EXPERIMENT NO - 01

FAMILIARISING WITH MOULDING OF

PLASTICS

INSTRUCTED BY

Mr. Jagath Rodrigo

GROUP MEMBERS

Herath H.M.D.P

Hettiarachchi H.A.H.C

Jayainghe M.D.J.D

Jayasinghe S.B.R.S.M

Jarathne D.S.D.S

Jayasinghe W.H.N.C NAME : H.M.D.P. Herath

Jayanga J.M.A.G.C INDEX NO : 150220V

Indupama S.V.A.A GROUP :M1.5

Imalka N.B.A.U DATE OF PER. : 20 / 09 / 2017

Jagoda S.U.M DATE OF SUB. : 04/ 10 / 2017

INTRODUCTION

In the manufacturing plastics have taken a great role. It is mainly due to its less weight.
When using plastics to productions most popular method is injection moulding. Plastic moulding is a
well-known method of making plastic items. This moulding process is done through various sub
processes such as extrusion, injection moulding, compression moulding, transfer moulding, casting,
etc. One or more of these sub processes are included in the moulding process.

Major things in this process are the mould and the materials which are used to make various
kinds of plastics. By changing those things, properties, size, shape, etc. of the product can be
changed.

Good finishing, high production rate, easiness to manufacture, cheapness, etc. are the most
valuable advantages of plastic moulding.

Two different kinds of plastics, thermoplastics and thermosets are used in this process. Also
two different kinds of impressions; single impression (produce one product) and multi impression
(produce more products) are used.
 The Production Process

The Product

The product is a cup which is made by plastics. There is parting line at the middle of the side
walls and around the cup. The gate of the mould is at the end of the cup on the parting line. There are
ejection pins marked on the cup.

This given product has some defects such as, not good enough finishing and the air bubble
marks which make the defects on the surface.

Production

The production process of this item has some major steps. The main step is making the
mould. It mainly has two parts; front (upper) cavity and rear (lower) cavity. Both of them are cavity
plates.

The cavity plates are made using the pattern which has the shape of the product. The pattern
is separated into two parts along the parting line.

(Otherwise we can use the proper drawings of the cavity plates with shrinkage allowances of
the product. Then according to the drawings, the cavity plates are made using CNC lathe machines.
The guide bolts, ejector return pins and ejection pins, bushes are also included in the drawing.)

When the pattern is made, the shrinkage of the plastic should be considered. Because plastic
gets shrinked while it is cooling. So the shrinkage and the machine allowances should be considered.

Then the shape of the cavity plates is made according to the pattern of the product. Then the
moulding plates are made using those patterns. To make the moulds, front plate pattern is kept on the
plate surface and the middle of the wooden block. Then same process is done to the rear part and the
mould is made. Than the runners and gates are made in the front plate. Pattern plates are kept in an
appropriate position and the melted metal is poured into the mould. After cooling, the part is removed
from the sand mould and it is machined to make good surface finish and to make bushes for the pins.
Other plate is also made using the same procedure.

After that guide bolts are fixed to the front cavity. The top clamp plates, supported plates
and ejector returner plate are made by CNC lathe machine, drills and other finishing machines.

Then it is fixed into the unimolder. The moving part is in the lower side as well as the
stationary part is in the upper side.
 The chips are put into the hopper and heat is above 400 °C. Then the plastic chips are
melted. Melted plastics are passed to the mould through the gate by moving the injector leaver. After
the solidification, the product is removed from the mould by moving the rising leaver. Then the
product is removed by the ejector pins.

Finally the gates and the other unnecessary parts are removed.

Block Diagram

Product Design Mould Design Mould Manufacture

Plastic Powder
Feeding Injection moulding Debonding

Binder

Testing Reprocessing Sintering

Product