/c Drilling holes for screw holes of M10,
& locating ring tap holes and guide
pillar relief hole and wedges holes.
3. Boring CNC Boring holes for sprue bush opening
machine
and locating ring.
4. Tapping Tap & Clamping hole & locating ring hole
Bench

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6) BOTTOM PLATE:
The raw material size is generally 5mm more than the required plate size.
Firstly the raw material is milled in the pre-tooling department keeping
0.5mm excess material for grinding allowance. Then the clamping holes
and counter bores for Allen screws is drilled as per the required pitch from
Is drilled exactly at the center of the base plate for knock out rod
movement. The top and bottom surface is accurately ground before the
assembly.

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Material:C-45
SIZE: 310*310*32
Sl.No Operation Machine Remarks

1 Milling Milling M/c For sizing.
2 Drilling Drilling M/c Drilling of M10 relief holes and

counter bore and boring the centre
hole for knock out rod.

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7) SPACERS:
Spacers are mounted in between the bottom plate and core back plate.
Spacers are used to provide space for actuation of ejector assembly. Height
and width of spacers milled. Clamping holes are relieved in suitable pitches
according to drawing dimensions. The height of the spacers is determined
by the thickness of the ejector plates, feet buttons with the total ejection
stroke required.
Material:C-45
SIZE: 310*65*90
SL.NO OPERATION MACHINE REMARKS

1 MILLING Milling M/c Pre Milling
2 DRILLING Drilling M/c Relief holes for allen screw
3 GRINDING Grinding M/c Top & Bottom sides

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8) EJECTOR PLATE:
Ejector plate houses the holes for threaded ejector bolts, push back pins
angular ejector rods, sliders etc. It also houses the holes for ejector bush.
The holes for ejector bush will have a p6 fit and the four sides of the plate is
accurately milled. Clamping holes are drilled and tapped according to
drawing dimension. The thickness of the ejector plate is ground and
finished to the required dimension.
Material:C-45
SIZE: 265*135*20
1 Milling Milling M/c Pre milling
2 Drilling Drilling M/c Ejector pin holes,M8 tap holes

3 Tapping Taps M8 for ejector back plate clamping
4 Grinding Grinding M/c Top and bottom sides
5 Milling CNC Milling Ejector guide bush, Pushback pin

hole and its counter bore & ejector
pin counter bores.

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9) EJECTOR BACK PLATE:
Ejector back plate is clamped to back of the ejector plate with the help of
screws. In this plate, counter bores are made for screw heads according to
the drawing dimensions to the required sizes. This plate does not allow the
pins to deflect or from falling. Relief holes are drilled for ejector bush. This
plate is accurately machined and is case hardened.
Material:C-45
SIZE: 265*135*20
1 Milling Milling M/c Pre milling
2 Drilling Drilling Relief hole of M8 allen screw and

M/c counter bore and M6 tap hole.
3 Tapping Taps M6 for rest button clamping
4 Grinding Grinding Top and bottom sides

M/c
5 Milling CNC Ejector guide bush H7 hole and
Milling counter bore

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CONVECTIONAL MACHINING PROCESS
01) GUIDE PILLARS:
 1ST Setting the raw material well be turn for a size of 35.5x180mm
length kept the 0.5 mm stock for grinding allowance.
 2nd setting to turn the 2nd step for a size of Ø 45x10mm length to kept
the 0.5mm stock for grinding allowance.And is case hardened up to
58-60 HRC. After case hardening to remove the scales in the surface,
we give to CG for grinding,with the help of between center they start
to grind and the actual dimension of the pillar is maintained.
02) GUIDE BUSHES:

 The 1st setting to turn the outer diameter of the guide bushes for the
size of Ø 35.5x88 mm to kept the 0.5mm stock for grinding. To start
the drilling for the size of Ø30mm through length and start the
boaring operation to kept the 0.5mm stock for grinding allowance.
And is case hardened up to 58-60 HRC.
 After case hardening to remove the scales in the surface. we give to
CG for grinding,with the help of the mandrels they start to grind and
the actual dimension of the pillar is maintained.
03) GUIDE RAILS:

The raw material is per machined for the required dimension and to kept he
0.5mm grinding allowance .To drill the hole for screw clamping as per
drawing to move the heat treatment a the hardened up to 48 to 50 HRC .
After hardening to remove the scales in the surface to start the grinding for
the required dimension and 2x45 chamfer for all the sharp corners.
04) REST BUTTON:

The 1st setting to turn the outer diameter of the rest button for the size of Ø
8*40 mm to kept the 0.5mm stock for grinding. To start the drilling for the
size of M6CSK screw through length and start countersunk upto CSK head
fit into it. And is case hardened up to 58-60 HRC. After case hardening to

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remove the scales in the surface.To start the grinding to the actual
dimension of the rest button size.
05) LOCATING RING:
The 1st setting to turn the outer diameter of the locating ring for the size of
Ø 100x15 mm to kept the 0.5mm stock for grinding. To start the drilling for
the size of Ø20mm through length and start the boaring Ø30. And do taper
for the ring in which the nozel should fit into it.
TYPE OF FIT IN THIS MOULD
SL.No. DESCRIPTION TYPE OF FIT
1 Main guide pillar-main guide bush Close running fit H7/g6
2 Main guide pillar-housing Light key fit H7/k6
3 Core pin – Core insert Light key fit H7/k6
4 Cavity insert- housing Light key fit H7/k6
5 Push back pin –core plate Close running fit H7/g6
6 Ejector pin – core insert Close running fit H7/g6
7 Cavity insert – cavity insert Light key fit H7/k6
8 Alignment bush – housing Slide fit H7/h6
9 Ejector guide pillar- housing Medium drive fit H7/m6
10 Ejector guide pillar- guide bush Close running fit H7/g6
11 Ejector guide bush –ejector plate Medium drive fit H7/m6
12 Register ring – housing Running fit H7/f6
13 Register ring – machine platen Running fit H7/f6

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PART LIST
SL. DESCRIPTION QTY RAW MATERIAL HRC
NO. MATERIAL
SIZE
01 Top Plate 01 310*310*32 C-45 -
02 Core Plate 01 310*260*45 C-45 -
03 Cavity Plate 01 310*260*40 C-45 -
04 Locating Ring 01 Ø110*15 MS -
05 Ejector Plate 01 265*135*25 C-45 -
06 Ejector Back Plate 01 265*135*25 C-45 -
07 Side Core 02 185*92*50 H-13 50-52HRC
08 Sprue Bush 01 Ø 35*65 EN24 45-50HRC
09 Cavity Insert 01 180*70*22 H-13 50-52HRC
10 Cavity Sub Insert 02 Ø 50*30 H-13 50-52HRC
11 Cavity Sub Insert-2 01 Ø12*50 HDS 50-52HRC
12 Core Insert 01 180*110*35 H-13 50-52HRC
13 Core Sub Insert 02 Ø 35*60 H-13 50-52HRC
14 Core Sub Insert-2 02 Ø 65*40 H-13 50-52HRC
15 Wear Plate 02 185*75*15 OHNS 50-52HRC
16 Wedge Wear Plate 02 135*40*10 OHNS 50-52HRC
17 Wedge 02 135*60*55 OHNS 50-52HRC
18 Guide Bush 04 Ø 45*150 20MNCR5 52-55HRC

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19 Guide Bush-2 04 Ø 45*350 20MNCR5 52-55HRC

20 Guide Pillar 04 Ø45*800 OHNS 50-52HRC
21 Wear Button 04 Ø 20*40 OHNS 48-52HRC
22 Bottom Plate 01 310*310*32 C-45 -
23 Spacers 02 310*65*90 C-45 -
24 Guide Rail 02 260*55*25 OHNS 50-52HRC
25 Ejector Guide Pillar 04 Ø 20*450 OHNS 50-52HRC
26 Ejector Guide Bush (Ball 04 Ø 22*32 STD -
Guage)
27 Rest Button 04 Ø25*40 OHNS 48-50HRC
28 Return Pin 04 Ø12*170 STD -
29 Ejector Pin 12 Dia 4*150 STD -
30 Core Back Plate 01 310*260*45 C-45 -
31 Spring Holder 04 Ø16*60 MS -
32 Core Block 02 260*20*50 C-45 -
33 Finger Cam 04 Ø 12*135 STD -
34 Spring-1 04 Ø 24*50 STD -
35 Spring-2 04 Ø24*70 STD -
36 Ball Catch of M8 04 M8*16 STD -
37 Allen Screw M6 04 M6*25 STD -

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43 Allen Screw M8 06 M8 *25 STD -
46 CSK Screw M6 12 M6*16 STD -
47 CSK Screw M8 16 M8*20 STD -
48 Grub Screw M8 08 M8*16 STD -
49 Dowel 04 Ø10*80 STD -
50 Tie Bar 01 280*30*30 MS Brite -
51 Cooling Nipples 04 1/8 bsp*115 STD -
52 Eye Bolt 01 M10*20 STD -

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HEAT TREATMENT
PROCESS OF HEAT TREATMENT:
Heat treatment is a process of includes desired mechanical properties like
wear resistance, corrosion resistance, and machine ability and also to
reduce internal stresses setup due to hot or cold working of steel. Heat
treatment consists of following three steps.

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HEATING:
Heating involves increasing the temperature of steel to desired temperature
SOAKING:
The steel is held at this temperature for a period of time called soaking
period. This result in formation of homogeneous austenite, throughout the
structure.
COOLING OR QUENCHING:
Quenching is done to cool the parts rapidly and to transform the austenite to
marten site structure without allowing the formation of pearlite. Some of
the quenching media are water, oil or salt bath etc.
Heat Treatment Process Carried Out In This Tool

SL.NO. DESCRIPTION QTY MATERIAL CONDITION
01 Wear Plate 02 OHNS 48-50 HRC
02 Guide Rail 02 OHNS 48-50 HRC
03 Core & Cavity Sub 04 H-13 44-46 HRC
Inserts-1
04 Guide Pillar 04 OHNS 48-50 HRC
05 Guide Bush 08 OHNS 50-52 HRC
06 Ejector Guide Pillar 04 OHNS 48-50 HRC
07 Wear Button 04 OHNS 48-50 HRC
08 Wedge Wear Plate 02 OHNS 48-50 HRC
09 Side Cores 02 H-13 50-52 HRC
10 Core & Cavity Insert 04 H-13 50-52 HRC
11 Rest Button 04 OHNS 48-50 HRC
12 Wedges 02 OHNS 48-50 HRC
13 Sprue Bush 01 EN 24 45-50 HRC
14 Core Sub Inserts-2 02 HDS 50-52 HRC
15 Cavity Sub Inserts-2 02 H-13 50-52 HRC
In this tool some parts are case hardened and some parts are through
hardened.

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HARDENING:
This process is to obtain marten site structure.
Process:
Heating the steel to austenitizing temperature at this temperature for a
considerable time. Rapid cooling by quenching the steel in a suitable
quenching medium like water, oil, air, brine solution etc.
Purpose Of Hardening:
To increase wear resistance.
To improve toughness, ductility and elasticity.
TEMPERING:-
It follows immediately after hardening. It further converts retained austenite
into marten site.
Purpose Of Tempering:
 To relieve internal stresses produced during hardening.
 To reduce some of the hardness produced.
 To induce toughness.
CASE HARDENED:-
Process:
Heating the steel to some temperature at this temperature for a considerable
time. The will be considerable on depth of hardening (3mm). Rapid
cooling by quenching the steel in a suitable quenching medium like water,
oil, air, brine solution etc.
The OHNS materials are through hardened up to 48-50HRC

The EN35 materials are case hardened up to 58-60-HRC

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Polishing is a process adopted in tooling to obtain predetermined finish in

the tool to achieve the finish required in the moulded product. During pre-
tooling operation such as Milling, Grinding, EDM, Wire cut etc.Machining
marks are left icon the moulding and it will lead to defect or problems
during processing to avoid these problems polishing is done.
Polishing is the most important aspect in the tool manufacturing
process and the finish required on the component mainly depends on the
finish on core and cavity. In metal injection mould usually requires high
polish, operation seems to be simple. But still polishing can damage the
material unless it is properly done. A very high skill is required for
polishing.

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PURPOSE OF POLISHING:
Purpose of polishing is to remove the week top layer of metal. It may be
week due to the stress induced, by machining.
Cleanliness is an important factor in improving the productivity of
polishing. The work piece area must be cleaned with soft tissue soft rage or
a soft brush and kerosene. Hard Polishing consists of removing metal in a
range 0.02 mm to maximum of steel of 0.05 mm. Quantity of polish ability
is mainly dependent on the composition of the steel. Presence of chromium
enhances the polish ability.
Smooth finish required on cavity & core to prevent

CORE & CAVITY catching & dull finish of the component polishing
by using emery paper, abrasive sticks & for fine
finish diamond paste used.
CORE & CAVITY Smooth finish required on core & cavity side core,
INSERTS, SIDE CORES core inserts to avoid catching of material, sticking
and for easy ejection purpose.
PRACTICAL HINTS FOR POLSHING OF MOULD:

1. Use only clean and free- cutting grinding tools. Soft stones should be
used for hard surface.
2. Between each change of grain size, the work piece and hands should
be cleaned in order to prevent `coarse particles from being carried
over to the next stage with a finer grain size.
3. When changing to next finer grain size grind in a direction of 450 to
550 the previous grinding direction until the surface only shows
scratches from the present grinding step. After scratches of previous
step have disappeared, continue for about 25% longer time before
changing to next gain size. This is to remove deformed larger.
4. Finish polishing of plastic moulds should be carried out in release
direction

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HOW TO JUDGE THE SURFACE QUALITY:
Two Things Are Important When Judging The Surface Of The Mould:
1. Primarily, the surface must have a correct geometry shape without
any long micro waves which will mostly be an inheritance from early
grinding and stoning steps.
2. Secondly the mirror finish of the mould surface is judged by naked
eye. The surface must be free from scratches, pores, orange peel,
pitting etc... in more sophisticated cases, the finish can judge by
instrument.
LUBRICANTS USED IN POLISHING:

Lubricant plays an important part in obtaining the max efficiency from
diamond abrasive polishing parts.
Commonly used lubricants are:
 Light spindle oil.
 Edm oil.
 Kerosene.
 Mixture of paraffin and light oil.
ADVANTAGE OF POLISHING:
1. Good surface finish.
2. Easy flow.
3. To reduce risk of local corrosion.
4. To remove week top layer in the mould.
5. To reduce risk of facture due to fatigue.
6. Easy ejection.

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POLISHING INGREDIENTS:
The following abrasives used for polishing.
1) Grinding wheel powder (Aluminum oxide) grit size-120.
2) Abrasive stick (800-2000)(Finer220, 320,400,600).
3) Emery paper (330,220 ).
4) Silicon carbide paper.
5) Polishing grinder.
6) Lapping paste.
7) Diamond paste.
SAFETY AND CARE OF POLISHED SURFACE:
1. Apply grease, anti-rust sprays and anti-rust compounds to avoid
oxidation.
2. Preserve polished items in dust free places.
3. Should not touch with bare hands.
Note: The surface roughness expected from the polishing process is from
0.04-0.16microns.
REPRESENTATION OF SURFACE FINISH

Roughness grade No Roughness value in  Roughness symbol
N12 50
N11, N10 25, 12.5 
N9, N8, N7 6.3, 3.2, 1.6 
N6, N5, N4 0.8, 0.4, 0.2 
N3, N2, N1 0.1, 0.05, 0.0025 

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Inspection plays an important role in tool making of manufacturing of any

part. It seems that the manufactured component or part will have its own
importance in a particular field in order to determine the fitness of anything
made. Man has always used inspection.
The quality of any product can be measured in terms of standard
items or drawings, this process is called inspection. In tool making, the
quality of each part of the tool is reflected on the quality of the component.
So inspection of the quality of each part process of manufacture is a must.
This is called stage inspection.
But industrial inspection is recent origin and scientific approach
behind it. It came into existence because of mass production, which involve
interchangeability of parts. Lastly inspection leads to improvement in raw
material manufacturing due to demands of high accuracy and precision.
Inspection has also introduced spirit of competition and led to production of
quality products.
Inspection of the core and cavity should be carried out thoroughly
because any slight dimensional variation affects the accuracy of the
components.

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PURPOSE OF INSPECTION:
 To collect information regarding the performance of the product with

established standards.
 To sort out poor quality manufactured products and thus maintain the
standard.
 To establish and increase the reputation by protecting consumers from
receiving bad products.
IMPORTANCE OF INSPECTION:
 Inspection traces defects in raw material, flaws in process, and those

arising in production due to defective machinery or process.
 Inspection avoids further work on non finish parts already detected as
spoiled.
 Inspection ensures that quality of goods supplied to customers are up to
mark.
INSPECTION METHODS:
Inspection can be categorized in respect to the method used.
1. MEASUREMENT: -
This involves determination of the numerical value of an
instrument vernier caliper, micrometer etc
2. FUNCTIONAL CHECKING: -
It involves testing, the function of a product practically by
assembling it with the mating part in order to clarify whether the
guiding and locking areas are mould properly for its efficient
function.
3. VISUAL INSPECTION: -
This method involves the use of the human eye to judge the quality
and aestheticism of a product.

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METHODS OF INSPECTION:
There are mainly three types of inspection.
1. Floor Inspection
2. Centralized Inspection
3. Combined Method Of Inspection
1. FLOOR INSPECTIONAL:
In floor inspection, the inspector walks around on the shop floor and
inspects the jobs.
2. CENTRALIZED INSPECTION:
In centralized type of inspection, all the jobs to be inspected and
moved to a separate room for inspection.In combined method of inspection,
shop floor and centralized inspection are combined together.
3. COMBINED METHOD OF INPECTION:

Combined method of inspection is used in our tool, because some
parts are required to be inspected on the shop floor itself and some work
piece are moved to the inspection room. Inspection is carried out in the
shop itself for checking dimensions, which are not very important and
accurate, and also which can be checked easily using instruments like
vernier caliper,micrometer,etc, can be easily handled and used. This
inspection includes checking of raw material size checking dimensions after
roughing etc.
Some inspection cannot be carried out in shop floor like
hardness checking of heat treated parts, checking of important profiles of
core, cavity and electrodes, which require some favorable conditions and
precision instruments. This type of inspection is carried out in a separate
room.
“INSPECTION PLAYS AN VERY IMPORTANT ROLE

IN THE SUCCESS OF A TOOL”

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TYPES OF INSPECTION USED IN TOOL:
1. Raw Material Checking Inspection
2. Profile Inspection
3. Material Hardens Inspection
4. Component Inspection
1. RAW MATERIAL CHECKING INSPECTION:

The raw material inspection means to check the raw material as per
dimension before pre machining.
2. PROFILE INSPECTION:
The profile inspection means to check the dimension of the profile for ex:
size of the insert profile, hole to hole pitch
3. MATERIAL HARDENS INSPECTION:

The material hardens inspection means to check the material hardens. After
heat treatment is done the company only inspects whether it is achived as
give per given hardens for required HRC.
4. COMPONENT INSPECTION:
The component inspection means to check the component dimension for
ex: Component size, component profile, pitches and Quality of the
component etc.
SOME OF THE INSPECTION INSTRUMENTS USED

IN TOOL ARE:
 PROFILE PROJECTOR
 TOOL MAKERS MICROSCOPE
 VERNIER CALIPER
 MICROMETER
 FERO ARM (CCM)

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Assembly is a high skilled operation, which is done by the

toolmaker. The skill of the toolmaker is required in fitting in each part into
the right place as per design to produce successful tool. The two important
things to be kept in mind while assembling are care and cleanliness. If the
care is not taken while handling the parts it leads to damages which in turn
leads to loss of time and increases the cost of the mould.
PONITS TO REMEMBER:
1. The guide bush and pillars are fitted with lubrication into their
respective bores.
2. The core and cavity inserts are side into their respective plates and
clamped from backside.
3. The ejector pins are placed in the proper holes.
4. Ejector back plate is clamped with ejector guide bush in alignment
with ejector guide pillar.

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5. Spacers are placed on either sides for the ejector assembly.
6. Rest buttons are fitted between bottom and ejector back plate.
7. Main clamping screws are inspected for its length.
8. Sprue bush is inserted and locating ring is clamped onto to plate.
MOULD ALIGNMENT:
Before going to final assembly to clamp the core inserts by the help of
screw. The side core holder is fitted in the core plate and the side core will
be slide on the side core holder and guide rail will be fitted on the suitable
position. The finger cam or wedge holders are fitted in cavity plate the
mould base should be checked for project alignment. All the plates are
clamped together as per design with pillars and bushes in their respective
places.
THE FINAL ASSEMBLY INCLUDES THE FOLLOWING PARTS

ALONG WITH THE MOULD BASE:
 Locating ring
 Top plate
 Bottom plate
 Core plate
 Core back plate
 Cavity plate
 Spacers
 Ejector guide pillar& guide bush.
 Guide rail
 Core insert
 Core sub insert-1
 Core sub insert -2
 Sprue bush
 Ejector pins
 Return pins
 Wedges
 Wedge wear plate
 Wear button
 Side cores
 Finger cams
 Wear plates

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 Guide pillar
 Guide bush
 Ejector plate
 Ejector back plate
 Cavity insert
 Cavity sub insert-1
 Cavity sub insert -2
 Core block
 Spring holder
 Allen screws
 CSK screws
 Ball catcher
 Grub screws
 Dowels
PRE-MACHINING ASSEMBLY
 Chamfer is done in hand grinding for the guide rail,wedges and wear
plate before assembly.
 Dowel has been put for locking for the core block and core plate
while guide pillar machining.
 Sprue bush matching is been done for split cavity.
 Sparking the gate point in split cavity.
 Grinding is done for guide rails for the sliding of side core.
 Fitting of moving core with the guide rails and maintaining the
dimension.
 Ball catching is provided for side core stopping.
 Giving the relief for core and cavity insert while fitting to the pocket
(5mm width & 0.05mm deepth)for suting in housing.
 Air vent is done where it is needed as per the component profile foe
escaping(0.025-0.035 & 3mm width).
 Ejector pin is been done according to the profile area and only one pin
is grind at a timeto maintain the height.

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Assembly Of The Tool May Be Divided Into Two Groups:
1. Top, Fixed or Cavity half.
2. Bottom, Movable or Core half.
CAVITY HALF ASSEMBLY:
 All the parts to be assembled are cleaned and lubricated with oil.
 Guide bush are fixed to cavity housing.
 Cavity plate and top plate are clamped together.
 Cavity inserts are fixed to cavity housing by wedges and spacers.
 Finger cam is clamped.
 Core sub inserts, inserts and wear button is clamped.

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CORE HALF ASSEMBLY:
 All the parts to be assembled are cleaned and lubricated.

 Guide pillar are fixed to core housing.
 Wear plate and core block has to be fixed to core plate.
 Core back plate and core plate are clamped together.
 Ejector guide pillar has to be fitted to core back plate.
 Core insert and sub inserts are fixed to core housing and spacers.
 The ejector guide bush and rest button are fixed to ejector back plate.
 The ejector pins and push back pins are assembled into this respective
hole in the ejector plate.
 Then the ejector plate is fitted to the ejector back plate with the help of
the screws.
 Spacer is aligned by centering sleeve to the core back plate.
 And bottom plate is fixed to core housing.

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BLUE MATCHING IN DIE SPOTTING IN A TOOL
Blue matching is a procedure where a paste known as Prussian blue is

applied on any one of the parting surfaces. The two halves are assembled
with some pressure for mating of the parting surface.
After opening the 2 halves the blue will highlight the high parts on the
parting surface. The high points are removed by polishing or by grinding.
This process is followed until an even film of blue is transformed from one
half to the other.
SIDE CORE MATCHING:

These side core are H-13material. After the completion of machining
process de-bur all the sides of side core and rubbed with oiled stone to
remove file chatter marks.
These are machined and side core profile area should be polished,
then we get started for suiting to core profile with the grinding and suited
neatly. Likely other two side cores are finely matched. In this tool blue
matching was done to check the matching surfaces
STEPS TAKEN DURING FINAL ASSEMBLY:
1. Mating surfaces of all plates and inserts are oil stoned and cleaned to
prevent any foreign materials being trapped during assembly.
2. Guide pillars are fitted as per marked reference.

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CHECK LIST FOR ASSEMBLY:
General: -
1. Fool proofing for assembly.
2. Confirm all the moving parts are guided properly.
3. Care about aesthetic detail.
4. Check the shut height before sending to trial.
5. Check the clamping facilities.
6. Check the mounting features correspond to the machine being used.
7. Check the pillar length in shut height condition.
8. Check for all the necessary information punched on the tool, which is
given in drawing.
CHECK LIST FOR MOULD:

1. Check for the alignment of core and cavity.
2. Check and maintain the height of ejector pins and push back pins.
3. Check for angle and nose radius of sprue bush.
4. Check the register ring diameter for suitability for the machine on which
it will be trailed.
5. Check for matching surfaces of core and cavity.
6. Check for smooth opening at the daylight.
7. Check for air vent and cooling provided.
8. Check for polishing of profile, runner and gate area.
9. Check for tie bar and eye bolt for lifting.

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CHECKLIST BEFORE TRYOUT

 Ensure whether draft has been given at required places.
 All the sharp edges and corners of the tool should be chamfered.
 Suitable means should be provided in the tool for carrying, loading and
unloading of the tool easily (clamping of tie bar with eye bolt).
 Ensure easy entry of tool between tie bars of the machine.
 Ensure whether locating ring size matches with the size of the hole in the
machine platen.
 Ensure whether the clamping arrangement provided in the tool suits the
platen bolt holes.

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 Ensure whether the shut height and the length of the tool when open are
within the minimum and maximum stroke of the machine.
 The total weight of the material to be injected should be within the shot
capacity of the machine.
 The locking force and the ejection stroke for the tool should lie within
the capacity of the machine.
 The butting surface of the tool should be free of dents, dust and oil.
 Check whether all the clamping screw is fully fastened.
 Be sure that the radius of the sprue bush is larger than that of the
machine nozzle.
TOOL MOUNTING AND TRIAL

MOULD SETTING:-
 A crane with a help of eye bolts, lifts tool. And place the tool between
the fixed and moving platen.
 Centerline the mould to the center axis of the machine nozzle with the
help of the locating ring & Ejector rod has to be fixed.
 Both top half and bottom half are clamped to machine platen by using
bed clamps and Tool is opened and checked for alignment.
 Maximum opening of the tool is set using control provided in the
machine.
 Ejection stroke is set and check limit switches are actuated.
 Cooling circuits are connected. Mould is preheated by hot oil
circulation if necessary & thus the mould is ready for taking
component.
 Mould spray is sprayed and mould is closed and material is injected to
the mould.
 Material is not injected to its full shot capacity, gradually the shot
capacity is increased after each cycle.

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MOULDING PROCESS:-
 First the material is loaded in the hopper where it is preheated to the
required temperature. Pre-heating is done to remove moisture content
in the material which otherwise will produce a defective component.
 The material, which is in the granular form, may be mixed with
pigments & dies for colouring also. A built in magnet separates the
ferrous particles from the plastic material. Next the material flows
from the hopper to the barrel. Barrel is heated by 4 stage heating
process. The barrel heats the material.
 Materials get plasticized by the rotating screw & by the action of the
heat, the rotating screw & the reciprocating mechanism pushes the
material forward.At the end of the barrel there is a nozzle with the
valve. The material is injected through the nozzle into the mould.
 Tryout is the process where the manufacture tool is exposed to actual

working condition on an injection moulding machine. This process is
carried out to know whether the manufactured tool is fit for
production, whether the component production is up to the working
condition.
 Whether the finest obtained is up to the mark etc, in case any defect is
found in the component, the tool can be reworked and sent for retrial.

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 The mould is free from oil and dust. The mould halves are closed and
the material is injected under pressure through the nozzle of the
machine into the feed system.
 The material reaches the cavities of the mould through the feed
system. The material is held under pressure till the component is
cured. Then the mould is opened and such that ejector assembly is
actuated to eject the component.
 For initial shots the injection of the material is done with low
pressure,because the die is new.The leakage of material should be
checked and also the core and cavity should be adjust to the hot
working conditions because gradually the injection pressure is
increased and so the locking force.
 In the initial shot unfilled component with defects were produced.
Later machine parameter was set and amount of injection material is
increased in steps. Components were produced till we obtained good
sets of components we achieved the good sets of component after 15
to 20 shots.
SPECIFICATION OF THE MACHINE

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NAME : ELECTONICA PLASTIC MACHINES LTD.
MODEL: FUTURA 90
Injection Unit:
Screw Diameter : 40MM
Maximum Injection Volume : 120cm3
Maximum Injection Pressure : 200 Kg/cm3
Maximum Back Pressure : 200 Kg/cm3
Maximum Injection Speed : 250mm/s
Maximum Screw Rotation Speed :150min-1
Clamping Unit:
Tonnage: 90Ton
Maximum Mould Height (mm) : 350mm
Minimum Mould Height(mm) : 100mm
Distance Between Tie Bar (mm*mm):360x360mm
Overall Size Of Platen (mm*mm) : 535x535mm
Ejection Stroke(mm) : 150mm
Ejection Force : 5KN
Clamping Stroke : 500mm
Mould Locating Ring Diameter : 125mm
Maximum Mould Weight (Kg) : 320
Maximum Mould Weight On Moving Platen (Kg) : 192
Maximum Mould Weight On Stationary Platen (Kg) : 128
CYCLE TIME: -
The time taken for complete cycle of producing one component (i.e., one
shot) is called cycle time, which includes closing of the mould, injection,
cooling, opening of the mould and ejection. The cycle of producing one
component is called moulding cycle.

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A Molding Cycle Is Explained As Follows:

Contact or Lead Frame Placing: -
The Lead frame or the contact is placed on the core pocket. Four legs are
there in core side so four slots are machine in core pocket.
Closing the mould: -

This is the time taken for rotation of table, closing the mould and applying
the locking force.
Injection of material: -
This is the time taken to inject the required amount of plastic material into
the mould.

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Cooling: -
This is the time taken for solidifying the molten material.
Opening of the mould: -

This is the time taken to open the mould maintaining the required daylight.
Ejection: -
This is the time taken to eject the component after the mould has opened
sufficiently.
Cycle Time For Each Molding Process Is As Follows

1 Mould Closing Time 6sec
2 Injection Time 5sec
3 Injection Holding/Packing Time 3sec
4 Cooling Time 30sec
5 Mould Opening Time 4sec
6 Ejection Time 2sec

TOTAL CYCLE TIME 50sec
A MOULDING CLOSING TIME

F26%
E22% A13%
B INJECTION TIME
B6%
C3% C INJECTION
HOLDING/PACKING TIME
E MOULD OPENING TIME
F EJECTION TIME

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It is the duty of every toolmaker to study and analyze the defects of a tool,
since all the requirements of the components cannot be fulfilled on a single
trial.
There are no defects in Cap Filter Intermediate SCMT+CB component,
after the second trial.
GENERAL DEFECTS AND REMEDIES

Problems Possible Reasons Suggested Solutions
Mould flashes 1) Material is too hot. 1) Reduce temperature.
2) Injection pressure is too 2) Reduce injection
High. Pressure.
3) Die faces warped. 3) Replace both half of
4) Core and cavity not Die.
Properly matched. 4) Match land area and
Reset mould adjustment.
Incomplete short 1) Material temperature too 1) Adjust to required

moulded Piece low. Temperature.
2) Injection pressure is too 2) Increase pressure.
Low.
Shrink marks on 1) Insufficient material shot 1) Sprue gate.

moulded piece into cavity. 2) Increasing curing time
2) Piece ejected too hot. and immense ejected
3) Pressure is too low. component in water.
4)” Suck back” when 3) Increase pressure.
Booster stroke ends. 4) Consider restricted
gating.

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DEFECTS AND REMEDIES

(DURING TRIALS)
During the time of trailing of the tool, the toolmaker faces several
problems. Some of the problems we faced during trail are as follows.
FIRST TRIAL:
Short filling, Flash and Ribs are catching
CAUSES:
Improper polishing.
Improper blue matching
High injection speed.
Cavity pin height are more.
EDM area will be not polished.
REMEDIES:
Did proper polishing.
Improve the blue matching.
Lower injection speed.
Increase the gates.
Cavity pin height are maintain.
EDM area will be polished.

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SECOND TRIAL:
In the second trail the component was good and dimensions are
achieved as per requirement by the customer and we send the
component to the customer, the customer said ok then we start
producing the component in our production area only.
TRIAL COMPONENT PHOTO

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COSTING
Standard costing is an important subtopic of cost accounting. Standard costs

are usually associated with a manufacturing company's costs of direct
material, direct labor, and manufacturing overhead.
Rather than assigning the actual costs of direct material, direct labor,
and manufacturing overhead to a product, many manufacturers assign the
expected or standard cost. This means that a manufacturer's inventories and
cost of goods sold will begin with amounts reflecting the standard costs, not
the actual costs, of a product. Manufacturers of course still have to pay the
actual costs. As a result there are almost always differences between the
actual costs and the standard costs, and those differences are known
as variances.
Standard costing and the related variance is a valuable management

tool. If a variance arises, management becomes aware that manufacturing
costs have differed from the standard (planned, expected) costs.

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A.Marginal Costing:
Through this method only the variable cost is allocated i.e. direct
materials, direct expenses, direct labour and variable overheads to
production. It does not include the fixed cost of production.
B.Absorption Costing:
It is the technique to absorb the fixed and variable costs to
production. In this method, full costs i.e. fixed and variable costs are
absorbed to the production.
C.Standard Costing:
When the costs are predetermined on certain standards in a given
set of operating conditions, it is called standard costing.
D.H istorical Costing:

In this method the costs are determined in terms of actual costs and
not predetermined standard costs. Costs are determined only after it is
incurred. Almost all organizations adopt this method of costing.

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TOTAL TOOL COST:
PRIME COST= Raw Material Cost + Machining Cost + Standard Item
Cost +Heat Treatment + Mould Base Cost
TOTAL COST= Prime Cost + Risk Factors + Overheads + Design

Charges +Inspection + Profit.
RAW MATERIAL COST
Sl. No Material Price/Kg Mass Cost

1 C-45 85Rs/Kg 190Kg 16,150 Rs
2 H-13 230Rs/Kg 55Kg 12,650 Rs
3 En -24 60Rs/kg 2Kg 120 Rs
4 OHNS 80Rs/Kg 50Kg 4000 Rs
5 COPPER 650Rs/Kg 35Kg 22,750 Rs
6 HDS 230Rs/Kg 2Kg 460 Rs
7 20mncr5 100Rs/kg 18Kg 1,800 Rs
8 MS Brite 60Rs/Kg 8Kg 480 Rs
TOTAL RAW MATERIAL CHARGES 58,410 Rs
MACHINING COST
WORK Rs/Hour
Milling 125
Turning 60
Cylindrical grinding 120
Grinding 150
Drilling 60
Bench work 80
Wire EDM 250
CNC milling 850
Sparking 200

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STANDARD ITEMS COST
Sl. No Material Quantity Price (Rs)
01 Screws 114 1600 Rs
02 Dowels 04 150 Rs
03 Cooling Nipples 04 320 Rs
04 Return Pin 04 1000 Rs
05 Ejector Pin 12 1200 Rs
06 Spring 08 1500 Rs
07 Eye Bolt 01 150 Rs
08 Finger Cam 04 1000 Rs
09 Ball Guage Bush 04 2800 Rs
10 Ball Catch 04 720 Rs
TOTAL STANDARD ITEMS CHARGES 10,440 Rs
ACTUAL MACHININING COST AND TIME

Sl. OPERATIONS RATE / M/C TOTAL COST IN
HR TIME Rs
No IN Rs IN Hrs
1 Milling 125 50 6250 Rs
2 Turning 60 10 600 Rs
3 Cylindrical 120 10
grinding 1200 Rs
4 Grinding 150 40 6000 Rs
5 Drilling 60 70 4200 Rs
6 Bench work 80 5 400 Rs
7 Wire EDM 250 10 2500 Rs
8 CNC milling 850 40 34000 Rs
9 Sparking 200 35 7000 Rs
10 Polishing 120 10 1200 Rs
11 Assembly 200 30 6000 Rs
TOTAL ESTIMATED MACHINING 69,350 Rs
COST

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ACTUAL COST AS FOLLOWS
SL.NO ELEMENTS TOTAL COST (Rs.)

1 RAW MATERIAL CHARGES 58,410 Rs
2 MACHINING CHARGES 69,350 Rs
3 STANDARD ITEM CHARGES 10,440 Rs
4 HEAT TREATMENT 4,000 Rs
TOTAL PRIME COST 1,42,200 Rs
TOTAL TOOL COST
SL.NO ELEMENTS TOTAL COST (Rs.)

01 Prime cost 1,42,200 Rs
02 Risk factor( 6% of prime cost) 8,532 Rs
03 Overheads(10%of prime cost) 14,220 Rs
04 Design charges ( 15% of prime 21,330 Rs
cost)
05 Inspection ( 3% of prime cost) 4,266 Rs
06 Tryout(5%of prime cost) 7,110 Rs
07 Profit ( 20% of prime cost) 28,440 Rs
TOTAL TOOL COST 2,26,098 Rs
TOTAL COST OF THE TOOL =2,26,098 Rs

Page 149
Project Report
DIFFERENCE BETWEEN ESTIMATED TOOL COST &
TOTAL TOOL COST
TOTAL ESTIMATED TOOL COST 2,84,337 Rs
TOTAL TOOL COST 2,26,098 Rs
DIFFERENCE 58,239 Rs
PIE CHART FOR TOTAL COST OF THE TOOL
20
3% 5% %
15% PRIME COST
RISK FACTOR
10% 41% OVER HEAD COST
DESIGN CHARGES
INSPECTION
6%
TRY OUT
PROFIT

Page 150
Project Report
Following are the safety measure, which should be followed while

completing the mould.
 While assembling,care to be taken that all the parts are without sharp
edges and fool proofing technique should be provided.
 The pillar and bush should be at the perfect right angle to the core and
cavity.
 See whether pillar project out of the plates, if it projecting they won’t
make the tool to butt platen at the right angle.
 Care should be taken that stroke given is too much, which may result in
jamming of tool.
 First and foremost and the least expensed is the breaking of sharp edges
and corners.
 Rigidity and fool proofing should be built in the tool.
 Safety glass to be worn in the working places when ever necessary.
TOOL SAFETY
 Safety of the operator and equipment should be considered while
planning the design and selection of feeding and ejecting mechanism.
 For manually feed operation it is usually an always preferable to design
the safety shield as a part of tool. Once the tool is set in the injection
moulding machine it is completely self-guarded required no additional
protection.
 Some sensors are also fixed as a fool proofing to the return of ejector
plate, when ever precise side core is used.
 The eyebolt should be rigid enough to lift the weight of the tool.

Page 151
Project Report

Page 152
Project Report
By manufacturing of this INJECTION MOULD, I have acquired

knowledge regarding mould manufacturing process, including design study,
process planning, and electrode planning, defects and remedies and trial
procedures. The problems faced during the manufacturing were brought to
the notice of senior toolmakers and our in-charge who helped us to solve
them with their useful advices.
I am able to complete this tool because of the immense training provided

to me during my three years training in GT&TC. Training imparted to us
was best in the field of tool engineering.
One-year in-plant training program in 3D PRECISION where I had an

opportunity to come across this project tool and it was of very much
importance to build my career and also it gives exposure to modern
industrial working atmosphere.
“At last I would like to conclude that the experience what I got while making
this report will certainly help me in developing my career.”

Page 153
Project Report

Page 154
Project Report
Injection Mould Design :R.G.W.Pye

Mould Making Hand Book :Gunter Menning
Heat Treatment : Howard E Boyer
Westerman Table : Hermannjutz & Scharkues
Tool Design : Cyril Donaldson
Industrial Management : Mahajan Sheeter
Internet : Google.com
Empolyee Encouragement : Manju & Ravi
SOFTWARE:
 SOLIDWORKS – For Tool & Component Designing.

 MASTER CAM – For CNC Milling.
 CAD – For wire EDM, 2D Drawing.
 MS.OFFICE, PAINT – For preparing project report

Page 155
Project Report
THANK YOU

Page 156

Final Project Nithin KP

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Project Report

GOVT. TOOL ROOM &TRAINING CENTRE

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

For Partial Fulfillment Of Sessional Requirement For The Award Of

“Diploma in Tool and Die Making”

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

This is to certify that the project titled

of “Diploma in Tool and Die Making”

PROJECT GUIDE PRINCIPAL

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

SL. MARKS MARKS

02. TOOL DESIGN ANALYSIS 50

SIGNATURE OF THE EVALUTOR

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

My Sincere Heartfull thanks to our Sir Mr.YOGISH.C.S. Proprietor, for

I wish to express my deep sense of gratitude to

My special thanks to Mr.SRINIVASA.J. Proprietor of 3D PRECISION,

I wish to thank Mr. SRINIVAS BHAT.S. (Tool Room) whose timely

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

(A Govt. of Karnataka Society)

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

Government Tool Room and Training Center is one of the

GT&TC is equipped with product development and component

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

GT&TC CENTRES IN KARNATAKA

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

1994 Hassan, Mangalore,Gulbarga

1998 Belgaum, Hubli, Harihar

2000 Maddur, Kudalasangama

2005 Kanakapura, Lingasugur, Kolar

2007 Gundlupet, Humnabad, Kadur

Diploma in tool and die making is a job-oriented course in which you

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

#65/2, 3RDMain Road Kaveripura,NearRammandira

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

Provide the Paramount quality in precision Tooling, machining,

3D PRECISION established in March 2004 as a SSI Unit, we are one of

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

We acquired huge base of clients in India due to ethical business practices,

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

This project gives detailed knowledge of mould designing and

It is helpful to toolmaker, by providing basic knowledge about design

This project report gives ideas regarding the different factors to be

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

Any products to be manufactured invariably require tools. Tool design and

The main objective of the project work is to have the detailed

The project work incorporates the details of studying the designs,

This presents an idea of fundamental necessary for processing the tool

Plot No. 93 94, Belagola Industrial Area, K.R.S Road, Mysore - 1

SL.NO DESCRIPTION PAGE.NO

02 COMPONENT ANALYSIS 31-40

03 TOOL DESIGN ANALYSIS 41-62

04 RAW MATERIAL SELECTION 63-71

06 TOOL TERMINOLOGY 80-84

07 PROCESS PLANNING 85-88

08 MANUFACTURING PROCESS 89-108

09 HEAT TREATMENT 109-112

12 FINAL ASSEMBLY 123-130

13 TRY OUT 131-138

14 DEFECTS AND REMEDIES 139-143

16 SAFETY RULES 151