Design and Fabrication of Pneumatic Blow Molding

Machine
A project report submitted in the partial fulfilment of requirements
For the award of Degree in Mechanical Engineering

(2014-2018)

Submitted By

B. Santosh Kumar G. Vamsi

(14A51A0310) (14A51A0337)

K. Kalyan K. Srikanth
(15A55A0310) (14A51A0353)

G. Prudhvi Raju
(15A55A0306)

Under the Guidance of

Mr. A. Satish
Assistant Professor
Department of Mechanical Engineering

Aditya Institute of Technology and Management

(An Autonomous Institution )

K. Kothuru, Tekkali.
 CERTIFICATE

This is to certify that that the project work entitled “ Design And
Fabrication Of Pneumatic Blow Molding Machine” is the work done by
B.SANTOSH KUMAR (14A51A0310), G.VAMSI(14A51A0337),
K.KALYAN(15A55A0310), K.SRIKANTH(14A51A0353) and
G.PRUDHVI RAJU(15A55A0306) during the academic year 2017-2018. The
work is submitted to the Department Of Mechanical Engineering in partial
fulfilment for the award of Degree In Mechanical Engineering to the ADITYA
INSTITUTE OF TECHNOLOGY AND MANAGEMENT (A) is a record of
bonafied work carried out by them under our guidance and supervision.

Signature of the Guide Signature of the HOD

____________________ ____________________

Mr. A. SATISH Garu Mr. C.J. Rao Garu

Assistant Professor Head of the Dept.

Department of Mechanical Engg. Department of Mechanical Engg.

AITAM(A), Tekkali AITAM(A), Tekkali

 ACKNOWLEDGEMENT

We express our sincere thanks and profound sense of gratitude to

Mr. A. Satish garu, Assistant Professor, for his esteemed guidance and
encouragement provided throughout the project. We greatly appreciate his
foresight which enabled us in choosing the topic “ Design and fabrication of
Pneumatic Blow Molding Machine”

We are also thankful to Mr. C.J. Rao garu, Head of the Department, of
Mechanical Engineering who helped us in successful completion of our project.

We would like extend our thanks to Mr. P. Srihari garu, Project Co-
ordinator, for his valuable support.

We are also thankful to Dr. K.B. Madhu Sahu garu, Principal-

AITAM(A) and Prof. V.V Nageswara Rao garu, Director- AITAM(A) who
made the atmosphere so congenial.

We are also thankful to all the Technicians of the laboratories of

Mechanical Engineering Department who helped us a lot and guiding us in
completion of this project and making it successful.
 ABSTRACT

Blow molding is a manufacturing process by which hollow plastic parts

are formed: It is also used for forming glass bottles. In general, there are three
main types of blow moulding: extrusion blow molding, injection blow moulding,
and injection stretch blow moulding. The blow moulding process begins with
melting down the plastic and forming it into a parison or in the case of injection
and injection stretch blow moulding (ISB) a preform. The parison is a tube-like
piece of plastic with a hole in one end through which compressed air can pass.

Integrating the system with the pneumatic system i.e., compressed air
power as the working medium is our project. By using the linear actuator of kind
double acting, and controlling them with the hand operated valves which
optimises the human effort in operating the job.

The main objective of our Project is to prepare the model which will be an
experimental setup in our “Production Technology lab”.
Introduction
Molding

Molding or moulding (see spelling differences) is the process of manufacturing

by shaping liquid or pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern or model of the final
object.

A mold or mould is a hollowed-out block that is filled with a liquid or pliable

material such as plastic, glass, metal, or ceramic raw material.[2] The liquid
hardens or sets inside the mold, adopting its shape. A mold is the counterpart to
a cast. The very common bi-valve molding process uses two molds, one for each
half of the object. Articulated moulds have multiple pieces that come together to
form the complete mold, and then disassemble to release the finished casting;
they are expensive, but necessary when the casting shape has complex overhangs.
Piece-molding uses a number of different molds, each creating a section of a
complicated object. This is generally only used for larger and more valuable
objects.

There are several types of molding methods. These include:

 Blow moulding
 Powder metallurgy plus sintering
 Compression molding
 Injection molding
 Laminating
 Reaction injection molding
 Matrix molding
 Rotational molding (or rotomolding)
 Spin casting
 Transfer molding
 Thermoforming
 Vacuum forming
Blow molding

Blow molding means we have to blow the air like usually blow the air by our
mouth. So, that is the principle of blowing. Here also, the plastic will be
deformed by pressurized air and the plastic will be pushed towards the valves of
the mold and it will take the shape of the mold.
Now that blowing thing is the air; pressurized air and that
will force the plastic against the valves of the mold and the plastic will take the
shape of the mold blow molding is a manufacturing process that is used to
produce hollow plastic parts. First thing we should remember, the application
why this process has been developed that is used to produce hollow plastic parts
by how that is done, by inflating a heated plastic. So, inflating means we have to
blow we have to
inflate it, we have to inject air inside, so that, the plastic inflates and takes the
shape of mold until it conforms to the mold shape. We will apply the air
pressure in such a way that the plastic is forced against the inner valves of the
mold and sticks to the inner valves of the mold and then it will form the desired
product.
So, there are 3 important things first is a raw plastic material
which usually called as a parison, then we are injecting pressurized air inside, it
is blowing like a balloon and then it adhere outside to control the shape of the
plastic there is a mold and inside the mold is plastic you can see it gets inflated
and it is forced against the inner parts of the mold and when the mold opens we
get our desired product and before that there is cooling of the plastic. So that, it
becomes sufficiently rigid and solid; so that, it do not deform once the mold has
opened. So, that is the basic principle of blow molding process.

Blow molding process can be broadly be classified into 2 categories;

These 2 classifications are:
1. Extrusion blow molding
2. Injection blow molding
Now, these 2 classifications are based on the raw material that we
used for extrusion process. So, the parison, p a r i s o n, is used as a raw material
in blow molding and the method for making the parison. If it is extrusion then
we call it as extrusion blow molding and the method of fabrication or
processing of parison is injection molding, in that case we will call the blow
molding process which uses a parison made by the injection molding process as
the injection blow molding process. So, they are combination of 2 processes.
So, you can see initially this is the shape that the dotted portion is the inner part
of the mold and this is a shape that we want to make this inner portion. And this
is split mold; this is one half of the mold and this is another half of the mold.
Through this pipe we will have pressurized air that will come inside and this is
the parison or the raw material that can be made by a extrusion process also, this
can be made by injection process also.
So, this parison is hollow and it is open from here, so air can
be pressurized through this particular nozzle into this parison and the parison
will blow. So, the second stage is, we can have pressurized air. The mold has
closed in this case. Here, you see the mold is open. Second stage mold has
closed down and we get our final cavity or the final replica of the product that
we want to make.
So, this is a hollow cavity. Third; air pressure from top, the
parison you can see here blows and takes the shape of the cavity inside the mold
and finally, the mold opens and the product is taken out. So,this is our final
product.
DESIGN CONSIDERATION OF THE PROJECT:

 Heat required for melting the plastic.

 Amount of pressure required for extruding the plastic material.
 Clamping force of the die.
 Actuator specifications as per extrusion and clamping intensity.
 Volume of air consuming per cycle.

Heat required for plastic melting

The basic melting temperature of the plastic is 150 deg. Celcius. This
temperature will varies with the type of plastic granules that are used for the
molding process. By using the rheostats and varying the voltage (V), and current
(A), will generates the heat that required for melting of plastic.

Power (P) = voltage(V) *current (I)

P = V*I
For heating coil of the copper element
1deg. = 0.62752 watt hr
As melting temperature of the plastic is 100 deg.
150 deg. = 94.125 watt hr
Therefore
94.125 = V*I
As the current supply on a single phase varies from 1A-5A with
respect to the voltage, and let be 2Amps.
94.125 = V*2
V =47.0625 volts
Pressure required for extruding the plastic material
The intensity of the pressure required to extrude the molten plastic from
the barrel into the die. This force that is required the molten liquid is 60N. This
data is collected from the old model.

Force =Pressure X Area

As Force of extrusion = 60 N and dia. Of bore is 50 mm

𝐹𝑋4
D2=
𝑃 𝑋𝜋

60 𝑋 4
502=
𝑃 𝑋100000 𝑋 𝜋

P= 300x103 N/m2

= 3 bar
Therefore,
A pressure of 3 bar is required from the compressor to the pneumatic
cylinder for Extrusion of molten plastic.

Clamping force of the die

The clamping force of the die is determined basing of weight of the die and
the blow pressure that is exerted at the blow of the bottle. As the weight of the
die is 10 kg (i.e., 98.1N) and blow pressure is 5 bar. Therefore total force of
600KN is required to clamp the die.

Force =Pressure X Area

Force = 600KN
𝐹𝑋4
Diameter =
𝑃𝑋𝜋
 600000 𝑋 4
502 =
𝑃 𝑋 100000 𝑋 𝜋

P = 785.23KN/m2

Let be 8 bar.

Actuator specifications as per extrusion and clamping intensity

With the above results, the chosen linear actuators specifications are as follows:
For the extruding process, the specifications of actuators are
Dia. Of the bore = 50mm

Stroke length = 350mm

Operating pressure = 0.7MPa to 8.5MPa

For operating the die and clamping for it, the specifications are

Dia. Of the bore = 50mm

Stroke length = 160mm

Operating pressure = 0.7MPa to 8.5MPa

Volume of air consuming per cycle

The quantity air consumed per is calculated basing on the diameter of the bore
and stroke length of the actuators.

FOR EXTRUDING ACTUATOR

Air Consumption in litres (forward stroke)
𝜋 2
𝑑 𝑋𝑃𝑋𝐿
4
Ac= Stroke length (L)=350 mm
1000

Pressure = 3bar
 0.785 𝑋 (0.0050)2 𝑋3𝑋0.350
=
1000

=2.099 lit………………………………..(forward stroke)

Air consumption in litres (reverse stroke)

𝜋 2
(𝐷 −𝑑2 ) 𝑋𝑃𝑋𝐿
4
Ac=
1000

0.785𝑋(0.00502 −0.00252 )𝑋 3𝑋0.350

=
1000

=1.749 litres……………………….(reverse stroke)

Total air consumption per cycle = 2.099+1.749=3.848 litres

FOR DIE CLAMPING ACTUATOR

Air Consumption in litres (forward stroke)

𝜋 2
𝑑 𝑋𝑃𝑋𝐿
4
Ac= Stroke length = 160mm
1000
Pressure = 8 bar

0.785 𝑋(0.0050)2 𝑋8𝑋0.160

= 1000

= 2.52 lit.
Air consumption in litres (return stroke)
𝜋 2
(𝐷 −𝑑2 ) 𝑋𝑃𝑋𝐿
4
Ac=
1000

0.785𝑋(0.00502 −0.00252 )𝑋 8𝑋160

` `=
1000

= 1.88lit
COMPONENTS USED AND FABRICATION

FABRICATION MACHINARY

Radial Drilling Machine:

A radial drilling machine is a geared drill head that is mounted on an arm
assembly that can be moved around to the extent of its arm reach. The most
important components are the arm, column, and the drill head. The drill head of
the radial drilling machine can be moved, adjusted in height, and rotated. The
tasks that a radial drilling machine can do include boring holes,counter sinking
and grinding off small particles in masonry

Welding Machine:
Arc welding uses an electrical arc to melt the work materials as well as filler
material (sometimes called the welding rod) for welding joints. Arc welding
involves attaching a grounding wire to the welding material or other metal
surface. Another wire known as an electrode lead is placed on the material to be
welded.

Grinding Machine:
A grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive
wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a
small chip from the work piece via shear deformation.
Components:
 Heating barrel
 Compressor
 Pneumatic cylinders
 Direction control valves
 Flow control valves
 Manifold
 Hose pipes
 Injection chamber
 Die
 FRL unit
 Rod end bearing

Heating barrel
Heating barrel is the hallow section that is used melt the plastic granules from
solid particles. The inner surface of the barrel is surrounded with copper heating
coils that powered with the electric supply.
The barrel is having two melting zones. Pre- melting zone, post- melting zone. In
pre-melting zone the plastic granules are partially turned into molten state. In post
melting zone the partially molten liquid is completely turned into molten state
and starts to bleed from the orifice.

Compressor
Piston compressors are available as single or double acting, oil lubricated or oil
free with different number of cylinders in different configurations. With the
exception of really small compressors with vertical cylinders, the V configuration
is the most common for small compressors. On double acting, large compressors
the L type with vertical low pressure cylinder and horizontal high pressure
cylinder, offer immense benefits and is why this the most common design. The
construction and working of a piston type reciprocating compressor is very much
similar to that of an internal combustion engine.

Pneumatic cylinders
Pneumatic cylinder (sometimes known as air cylinders) are mechanical
devices which use the power of compressed gas to produce a force in a
reciprocating linear motion like hydraulic cylinders, something forces a piston to
move in the desired direction. The piston is a disc or cylinder, and the piston rod
transfers the force it develops to the object to be moved. Engineers sometimes
prefer to use pneumatics because they are quieter, cleaner, and do not require
large amounts of space for fluid storage. Because the operating fluid is a gas,
leakage from a pneumatic cylinder will not drip out and contaminate the
surroundings, making pneumatics more desirable where cleanliness is a
requirement

Types
 Single acting cylinder
 Double acting cylinder

Single acting cylinder

Single-acting cylinders (SAC) use the pressure imparted by compressed air to
create a driving force in one direction (usually out), and a spring to return to the
"home" position. More often than not, this type of cylinder has limited extension
due to the space the compressed spring takes up. Another downside to SACs is
that part of the force produced by the cylinder is lost as it tries to push against the
spring.

Schematic symbol single acting cylinder

Double acting cylinder
Double-acting cylinders (DAC) use the force of air to move in both extend and
retract strokes. They have two ports to allow air in, one for outstroke and one for
in stroke. Stroke length for this design is not limited, however, the piston rod is
more vulnerable to buckling and bending. Additional calculations should be
performed as well.

Schematic symbol double acting cylinder

Direction Control valves:

Pneumatic systems like hydraulic system also require control valves to direct and
regulate the flow of fluid from the compressor to the various devices like air
actuators and air motors. In order to control the movement of air actuators,
compressed air has to be regulated, controlled and reversed with a predetermined
sequence. Pressure and flow rates of the compressed air to be controlled to obtain
the desired level of force and speed of air actuators.

The function of directional control valve is to control the direction of flow in the
pneumatic circuit. DCVs are used to start, stop and regulate the direction of air
flow and to help in the distribution of air in the required line.
Classification
 Classification of DCVs based Fluid Path
 Classification of DCVs based on Design Characteristics
 Classification of DCVs based on the Control Method
 Classification of DCVs based on the Construction of Internal Moving
Parts
 Classification of DCVs based on actuating methods.
Classification of DCVs based on fluid path
 Check valves.
 Shuttle valves.
 Two-way valves.
 Three-way valves.
 Four-way valves.

2/2-Way DCV
Figure shows a two-way two-position (normally closed) of spool type. A spool
valve consists of a cylindrical spool that slides back and forth inside the valve
body to connect or block flow between the ports. The larger diameter portion of
the spool, the spool land blocks flow by covering the port. This particular valve
has two ports labelled P and A. P is connected to the pump line and A is connected
to the outlet to the system. Figure (a) shows the valve in its normal state and its
corresponding symbol. The valve is held in this position by the force of the spring.
In this position, the flow from the inlet port P is blocked from going to the outlet
port A. Figure (b) shows the valve in its actuated state and its corresponding
symbol. The valve is shifted into this position by applying a force to overcome
the resistance of the spring. In this position, the flow is allowed to go to the outlet
port.

Figure shows a two-way, two-position normally open DCV. The spring holds the
valve in a position in which ports P and Aare connected as shown in Fig (a). When
the valve is actuated, the flow is blocked from going to A as shown in Fig (b).
Three-way valves
3/2-Way DCV (Normally Closed)
Three-way valves either block or allow flow from an inlet to an outlet. They also
allow the outlet to flow back to the tank when the pump is blocked, while a two-
way valve does not. A three-way valve has three ports, namely, a pressure inlet
(P),an outlet to the system(A)and a return to the tank(T). Figure shows the
operation of a 3/2-way valve normally closed. In its normal position, the valve is
held in position by a spring as shown in Fig (a). In the normal position, the
pressure port P is blocked and outlet A is connected to the tank. In the actuated
position shown in Fig (b), the pressure port is connected to the tank and the tank
port is blocked.

Figure shows a three-way two-position DCV (normally open)with push button

actuation and spring return. In the normal position, shown in Fig (a), the valve
sends pressure to the outlet and blocks the tank port in the normal position. In the
actuated position, the pressure port is blocked and the outlet is vented to the tank.

Four-way valves
Four-way DCVs are capable of controlling double-acting cylinders and
bidirectional motors. Figure shows the operation of a typical 4/2 DCV. A four-
way has four ports labeled P,T,A and B. P is the pressure inlet and T is the return
to the tank; A and B are outlets to the system. In the normal position, pump flow
is sent to outlet B. Outlet A is connected to the tank. In the actuated position, the
pump flow is sent to port A and port B connected to tank T. In four-way DCVs,
two flows of the fluids are controlled at the same time, while two-way and three-
way DCVs control only one flow at a time.
5/3 Way Direction control valve:
5/3 way single-pilot pneumatic valve, pneumatically actuated in both directions,
spring centred, exhausted and mid position. For this kind there will be 5 ports and
3 positions. Among 5 ports, 3 ports are on one side and 2 are on other side. On
the 3 port side the centre port is the inlet, and the other 2 are for exhaust. On the
2 ports side, the 2 ports are connected to the actuator. Basically this kind of
actuator is used for double acting cylinder. The three positions are forward, centre
and backward.

Classification of DCVs based on Design Characteristics

Based on design characteristics, DCVs can be classified as follows:
 An internal valve mechanism that directs the flow of fluid. Such a
mechanism can either be a poppet, a ball, a sliding spool, a rotary plug or
a rotary disk.
 Number of switching positions (usually 2 or 3).
 Number of connecting ports or ways.
 Method of valve actuation that causes the valve mechanism to move into
an alternate position.

Classification of DCVs based on the Control Method
Based on the control method, DCVs can be classified as follows:
 Direct controlled DCV: A valve is actuated directly on the valve spool.
This is suitable for small sized valves.
 Indirect controlled DCV: A valve is actuated by a pilot line or using a
solenoid or by the combination of electrohydraulic and electro-pneumatic
means. The use of solenoid reduces the size of the valve. This is suitable
for large-sized valves.

Classification of DCVs based on the Construction of Internal Moving Parts

Based on the construction of internal moving parts, DCVs can be classified as
follows:
  Rotary spool type: In this type, the spool is rotated to change the direction
of fluid. It has longitudinal grooves. The rotary spools are usually manually
operated.
 Sliding spool type: This consists of a specially shaped spool and a means
of positioning the spool. The spool is fitted with precision into the body
bore through the longitudinal axis of the valve body. The lands of the spool
divide this bore into a series of separate chambers. The ports of the valve
body lead into these chambers and the position of the spool determines the
nature of inter-connection between the ports.
Classification of DCVs based on actuating methods
 Manual
 Spring
 Electrical
 Pneumatic
 Hydraulic
Manual operated
Manually operated valves work with simple levers or paddles where the operator
applies force to operate the valve. Spring force is sometimes used to recover the
position of valve. Some manual valves utilize either a lever or an external
pneumatic or hydraulic signal to return the spool.

Mechanical operated
Mechanically operated valves apply forces by using cams, wheels, rollers, etc.,
hence these valves are subjected to wear.
Hydraulically operated
A hydraulically operated Directional control valve works at much higher
pressures than its pneumatic equivalent. They must therefore be far more robust
in nature so are precision machined from higher quality and strength materials.

Flow control valve

Flow-control valves, as the name suggests, control the rate of flow of a fluid
through a hydraulic circuit. Flow-control valves accurately limit the fluid volume
rate from fixed displacement pump to or from branch circuits. Their function is
to provide velocity control of linear actuators, or speed control of rotary actuators.
Typical application include regulating cutting tool speeds, spindle speeds, surface
grinder speeds, and the travel rate of vertically supported loads moved upward
and downward by forklifts, and dump lifts. Flow-control valves also allow one
fixed displacement pump to supply two or more branch circuits fluid at different
flow rates on a priority basis. Typically, fixed displacement pumps are sized to
supply maximum system volume flow rate demands. For industrial applications
feeding two or more branch circuits from one pressurized manifold source, an
oversupply of fluid in any circuit operated by itself is virtually assured. Mobile
applications that supply branch circuits, such as the power steering and front end
loader from one pump pose a similar situation. If left unrestricted, branch circuits
receiving an oversupply of fluid would operate at greater than specified velocity,
increasing the likelihood of damage to work, hydraulic system and operator.

Classification
 Non-pressure compensated
 Pressure compensated.
Non-pressure compensated
Non-pressure-compensated flow-control valves are used when the system
pressure is relatively constant and motoring speeds are not too critical. The
operating principle behind these valves is that the flow through an orifice remains
constant if the pressure drop across it remains the same. In other words, the rate
of flow through an orifice depends on the pressure drop across it. The
disadvantage of these valves is discussed below. The inlet pressure is the pressure
from the pump that remains constant. Therefore, the variation in pressure occurs
at the outlet that is defined by the work load. This implies that the flow rate
depends on the work load. Hence, the speed of the piston cannot be defined
accurately using non-pressure-compensated flow-control valves when the
working load varies. This is an extremely important problem to be addressed in
hydraulic circuits where the load and pressure vary constantly.
Schematic diagram of non-pressure-compensated needle-type flow-control valve
is shown in Fig (a) It is the simplest type of flow-control valve. It consists of a
screw (and needle) inside a tube like structure. It has an adjustable orifice that can
be used to reduce the flow in a circuit. The size of the orifice is adjusted by turning
the adjustment screw that raises or lowers the needle. For a given opening
position, a needle valve behaves as an orifice. Usually, charts are available that
allow quick determination of the controlled flow rate for given valve settings and
pressure drops. Sometimes needle valves come with an integrated check valve for
controlling the flow in one direction only. The check valve permits easy flow in
the opposite direction without any restrictions. As shown in Fig (b) only the flow
from A to B is controlled using the needle. In the other direction (B to A), the
check valve permits unrestricted fluid flow

Figure (b)

Pressure compensated
Pressure-compensated flow-control valvesovercome the difficulty causedby non-
pressurecompensated valves by changing the size of the orifice in relation to the
changes in the system pressure. This is accomplished through a spring-loaded
compensator spool that reduces the size of the orifice when pressure drop
increases. Once the valve is set, the pressure compensator acts to keep the
pressure drop nearly constant. It works on a kind of feedback mechanism from
the outlet pressure. This keeps the flow through the orifice nearly constant.
 Figure (a)

Figure (b)

Schematic diagram of a pressure compensated flow-control valve is shown in Fig

(a) and its graphical symbol in Fig (b) A pressure-compensated flow-control
valve consists of a main spool and a compensator spool. The adjustment knob
controls the main spool’s position, which controls the orifice size at the outlet.
The upstream pressure is delivered to the valve by the pilot line A. Similarly, the
downstream pressure is ported to the right side of the compensator spool through
the pilot line B. The compensator spring biases the spool so that it tends toward
the fully open position. If the pressure drop across the valve increases, that is, the
upstream pressure increases relative to the downstream pressure, the compensator
spool moves to the right against the force of the spring. This reduces the flow that
in turn reduces the pressure drop and tries to attain an equilibrium position as far
as the flow is concerned.

Hoses
A hose is a flexible hollow tube designed to carry fluids from one location to
another. Hoses are also sometimes called pipes (the word pipe usually refers to a
rigid tube, whereas a hose is usually a flexible one), or more generally tubing.
The shape of a hose is usually cylindrical (having a circular cross section).
Hose design is based on a combination of application and performance. Common
factors are size, pressure rating, weight, length, straight hose or coilhose, and
chemical compatibility.
Hoses are made from one or a combination of many different materials.
Applications mostly use nylon, polyurethane, polyethylene, PVC, or synthetic or
natural rubbers, based on the environment and pressure rating needed. In recent
years, hoses can also be manufactured from special grades of polyethylene
(LDPE and especially LLDPE). Other hose materials
include PTFE (Teflon), stainless steel and other metals.

Pneumatic connectors
FRL Unit

An FRL combined box set is made up of a filter /regulation ,a lubrication and the
associated fitting and wall mounting brackets. The FRL box set offers complete
air treatment solution. The potential applications of an FRL unit can vary
depending on various accessories, including:
o 3/2 way shut off valves
o Pressure switches

FILTER

Filtering compressed air is widely regarded as the initial phase of air

preparation. To allow machinery and pneumatic components to work at their
optimum, they must be fed with clean, filtered air that is free of dust, water and
other particles. Various filtration levels are available between 5 and 40 microns.

PRESSURE REGULATORS

Air pressure regulators benefit the FRL boxset in many ways. Firstly, and
most importantly it provides an element of safety. Subsequent to this, it also helps
to reduce costs. The role of a regulator is to control the air pressure to air tools,
air gauging equipment and cylinders. The air pressure is regulated by a spring
which acts through a diaphragm.
PNEUMATIC LUBRICATORS

Like pressure regulators, the lubricator function of an FRL unit ensures that
the air is dosed with a small amount of lubrication oil to help pneumatic
components work effectively. Lubricators ensure that the correct amount of oil is
being used to reduce the friction between moving components. This feature is
very important to ensure a long machinery life span.

Rod end bearing

A rod end bearing, also known as a heim joint or rose joint , is a mechanical
articulating joint. Such joints are used on the ends of control rods, steering links,
tie rods, or anywhere a precision articulating joint is required, and where a clevis
end (which requires perfect 90 degree alignment between the attached shaft and
the second component) is unsuitable. A ball swivel with an opening through
which a bolt or other attaching hardware may pass is pressed into a circular casing
with a threaded shaft attached. The threaded portion may be either male or female.
The heim joint's advantage is that the ball insert permits the rod or bolt passing
through it to be misaligned to a limited degree (an angle other than 90 degrees).
A link terminated in two heim joints permits misalignment of their attached shafts
(viz., other than 180 degrees) when used in tension. When used in compression,
the through-rods are forced to the extreme ends of their ball's misalignment range,
which cocks the link at an oblique angle.
Automation Stimulation Design in Automation Studio Software
ASSEMBLY
MOUNTING OF EXTRUDING CYLINDER

As the piston should extrude the molten liquid and the application of force is
vertically downward, the actuator is mounted over the heating barrel, such that
piston rod passes into the barrel cavity and applies force on the molten liquid.
The speed of the piston can be regulated by incorporating the flow control
valves at actuator inlet and at DCV.

MOUNTING OF DIE CLAMPING CYLINDER

The cylinder is mounted in such a way that it is capable of operate in the direction
of die open and withstanding the blow pressure. For this the die is mounted
horizontally. And for die actuation, the piston end fixed with rod end bearing,
which offer an angular clearance of about 90deg. This cylinder if fixed over the
brackets which are made of L- sections and the brackets are fastened to the
basement.
FIXING OF PNEUMATIC ACCESSORIES

Components that are required for operation are DCVs, FRL unit, Air Manifold
are fixed to the operating table by fastening with the nuts and bolts to the board.

The compressor is placed at the ground beside to the setup.

The dimmerstat is fixed to the basement, to operate the coils in the heating coil
by regulating the voltage.
Final Model Setup Of Our Project