Fabrication of Injection Moulding Machine 1st Sem Report SSGB BE

Design And Fabrication Of Gear Type Injection Moulding Machine
CHAPTER -1
INTRODUCTION
S.S.G.B, BHUSAWAL 1
CHAPTER NO. 01
INTRODUCTION
The project deals about the injection moulding machine. The main principle is to
compress the plastic material in a barrel and the compressing motion is developed by
rotating the gear box arrangement. The plastic material is heated by the heater
surrounding the barrel. Then it is converted into molten state. The molten plastic is
injected through the nozzle in barrel to the die by the compressing force. After
completing this process, we will get the product from the die. Commercial products
like bushes, couplings, switches etc., can be produced.
1.1 Fabrication Techniques:
The polymer material are converted into plastics and used as tubes, sheets, foams,
rods, adhesives, etc., The theological properties, softening, tempering, stability, the
size and shape are important in describing the method. These methods are different
kinds of plastics. Broadly speaking the method may be discussed under the following
headings,
1. MOULDING PROCESS
2. FOAMING PROCESS
1.1.1 Moulding Process:
In this process the plastics are fabricated under the effect pressure and heat and both
thermoplastics and thermosetting plastics may be starting materials.
Injection Moulding:
Thermoplastics are produced by this method. In this the material is softened by

heating and the hot softened plastic is forced under high pressure into the mold, when
it is set by cooling and the mold is ejected. The injection moulding is performed on
materials mainly metals, thermoplastic and thermosetting polymers. For inject ing the
material some equipment are required. It uses the ram or plunger to force the molten
plastic material into the mould cavity. . After completing this process, we will get the
product from the die. Commercial products like bushes, couplings, switches etc., can be
produced.
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1.1.2 Foaming Process:
This involves the blowing of a volatile organic liquid, which is entrapped into a
polymer network resulting in the formation of foamed plastics. Foamed polysterens
are produced in this process.The manually operated plastic in jection moulding
machine, it is cheaper then hydraulic and pneumatic machine. It can solve the
problem of s mall and mediu m scale industries to create small plastic components. In
1868 John Wesley Hyatt became the first to inject hot cellulo id into a mould,
producing Billiard balls. He and his brother Isaiah patented an injection mould ing
machine that used a Plunger in 1872, and the process remained mo re or less the same
until 1946, when James Hendry built the first screw injection mould ing machine,
revolutionizing the plastics industry. Roughly 95% of all mould ing machines now
use screws to efficiently heat, mix, and inject Plastic into moulds. Injection moulding
is a manufacturing process for producing parts by inserting molten or plasticized
material into a mould.
The injection moulding is performed on materials mainly metals, thermoplastic and

thermosetting polymers. For inject ing the material some equipment are required. It
uses the ram or plunger to force the molten plastic material into the mould cavity.
Thermoplastics polymer are preferred due to characteristics which makes them highly
suitable for injection mould ing such as ease to recycle, versatility allo wing to used in
wide range of application, and ability to soften and flow upon heating. Injection
moulding machine is similar to injection with syringe and also with the screw of
thrust, in which mo lten material is forced into the mould cavity to obtain a final
product. Plastic injection moulding machine can be classified into horizontal, vertical,
inclined, screw, rotary, mu lti-material and sandwich type based on the direction of
clamp ing unit, axis of ram and type of ram. In vertical inject ion mould ing machine
the material is fed from the top side of the machine into the barrel which is
surrounded by the heating coils. The plastic is forced into the mould cavity with the
help of ram or plunger placed inside the barrel.
The manually operated plastic in jection moulding machine, it is cheaper
then hydraulic and pneumatic machine. It can solve the problem of s mall and mediu
m scale industries to create small plastic components. In 1868 John Wesley Hyatt
became the first to inject hot cellulo id into a mould, producing Billiard balls. He and
his brother Isaiah patented an injection mould ing machine that used a Plunger in
S.S.G.B, BHUSAWAL 3
1872, and the process remained mo re or less the same until 1946, when James
Hendry built the first screw injection mould ing machine, revolutionizing the plastics
industry. Roughly 95% of all mould ing machines now use screws to efficiently heat,
mix, and inject Plastic into moulds. Injection moulding is a manufacturing process for
producing parts by inserting molten or plasticized material into a mould.
The inject ion moulding is performed on materials mainly metals,
thermoplastic and thermosetting polymers. For inject ing the material some equipment
are required. It uses the ram or plunger to force the molten plastic material into the
mould cavity. Thermoplastics polymer are preferred due to characteristics which
makes them highly suitable for injection mould ing such as ease to recycle, versatility
allo wing to used in wide range of application, and ability to soften and flow upon
heating. Injection moulding machine is similar to injection with syringe and also with
the screw of thrust, in which mo lten material is forced into the mould cavity to obtain
a final product.
Whether we want to make a toy or fabricate a spacecraft, polymers would
often have some crucial role to play. But how does one convert a polymer into a
broad spectrum of useful shapes and structures? To answer this question, we need to
look at another branch of polymer technology called “polymer processing” which it’s
the theme of this chapter.In a very broad sense, polymer processing may be defined as
an engineering specialty used to convert polymeric materials into useful end products.
Most of the available techniques now employed in processing technology of polymers
are basically refined versions of those used in ceramic or metal industries. In fact, the
need to understand finer aspects of polymer processing surfaced as conventional
materials were required to be substituted by those with better finish and elegant. They
black ebony or the costly ivory keys in a harmonium or a piano gave way to wooden
keys with a covering of celluloid.
The injection moulding issued in modern age. The human beings make use of one or
other material made up of plastics in their routine life.The frame is designed like a
chassis frame with the help of L angle. The frame is finished accurately & it has
provisions to mount the components.
There is also a provision to mount the channels on which the die locking & Die
setting system works.The threads are formed on the shafts. The two shafts are
mounted on the either side of the channel.
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CHAPTER NO.02
LITERATURE SURVEY
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CHAPTER NO.02
LITERATURE SURVEY
[1] Amol J. Asalekar, Somashekhar G. Ganiger, “ Design & Analysis in Injection
Moulding Machine “ International Journal of Engineering Research &
Technology (IJERT) ISSN: 2278-0181 Vol. 3 Issue 9, September- 2014
The Injection moulding process is commonly used manufacturing process for the
production of plastic parts. The plastic being melted in injection molding machine and
then injected into the mould. The barrel contains reciprocating screw for injecting the
material into the mould and the material is also melted into the barrel. This project
deals with, the solution of problem occurred for reciprocating screw of Injection
molding machine. It identifies and solves the problem by using the modeling and
analysis techniques. The problem occurred in the reciprocating screw of machine
which is wearing of threads due to effect of temperature of mold materials (flow
materials) i.e. Nylon, low-density polypropylene, polystyrene, PVC etc., The main
work was to model the components of machine with dimensions, and perform static
and thermal analysis with parts of injection molding machine parts like reciprocating
screw.[2] The analysis of reciprocating screw provides the possible solution to reduce
the wear or damage on reciprocating screw, hence avoiding the high cost and time
lapse
[2] Rashi A.Yadav1Reserach Scholar, Principal S.V.Joshi2, Asst. Prof.

N.K.Kamble2 “Recent Methods for Optimization of Plastic Injection Molding
Process ” International Journal of Scientific & Engineering Research ISSN
2229-5518Volume 3, Issue 12, December-2012
The barrel contains reciprocating screw for injecting the material into the mould and
the material is also melted into the barrel. This project deals with, the solution of
problem occurred for reciprocating screw of Injection molding machine. It identifies
and solves the problem by using the modeling and analysis techniques. The problem
occurred in the reciprocating screw of machine which is wearing of threads due to
effect of temperature of mold materials (flow materials) i.e. Nylon, low-density
polypropylene, polystyrene, PVC etc., The main work was to model the components
of machine with dimensions, and perform static and thermal analysis with parts of
injection molding machine parts like reciprocating screw.
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 Yunoki and akio invented a hand operated injection mould ing mach ine
comprising a heating chamber therein ismounted on a base and has a discharge
nozzle with an orifice therein a plunger being movable into the chamber toward the
discharge nozzle. A mould holder is supported on the base andhas a mould including
first and second mould members wh ich jointly provide a mould cavity there between.
The mou ld holder is pivotable between a first position in which the mould is held
in contact with the discharge nozzle with a sprue in one of the mould member being
held in co mmunication with the orifice and a second position in which the mould is
located away from thedischarge nozzle. There is a means on the base for locking the
mould holder in the first position.
[3] Rohit Narad, Suraj Paithankar, Sushant Umale, Mohanish nimje, A mo l

Ingole “Fabrication of Manual Plastic Injection Moulding Machine
” International Conference on Ideas, Impact and Innovation in Mechanical
Engineering (ICIIIME 2017)Volume 06-2321-8169
Injection mould ing machine is one of the most widely used method for conversion of
plastics into various end products application to wide range of plastic material. The
main princip le is to compress the plastic material in a heating chamber (barrel) with
the help of plunger and induction coil convert plastic polymer into mo lten (semi-
solid) state. Then the plastic polymer in predetermined quantity is forced through the
nozzle into the die under pressure. After completing the process , final product is
obtained from the die. We can use plastics, metals or alloys for this process. In our
project we are using plastics polymers for making bushes, switches, fis hing hooks,
mobile covers etc. This machine is a prototype for producing small plastic
components. This injection moulding machine is very useful for the small scale
industries because of its low manufacturing cost, low maintenance cost, no skilled
worker is req uired. It can be recommended for small scale investors those who are
willing to produce small plastic products.
Lee and yuan-ho invented a moulding device with hand operable mould. A
moulding device includes at least two components from boards and a wedge
shaped spacer board between them. An operating mechanism is associated with
the form boards and the spacer, and moves them relative to one another. The
operating mechanism includes at least one rack member and at least one lever
S.S.G.B, BHUSAWAL 7
connected with a pawl wh ich swings about an axis eccentric with the axis of the
lever. The pawl engages with the rack and moves the rack forward when the lever
is operated.
[4] C. Sasikumar, S. Srikanth, S.K. Das. “Analysis of premature failure of a

tie bar in an injection molding machine” in Engineering Failure Analysis,
Volume 13, Issue 8, December 2006, Pages 1246-1259.
The project deals about the injection moulding machine. The main principle is to
compress the plastic material in a barrel and the compressing motion is developed
by rotating the rack and pinion arrangement. The plastic material is heated by the
heater surrounding the barrel. Then it is converted into molten state. The molten
plastic is injected through the nozzle in barrel to the die by the compressing force.
After completing this process, we will get the product from the die. Commercial
products like bushes, couplings, switches etc., can be produced.
S.S.G.B, BHUSAWAL 8
CHAPTER NO. 03
THEORETICAL BACKGROND
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CHAPTER NO. 03
THEORETICAL BACKGROND
3.1 Injection Moulding Process :
The injection-moulding process is best suited for producing articles made of

thermoplastic materials. Here, the equipment cost is relatively high but the main
attraction is the amenability of the injection-moulding process to a high production
rate. In injection molding, a definite quantity of molten thermoplastic material is
injected under pressure into a relatively cold mold where it solidifies to the shape of
the mould.
The injection – moulding machine is shown in the process consists of feeding the
compounded plastic material as granules, pellets or powder through the hopper at
definite time intervals into the hot horizontal cylinder where it gets softened. Pressure
is applied through a hydraulically driven piston to push the molten material through a
cylinder into a mould fitted at the end of the cylinder. While moving through the hot
zone of the cylinder, a device called torpedo helps spread the plastic material
uniformly around the inside wall of the hot cylinder sand thus ensures uniform heat
distribution. The molten plastic material from the cylinder is then injected through a
nozzle material from the cylinder is then injected through a nozzle into the mould
cavity.
The mould used, in its simplest form, is a two-part system. One is a movable
part and the other stationary. The stationary part is fixed to the end of the cylinder
while the movable part can be opened or locked on to the stationary part. By using a
mechanical locking device, the mould is proper held in position as the molten plastic
material is injected under a pressure as high as 1500kg/cm. The locking device has to
be very skillfully designed in order to withstand high operating pressures. Further
more, a proper flow of the molten material to the interior regions of the mold is
achieved by preheating the mould to an appropriate temperature. Usually, this
temperature is slightly lower than the softening temperature of the plastic material
under going moulding.
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After the mould is filled with the molten material under pressure, then it is cooled by
cold water circulation and then opened so as to eject the molded article. The whole
cycle could be repeated several time either manually of in an automated mode.
Injection moulding machine is a machine that always been use in the

competitive industries such as automotive industry, electrical and electronic
industries, medical industry and etc. Injection moulding machine offers many
advantages compare to others manufacturing methods such as minimal losses from
scrap due to recycled plastic and minimal finishing requirement. Refer figure 1.0.
Conventional injection moulding machine and micro injection moulding machine has
the same purpose which is producing product by injecting process. But what make the
micro injection moulding machine is differ compare to injection moulding machine
are the specification and parameters that need to control in the micro injection
moulding machine. Micro injection moulding is a machine that produces a product
that has a weight less than 1 gram and a diameter less than 1mm
Figure :3.1 Example Of Injection Moulding Machine

Injection moulding machine is a machine that always been use in the competitive
industries such as automotive industry, electrical and electronic industries, medical
industry and etc. Further more, a proper flow of the molten material to the interior
regions of the mold is achieved by preheating the mould to an appropriate temperature
3.2 Fundamentals of Injection Moulding Machine :

3.2.1 Injection Unit :
The injection unit is responsible for both heating and injecting the material into the
mould. The first part of this unit is the hopper, a large container into which the raw
plastic is poured. It has an open bottom, which allows the material to feed into the
barrel. The barrel contains the mechanism for heating and injecting the material into
the mould. This mechanism is usually a ram injector or a reciprocating screw. A ram
injector forces the material forward through a heated section with a ram or plunger
that is usually hydraulically powered. Refer figure belove.
Figure :3.2 Injection Unit Of Injection Moulding Machine

The injection unit can be divided into several parts which are feed hopper, injection
ram, injection screw, injection cylinder and barrel. Below are the description for every
parts of the injection unit .
I. Feed hopper – the container that commonly in a shape of triangle holding a

supply moulding material to be fed to the screw to be heated.
II. Injection plunger/ ram – the molten plastic in the barrel can be fed in to the
mould by apply the force or pressure towards the material using this ram or
screw.
III. Injection screw – the common screw that use in the machine is reciprocating
screw. The function of reciprocating screw is to melt the material and at the
same time inject the molten plastic into the mould.
IV. Barrel – the major section that functions to melts the plastic material that
transfer from the hopper. Barrel has a control system that can control the
suitable and proper temperature to meet the plastic characteristics and get the
best uniformity.
V. Injection cylinder – Injection cylinder is composed of cylinder body, piston,

and piston load. Hydraulic motor located inside bearing box, which is
connected to injection cylinder load, rotates screw, and the melted resins are
measures at the nose of screw.
3.2.2 Clamping Unit

Prior to the injection of the molten plastic into the mould, the two halves of the mould
must first be securely closed by the clamping unit. When the mould is attached to the
injection moulding machine, each half is fixed to a large plate, called a platen. The
front half of the mould, called the mould cavity, is mounted to a stationary platen and
aligns with the nozzle of the injection unit. The rear half of the mould, called the
mould core, is mounted to a movable platen, which slides along the tie bars. The
hydraulically powered clamping motor actuates clamping bars that push the moveable
platen towards the stationary platen and exert sufficient force to keep the mould
securely closed while the material is injected and subsequently cools.
After the required cooling time, the mould is then opened by the clamping motor.
An ejection system, which is attached to the rear half of the mould, is actuated by
the ejector bar and pushes the solidified part out of the open cavity. Clamping unit
consists of injection mould, injection platens, clamping cylinder and tie bar.
Below are the descriptions for each parts of the clamping unit.
I. Injection mould – the mould is the part where the molten plastic is injected to
fill the cavity in the mould.
II. Injection platens – the section where the mould is attached. Commonly there are
two platens are used which are fix halve and movable halve. The cavity side of
the mould is attaching at the fix platens while the core side of the mould is
attach at the movable platen. The platens consist of several holes so that the
mould can be mounted using clamps.
III. Clamping cylinder - A device that actuates the chuck through the aid of
pneumatic or hydraulic energy.
IV. Tie bar – it function to support the force of the clamping. Generally, there are
four tie bars located between the fix platen and movable platen.
Figure :3.2.2 Clamping Unit Of Injection Moulding Machine

3.2.2.1 Clamping Mechanism:
The clamping mechanism opens and closes the mould (preferably rapidly) as
required during the cycle. It must also supply the necessary clamping force to keep
the mould closed during injection, because the injection pressure acting on the
internal, or projected, surface of the cavity space tends to open the mould at the
parting-plane or parting line.
3.2.2.2 Types Of Clamping System:
The clamping system opens and closes the mould, supports and carries the
constituent parts of the mould, and generates sufficient force to prevent the mould
from opening. Clamping force can be generated by a mechanical (toggle) lock,
hydraulic lock, or a combination of the two basic types.
3.3 Plasticizing Unit :

Today’s plasticizing unit is almost exclusively an extruder that heats the cold
plastic material to the required temperature to make it fluid for injection, or melt. The
heating is generated mostly by the mechanical energy that created by the screw motor,
as the extruder screw rotates in the barrel and works the plastic. This screw action also
advances the plastic toward the tip of the screw.
Heaters around the barrel, usually in three or more heating zones, provide
additional heating, which is mainly required during start-up of the machine but also
where the mechanical working of the screw alone would not plasticize the amount of
plastic required for each shot.
3.4 Melt Temperature :
The melt temperature of the moulding material (stock temperature) is
controlled by the barrel temperatures, screw speed, injection speed and back pressure.
The water jackets around the barrel regulate the point at which the material will start
to plasticize. The screw speed, injection speed and back pressure create frictional
heat. To maintain a consistent and workable melt temperature, all of these variables
must to be coordinated and adjusted. The stock temperature cannot be so hot that the
material cures before it is able to fill the parts, nor so cold that the cycle times have to
be extended in order for acceptable parts to be produced from the mould.
3.5 Injection Pressure :
The pressure on the material is controlled by the primary pressure, which
moves the screw forward at a rapid speed to fill the cavities. The secondary pressure
(holding pressure) finishes the filling of the cavities and maintains pressure on the
material until it is sufficiently cured to allow the screw to return and plasticize the
next shot.
Plastic Injection pressure involves two stages. The first stage is, inject the melt
plastic material into mould by a high speed, this pressure called first plastic injection
pressure. We always called it plastic injection pressure too. Second stage is, the
pressure we put after plastic material filled mould, called second plastic injection
pressure or packing pressure. The secondary pressure (holding pressure) finishes the
filling of the cavities and maintains pressure on the material until it is sufficiently
cured to allow the screw to return and plasticize the next shot.
3.6 Thermoplastics And Thermosetting Plastics:
Plastics are formed by the combination of polymers with compounding ingredients.
These are classified as
I) thermoplastics
Ii) thermosetting plastics.
Thermoplastics are materials that can be softened by heat and then formed.
Thermosetting plastics are permanently hardened when formed. During heating
followed by cooling of thermoplastics, the bonds soften but the destruction of
materials do not take place on the other hand, in thermosetting plastics, heating affects
the chemical structure and the plastics crumble to powder. Thermoplastics are
produced generally by addition polymerization while thermosetting plastics are
produced by condensation polymerization. Thus the processing of these materials has
to be done in different manners.
The following materials are thermoplastics:
Polyethylene, polypropylene, polyvinyl chloride, ply acrylics, polyamides,

nylon, polystyrene celluloses, polyesters. (saturated).
The following materials are thermosetting plastics:
Phenol-formaldehyde resins, urea formaldehyde resins, mel amine-

formaldehyde resins, polyesters (unsaturated) epoxy resins silicon.
To produce plastics, it is essential to have polymers blended with some external

materials. These external materials are termed “compounding ingredients”. For the
purpose of processing of polymers two plastics these are added to give not only the
required property to plastics but also sturdiness and economical aspects to virgin
polymers. The components of compound of plastics.
1) Fillers
2) Plasticizers
3) Colorants
4) Lubricants
CHAPTER NO. 04
COMPONENTS AND DESCRIPTION
CHAPTER NO. 04
COMPONENTS AND DESCRIPTION

The Following Are The Components Used In Our Project:
1. L-angle
2. Shaft
3. Plates
4. Spindle
5. Barrel
6. Hopper
7. Heating coil
8. Plunger
9. Rack and pinion
10. Die
11. Rack and pinion
12. Smps
DESCRIPTION
4.1 L-ANGLE:
Fig :4.1 L –Angel
Mild steel ‘L’ type angle is used to fabricate the frame to mount the all the
parts of the injection molding unit. They are formed by bending a single angle in a
piece of steel. Angle Steel is 'L' shaped; the most common type of Steel Angles are at
a 90 degree angle. The legs of the “L” can be equal or unequal in length.
Steel angles are used for various purposes in a number of industries.
4.2 SHAFT:
The shafts are used to hold the injecting system by using two plates and hard
wares. A shaft is a rotating machine element, usually circular in cross section, which
is used to transmit power from one part to another, or from a machine which produces
power to a machine which absorbs power. The various members such
as pulleys and gears are mounted on it.
4.3 PLATES:
Two plates are used in injecting system. one plate is used to hold the plunger
and rack and pinion system. The other plate holds the Barrel, Hopper, Nozzle, Coil
spring.
4.4 SPINDLE:
The spindle is used in die locking system to lock the die in correct position. The
spindle is hold in slotted plate.
4.5 BARREL:
Fig :4.5 Barrel For Moulding Machine
The barrel is used to hold the molten and unmated plastic raw materials.
4.6 HOPPER:
The hopper on the injection molding machine holds these pellets. The pellets are
gravity-fed from the hopper through the hopper throat into the barrel and screw
assembly.
Fig :4.6 Hopper Palet

The hopper on the injection molding machine holds these pellets. The pellets are
gravity-fed from the hopper through the hopper throat into the barrel and screw
assembly.The hopper is used to pour the plastic raw materials in to the barrel.
4.7 HEATING COIL:
Fig :4.7 Heating Coil
The heating coil is used to melt the plastic raw materials to the molte form
which is inside the barrel. A typical heating element is usually a coil, ribbon (straight
or corrugated), or strip of wire that gives off heat much like a lamp filament. When
an electric current flows through it, it glows red hot and converts the electrical energy
passing through it intoheat, which it radiates out in all direction.
4.8 PLUNGER:
The plunger is used to compress the molten material into the die which is in the
barrel. The plunger moves up and down by using rack and pinion mechanism.
4.9 RACK AND PINION BLOCK:
Fig 4.9 :Rack And Pinion Arrangement
This is the main part of the compression unit. It houses the rack and pinion. The
plunger is attached to the rack. Rack and pinion combinations are often used as part of
a simple linear actuator, where the rotation of a shaft powered by hand or by a motor
is converted to linear motion.
The rack carries the full load of the actuator directly and so the driving pinion is
usually small, so that the gear ratio reduces the torque required.
4.10 DIE:
Fig :4.10 Dia Mould
The die is used to produce the required product. By using different types of dies
different types of product can be produced. 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. 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.
4.11 SMPS :
Fig :4.11 Switched-Mode Power Supply
A switched-mode power supply (SMPS) is an electronic circuit that converts power

using switching devices that are turned on and off at high frequencies, and storage
components such as inductors or capacitors to supply power when the switching
device is in its non-conduction state
CHAPTER NO. 05
WORKING PRINCIPLE
CHAPTER NO. 05
WORKING PRINCIPLE
The injection-moulding process is best suited for producing articles made of
thermoplastic materials. Here, the equipment cost is relatively high but the
main attraction is the amenability of the injection-moulding process to a high
production rate. In injection molding, a definite quantity of molten
thermoplastic material is injected under pressure into a relatively cold mold
where it solidifies to the shape of the mould.
The injection – moulding machine is shown in the process consists of feeding
the compounded plastic material as granules, pellets or powder through the
hopper at definite time intervals into the hot horizontal cylinder where it gets
softened. Pressure is applied through a hydraulically driven piston to push the
molten material through a cylinder into a mould fitted at the end of the
cylinder. While moving through the hot zone of the cylinder, a device called
torpedo helps spread the plastic material uniformly around the inside wall of
the hot cylinder sand thus ensures uniform heat distribution. The molten plastic
material from the cylinder is then injected through a nozzle material from the
cylinder is then injected through a nozzle into the mould cavity.
Fig :5.1 Injection Moulding Working Principle
The injection unit is responsible for both heating and injecting the material into the
mould. The first part of this unit is the hopper, a large container into which the raw
plastic is poured. The hopper has an open bottom, which allows the material to feed
into the barrel. The barrel contains the mechanism for heating and injecting the
material into the mould. This mechanism is usually a ram injector or a reciprocating
screw. A ram injector forces the material forward through a heated section with a ram
or plunger that is usually hydraulically powered. Today, the more common technique
is the use of a reciprocating screw.
A reciprocating screw moves the material forward by both rotating and sliding
axially, being powered by either a hydraulic or electric motor. Injection moulding is
an economical and very efficient method of producing injection moulded parts. It can
produce millions of parts with exactly the same shape, dimension, and quality. Some
examples of injection moulded parts are the mobile phones, mouse, keyboard, and
many components found inside the automobile.
Fig :5.2 Injection Moulding Machine

As the molten resin is being injected into the mould, it enters the mould opening
called the sprue. From the sprue this molten material will then be distributed to the
runners then it will be forced into the gate and then into the cavity.
The cavity must be filled precisely to avoid short shots but it must not be over packed
(over packing is forcing more than enough pressure to the resin and it can damage the
mould). The molten resin will stay in the cavity for 30 seconds to 1 minute or more
until it cools down and solidify. When the resins solidify a moulded part is formed.
The mould will open and then the moulded part will be ejected. The mould closes and
its ready for another shot.
CHAPTER NO. 06
DESIGN
CHAPTER NO. 06
DESIGN
6.1 Design Of Mechanism :
we are using rack and pinion mechanism because of oblivious advantages of reduced
complexity, ease of construction and less space requirement compare to other steering
mechanisms. The analytical steps involved in designing if rack and pinion system are
as follow: Selection of gear tooth profile A gear tooth profile was selected based on
BIS( Bureau of Indian Standard) recommendation and the manufacturability . A 200
full depth involute profile system was selected because of the following advantages:
 It reduces the risk of undercutting.

 It reduces the interference.
6.1.1 The properties of teeth of 200 full depth involute profile system :
Parameter value
Pressure angle (φ) 200

Addendum (ha) m
Dedendum (ha) 1.25m
Clearance (c) 0.25m
Working depth 2m
Whole depth 2.25m
Tooth thickness 1.5708m
6.1.2 Minimum number of teeth on pinion :

The minimum number of teeth required on pinion in order to avoid the interference
were computed using following relation:
Zp = 2*ha/( m*sin2(φ))
Substituting values in above equation;
Zp = 2*m/( m*sin2(φ)) = 2/ sin2(φ)
Zp = 17.09
Hence minimum number of teeth on pinion are :17.
6.2 Analytical Calculations :

6.2..1 Beam Strength:
a. bending endurance strength of pinion (σbp)
(σbp) = (Sut)/3 = 541/3 =180.33
b. bending endurance strength of gear (σbg):
(σbg) = (Sut)/3 = 541/3 = 180.33
1.Lewis form factor (Y):
i. YP = 0.484 - (2.87/ Zp) = 0.484 - (2.87/17)
YP = 0.3151
2. Yg = 0.484 - (2.87/ Zg) = 0.484 - (2.87/29) Yg = 0.3850
σbp* YP < σbg* Yg
Pinion is weaker in bending than gear in bending. Hence it is necessary to design the
pinion for bending.
assuming b = 10*m,
The beam strength is given by,
Pb = σbp*b*m*y
Pb = 180.33*10*m*m*0.4172 Pb = 752.336 m2 N
6.2.2 Wear Strength :
Buckingham’s theory is based on hertz theory of contact stresses. From his theory we
can conclude that Wear strength of a gear tooth is the maximum tangential load the
gear tooth can take without causing a pitting failure.
Pw = b.Q.dp.k
Q = Ratio factor for external gear pair = [ (2.Zg) / (Zg + Zp) ]
Here Zg = 29 , Zp = 17 So that Q = 1.260
k = [ σc2. Cosϕ Sinϕ. ( 1/є1 + 1/є2) ] / 1.4
k = { [ ( 0.27). (9.81).(BHN) ]2. Cos(20).Sin(20). (1/71700)}/1.4

k = 0.45. ( BHN/100)2
k = 0.45. (150/100)2 k = 1.0125

Hence wear strength can be calculated as follow;
Pw = 255.15m2 N
6.3 Dimensions Of Rack And Pinion :


6.3.1 Dimensions Of Pinion Gear :
Parameter Pinion
d (mm) 42.5
Addendum(ha) 2.5
Dedendum (hf) 3.125
Face width(b) 25
Circular pitch(Pc) 7.85
Module(m) 2.5
Zp 17
6.3.2 Dimensions Of Rack :

Parameter Rack
d (mm) 72.5
Addendum(ha) 2.5
Dedendum (hf) 3.125
Face width(b) 25
Circular pitch(Pc) 7.85
Module(m) 2.5
Zg 29
CHAPTER NO. 07
FACTORS INFLUENCING THE
FABRICATION WORK
CHAPTER NO. 07
FACTORS INFLUENCING THE FABRICATION WORK
The following are the factors influencing the fabrication work,
 Working Stress
 Working Strain
 Elasticity
 Hookes Law
 Bulk Modulus
 Poisson’s Ratio
 Factor Of Safety
WORKING STRESS:
The internal resistance must be equal to the external load if the body is to be in
equilibrium. This internal resistance per unit area is called intensity of stress or
simple stress.
STRESS = Internal resistance / Area of cross section.
WORKING STRAIN:
The deformation per unit length is called strain.
STRAIN = Change in length / Original length.
Strain has no unit since it is only a ratio.
ELASTICITY:
The property of a material body to regain its original condition on the removal
of the deformation forces is called elasticity.
HOOKES LAW:
It states that when a material is loaded with in its elastic limit the stress is
proportion to the strain.
Stress / Strain is a constant.
BULK MODULUS:The ratio of the change in the volume to the original volume of
the body is known as the volume strain or the bulk strain.The ratio of the bulk stress
to the bulk strain of a body is called the bulk modulus.
POISSON’S RATIO:
With in the elastic limit the lateral strain bears a constant ratio with the linear strain.
The ratio is called the Poisson’s ratio and is denoted by 1/m.Poisson’s ratio 1/m
=Lateral strain / Linear strain.The value of 1/m lies between 0.25 to 0.45
FACTOR OF SAFETY:
The ratio of ultimate stress to working stress is known as factor of safety.
Factor of safety = Ultimate stress / Working stress.
CHAPTER NO. 08
MERITS , DISADVANTEGES AND
APPLICATION
CHAPTER NO. 08
MERITS , DISADVANTEGES AND APPLICATION
8.1 Merits:
1. The daily using components can be easily made. 


2. The cost of the project is very less. 

3. High electricity consumption. 

4. Textile products can be produced. 

5. Less skilled labour is enough. 

6. Different shape of the components can be made according to the die what are
used. 

8.2 Disadvanteges:
1. High Manual Force is required.
2. Heating coil consumes high current.
8.3 Applications :
1. Injection moulding is a manufacturing technique for making parts from plastic

material .
2. Heated, fluide plastic is injected at high pressure into the mould , which is inverse
of desired shape.
REFERENCES
1. Rashi A.Yadav1Reserach Scholar, Principal S.V.Joshi2, Asst. Prof.
N.K.Kamble2 “Recent Methods for Optimization of Plastic Injection Molding
Process ” International Journal of Scientific & Engineering Research ISSN
2229-5518Volume 3, Issue 12, December-2012
2. Amol J. Asalekar, Somashekhar G. Ganiger, “ Design & Analysis in Injection

Moulding Machine “ International Journal of Engineering Research &
Technology (IJERT) ISSN: 2278-0181 Vol. 3 Issue 9, September- 2014
3. Rohit Narad, Suraj Paithankar, Sushant Umale, Mohanish nimje, A mo l

Ingole “Fabrication of Manual Plastic Injection Moulding Machine
4. ” International Conference on Ideas, Impact and Innovation in Mechanical

Engineering (ICIIIME 2017)Volume 06-2321-8169
5. Kwong, C.K.; and Smith, G.F. (1998). A computational system for process
design of injection moulding: Combining blackboard-based expert system and
case-based reasoning approach. International Journal of Advanced
Manufacturing Technology, 14(4), 239-246.
6. Khurmi, R.S.; and Gupta, J.K. (2003). Machine design. S. Chand and
Company Limited, New Delhi, India, 920-959.
7. Joseph, E.S.; and Mischke, C.R. (1976). Mechanical engineering design. Mc-
Graw-Hill Publishers, Aucland, 162-164.

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Design And Fabrication Of Gear Type Injection Moulding Machine

Thermoplastics are produced by this method. In this the material is softened by

1.1.2 Foaming Process:

The injection moulding is performed on materials mainly metals, thermoplastic and

[2] Rashi A.Yadav1Reserach Scholar, Principal S.V.Joshi2, Asst. Prof.

[3] Rohit Narad, Suraj Paithankar, Sushant Umale, Mohanish nimje, A mo l

[4] C. Sasikumar, S. Srikanth, S.K. Das. “Analysis of premature failure of a

3.1 Injection Moulding Process :

The injection-moulding process is best suited for producing articles made of

Injection moulding machine is a machine that always been use in the

Figure :3.1 Example Of Injection Moulding Machine

3.2 Fundamentals of Injection Moulding Machine :

Figure :3.2 Injection Unit Of Injection Moulding Machine

I. Feed hopper – the container that commonly in a shape of triangle holding a

V. Injection cylinder – Injection cylinder is composed of cylinder body, piston,

3.2.2 Clamping Unit

Figure :3.2.2 Clamping Unit Of Injection Moulding Machine

3.3 Plasticizing Unit :

3.6 Thermoplastics And Thermosetting Plastics:

Plastics are formed by the combination of polymers with compounding ingredients.

These are classified as

Ii) thermosetting plastics.

The following materials are thermoplastics:

Polyethylene, polypropylene, polyvinyl chloride, ply acrylics, polyamides,

The following materials are thermosetting plastics:

Phenol-formaldehyde resins, urea formaldehyde resins, mel amine-

To produce plastics, it is essential to have polymers blended with some external

COMPONENTS AND DESCRIPTION

9. Rack and pinion

11. Rack and pinion

Fig :4.1 L –Angel

Fig :4.5 Barrel For Moulding Machine

Fig :4.6 Hopper Palet

Fig :4.7 Heating Coil

4.9 RACK AND PINION BLOCK:

Fig 4.9 :Rack And Pinion Arrangement

Fig :4.10 Dia Mould

Fig :4.11 Switched-Mode Power Supply

A switched-mode power supply (SMPS) is an electronic circuit that converts power

Fig :5.1 Injection Moulding Working Principle

Fig :5.2 Injection Moulding Machine

 It reduces the risk of undercutting.

Pressure angle (φ) 200

Dedendum (ha) 1.25m

Clearance (c) 0.25m

Whole depth 2.25m

Tooth thickness 1.5708m

6.1.2 Minimum number of teeth on pinion :

Substituting values in above equation;

Zp = 2*m/( m*sin2(φ)) = 2/ sin2(φ)

Hence minimum number of teeth on pinion are :17.

6.2 Analytical Calculations :

(σbp) = (Sut)/3 = 541/3 =180.33

b. bending endurance strength of gear (σbg):

(σbg) = (Sut)/3 = 541/3 = 180.33

1.Lewis form factor (Y):

i. YP = 0.484 - (2.87/ Zp) = 0.484 - (2.87/17)

2. Yg = 0.484 - (2.87/ Zg) = 0.484 - (2.87/29) Yg = 0.3850

σbp* YP < σbg* Yg

The beam strength is given by,

6.2.2 Wear Strength :

Q = Ratio factor for external gear pair = [ (2.Zg) / (Zg + Zp) ]

Here Zg = 29 , Zp = 17 So that Q = 1.260

k = [ σc2. Cosϕ Sinϕ. ( 1/є1 + 1/є2) ] / 1.4

Zp = 2m/( msin2(φ)) = 2/ sin2(φ)