GTTI PDTD 12-13

PREFACE

PROJECT REPORT 1
GTTI PDTD 12-13

PREFACE
This is the report of the project work done by us as the
part of fulfillment of the course

POST DIPLOMA IN TOOL DESIGN

AT

GEDEE TECHNICAL TRAINING INSTITUTE

COIMBATORE-18

During the period of the project work, we studied the

overall design concepts and process of injection moulds and
dies casting. We developed the design in Auto CAD-2005 and
PRO/ENGINEER Wildfire 4.This has helped to great extend
in simulation and determining the ideal design of mould.

GROUP MEMBERS

 FARHAN.PP

 EMMANUEL .MECHERY

 SHYAM KRISHNAN.MK

 NIVIN. G

 SREEJISH .PK

 AMRUTHLAL.AK

PROJECT REPORT 2
GTTI PDTD 12-13

ACKNOWLEDGEMENT

PROJECT REPORT 3
GTTI PDTD 12-13

ACKNOWLEDGEMENT

We would like to express our gratitude to our

General Manager (Trg) Mr. Mallinathan and
Superintendent (Trg) Mr. Joy Varghese M, for the
facilities provided to us.

We would like to express our heartiest gratitude to our

Training Officer Mr.M.Sagith (Project co-ordinator)
who helped us to achieve our goal.

We express our gratitude to Mr. C.V. Jathin for his

valuable suggestions and encouragement.

Our sincere thanks to all GTTI staff members and our

friends for their unrelenting support and co-operation.

Our sincere thanks to our beloved parents for all the

support provided to us.

We are deeply grateful to the almighty lord for leading

us throughout the project.

PROJECT REPORT 4
GTTI PDTD 12-13

CONTENTS

PROJECT REPORT 5
GTTI PDTD 12-13

CONTENTS
 SYNOPSIS

 INTRODUCTION
 OBJECTIVES
 INTRODUCTION TO PRODUCT DESIGN

 PLANNING AND SCHEDULING

 INTRODUCTION
 DESIGN PROCEDURE
 PROCESS PLAN CHART

 COMPONENT REVIEW

 PROJECT INTRODUCTION
 COMPONENT MATERIAL DATA
 MACHINE DATA
 MACHINE SELECTION
 DIE CASTING PROCESS
 DESIGN CALCULATION
 FEED SYSTEM DESIGN AND CALCULATION

 SELECTION OF DIE MATERIAL

 LIST OF MATERIAL (DIECASTING DIE)

 DIE ELEMENTS
 HEAT TREATMENT
 DIE CASTING DEFECTS
 DESIGN VERIFICATION CHECKLIST

 ESTIMATION AND COSTING

 CONCLUSION
 BIBLIOGRAPHY

PROJECT REPORT 6
GTTI PDTD 12-13

SYNOPSIS

PROJECT REPORT 7
GTTI PDTD 12-13

INTRODUCTION
Tool engineering is one of the most important aspects of
Production engineering which enables industries to produce
standard plastic and metal items economically. Stamped and
molded components have found unlimited market in
industries like Automobile, Electrical and Electronics,
Consumer appliances etc. Design of an engineering product is
made with the intention of ultimately manufacturing
economically.

Plastics are now well established materials along with metal

and ceramics. The light weight, simplified assembly,
durability and environmental advantages have resulted in
plastics replacing many other materials such as steel,
aluminum and wood etc.

Similarly, several products which were earlier made by

casting and machining are being replaced by sheet metal
components. Materials economy and the resultant in less
weight and cost, high productivity, use of unskilled labor
and high degree of possible precision have rendered goods
such as electronics appliances, steel furniture utensils and
vehicles.

Even though designs is a specialized phase in engineering

field in tool and die design it is divided into two wings as
product design and tool and die design. A designer must
incorporate ideas related with lines like manufacturing and
production shop, quality control etc. with the evolution of new
technologies like CAD, CAM and CNC machine and mould
analysis the designers can implement their ideas apart from
conventional procedure.

PROJECT REPORT 8
GTTI PDTD 12-13

OBJECTIVES

 To involve in the activity of the project undertaken and

to learn various aspects of TOOL and DIE DESIGN.

 To get proficient in DIE CASTING.

 To understand various processes involved in DIE

CASTING and INJECTION MOULDING from
designing to manufacturing.

 To get practical exposure and understand the dos and

don’ts to be followed in design.

 To promote our design for practicability and simplicity

 To check for the manufacturing feasibility and

understand the benefits of standardization.

 To incorporate notification and justify the design

principles as clearly as possible.

 To analyze our drawings and make the required changes

after viewing from the shop floor perspective.

 To get the design approved.

PROJECT REPORT 9
 GTTI PDTD 12-13

INTRODUCTION TO PRODUCT DESIGN

As our academic project from our institute,

We received SPECATACLES as our project.

PARTS OF THE PRODUCT

3
1

SL.NO DES MATERIAL DIE/MOULD

Aluminum
1 Spectacles frame Die casting
LM 24
Injection
2 Legs Plastic molding

Injection
3 Nose pad Silicone molding

PROJECT REPORT 10
GTTI PDTD 12-13

PRODUCT DETAILS

1. FRAME

Frame is used in spectacles to fix lenses

vision purpose. It requires properties like
stiffness, non-allergic properties to skin.
The material used here is LM24, because of
its properties like fluidity (internal structure),
and high accuracy. Very thin slandered parts
can be casted. When used under high pressure
component is seen with proper properties. It’s
corrosion resistant. Its allergic response to skin
is very less when compared to properties of other
metals.

PROJECT REPORT 11
GTTI PDTD 12-13

2. LEGS

Leg is used in spectacles to join it with

frame thus provides a hold to spectacles. It
requires properties like less weight, fallibility. It
should also not harm the skin.

The material used here is ZYL (zylonite

(cellulose acetate) because of its properties like
light weight, flexibility and it can be easily
bounded with plasticizers, heat and pressure. Its
allergic response to skin is very less when
compared to properties of other metals.

Shrinkage: 0.2% -0.5%

Density : 1.28gms/cc
Injection pressure: 600- 1400 kg/cc
Mould temperature: 50º c - 80º c

PROJECT REPORT 12
GTTI PDTD 12-13

3. NOSE PAD

Nose pad is used in spectacles to keep the

spectacles firmly to head for holding purpose. It
requires properties like less weight, flexibility,
non-allergenic.

The material used here is silicone, because

of its above mentioned properties. It is less
expensive and required shape can be easily
formed prior to nasal area. The nose pad is fixed
to frame with the help of center slot and a joining
agent.

PROJECT REPORT 13
GTTI PDTD 12-13

PLANNING
AND
SCHEDULING

PROJECT REPORT 14
GTTI PDTD 12-13

PLANNING AND SCHEDULING

INTRODUCTION

In design, planning plays it relevant role as organizing

the decision to simplify and systemize design procedures. It
begins right from the orders confirmation to the supply of
design to the customer or sub venders. Planning work
according to a schedule makes work distribution easy. To
create an efficient plan should identify the various needs and
data necessary and chronologically put them as events and
relate them.

Scheduling is arranging event such that they achieved the

planned purpose. There are some tools such as grant charts
and CPM/PERT.
Grant chart is the form of a bar chart established as follows,
 List all the events or milestone of the project in ordered
list.
 Estimate the time required to establish the event.
 List the starting time and end time for the each events.
 Represent the information in a process planning chart.
CPM/PERT (Critical path method / program evaluation
and review technique) it has characteristic such as clearly
defined activities, activities or tasks or manner. It involves
the following steps,
 Break the design in to the individual activities and
identify each activity.
 Estimate the time required for each activity.
 Determine the activities sequence
 Construct the CPM / PERT net work, using defined
symbols.
 Determine the critical path of the network.

PROJECT REPORT 15
GTTI PDTD 12-13

DESIGN PROCEDURE (ISO FORMAT)

IWO Receivable (Internal Work Order)

↓
Input Verification
↓
CFT
↓
Design Time Plan
↓
Concept Drawing
↓
Drawing Review
↓
Initial Bill of Material (Core & Cavity) (In both INJECTION
MOULDING & DIECASTING)
↓
Mould Base Release
↓
Mould Base Soft Copy to Logistics
↓
3D Splitting
↓
Update assembly Drawing using in 3D split
↓
Insert Detailing
↓
Design Verification
↓
Design Validation
↓
2D Softcopy to Tool Room
↓
3D Models to CAM
↓
Arrange the Files
↓
2D Hard copy Release

PROJECT REPORT 16
GTTI PDTD 12-13

DESIGN TIME PLAN – INJECTION MOULD/DIE CASTING

GROUP NAME PROJECT_02                        

PROJECT NAME EYE WEAR CUSTOMER GTTI Start Date 3-Jul

PART NO :   Finish Date 30-Jul
1 1 1 1 1 1 1 1 2 2 2
DAYS     1   2 3   5 6   7 8 9
0 1
 
2
13
4 5 6 7
 
8
19
0 1 2
MONTH   Jul-13
   
1 1 1 1 1 2 2 2 2 2 2 3
3 4 5 6 7 8 9 10 11 14 16 17 20 21 23 28 30 1 2
DATE   2 3 5 8 9 2 4 5 6 7 9 1
P                                  

 
PRODUCT DESIGN
A                                        

P                                        
DESIGN REVIEW
A                                        

MATERIAL P                                      

DATACOLLECTION A                                        
INPLANT TRAINING

INPLANT TRAINING

INPLANT TRAINING

INPLANT TRAINING

INPLANT TRAINING
P                                        
ASSEMBLY DRAWING
SATUR DAY

SATUR DAY
A                                        
SUNDAY

SUNDAY

SUNDAY

SUNDAY
P                                        
DETAIL DRAWING
A                                        

P                                        
DESIGN VERIFICATION
A                                        

P                                        
DESIGN RELEASE
A                                        
P                                        
DESIGN VALIDATION
A                                        
PROJECT REPORT P                                        

PREPARATION A                                        

PLANNED ACTUAL
   

PROJECT REPORT 17
GTTI PDTD 12-13

COMPONENT
REVIEW

PROJECT REPORT 18
GTTI PDTD 12-13

PROJECT INTRODUCTION

As for our report preparation we are

only including spectacles frame (die casting).

SPECTACLE FRAME

CUSTOMER : GTTI

COMPONENT : SPECTACLES FRAME

COLOR : SILVER

MATERIAL : ALUMINIUM ALLOY (LM24)

VOLUME : 8.715 cm³

PROJECT REPORT 19
 GTTI PDTD 12-13

COMPONENT MATERIAL DATA (LM 24)

MATERIAL DATA (LM 24)

Color GREY TO SILVER

Shrinkage 0.6%

D Density 2.79 g/cm²

Injection pressure 600 – 1400 kg/cm²

Die temperature 50º c - 80º c

Melt temperature 520º c - 580º c

Ejection temperature 80º c

Specific heat 0.30 – 0.42 cal/ º c/gm

Volume 8.715 cm³

Thermal conductivity of
96.3W/mK
mold material (K)

PROJECT REPORT 20
GTTI PDTD 12-13

MACHINE DATA FOR DC 80

MACHINE DATA

Machine name DC 80

Platen size 530 x 530

Shot weight 705gms

Plunger diameter 40 mm

Maximum die height 400 mm

Minimum die height 150 mm

Die opening stroke 350 mm

Ejector system Hydraulic

Sleeve fitting Dia 70 X 10

Tonnage Required 250 T

Temperature Control Water / Oil Circulation

Motor capacity 18.5 kW

MACHINE SELECTION

PROJECT REPORT 21
GTTI PDTD 12-13

The essential considerations are,

METAL

1.Alloy composition
2.Metal temperature
3.Shot weight

MACHINE

1.Accumulator pressure
2.Injection pressure
3.Solidification
4.Plunger diameter
5.Locking force
6.Mode of injection
7.Stages
8.Lubrication

DIE

1.Die temperature
2.Filling rate
3.flow rate

 METAL

PROJECT REPORT 22
GTTI PDTD 12-13

1.Alloy composition:
A metal having good casted qualities is of value
unless it has the properties like dimensional stability
and reasonable price to ensure casting. If a wrong
alloy is taken for making a specified casting, it can be
molded and put to use but it will not perform its
functions properly.

2.Metal temperature:
The temperature for the metal entering into the
cavity depends upon the holding furnace temperature
and the temperature of the sleeve, the mode of
injection and delay between pouring and start of
injection. If the temperature is less than 650C die
casting alloys like LM2, LM4, and LM24 contains
silicon, iron (impurity) and manganese. (Aluminum is
molded by the cold chamber process).

3.Shot weight:
It is the amount of metal per each shot. It affects
the volume of gases in the shot sleeve, average heat
input by the metal entering in the die and the size of
slug which in turn influence the transmission of force
from the plunger to the die cavity. If the size is less in
the final stages of injection the slug will be thin
(biscuit).The ideal biscuit thickness can range from 6-
50mm.
 MACHINE

PROJECT REPORT 23
GTTI PDTD 12-13

1. Accumulator pressure:
Accumulators are used to store up energy from
hydraulic pump during the process cycle. If the
pressure inside the accumulator is too high it can
result in the separator not being lifted. If less it will
not work.

2. Injection pressure:
This controls the maximum force on the plunger
and it influences the maximum injection force.

3. Intensification (Solidification):
It is defined as the controlled increase of
pressure on the casting alloy at the end of the cavity
fill, immediately following impact. It is achieved by
increasing the hydraulic pressure over the nominal
value by shifting to alternate relief valves opening
high pressure accumulators or operating multipliers
called cylinder intensifiers. The usual ratio is 3:1
compared to the pressure of filling the cavity.

4. Plunger speed:
A controlling valve sets plunger speed. Small
variation in plunger speed can happen due to the
fluctuations in the injection line pressure and also
with the die temperature. If the plunger speed is too
high it can result in flashed cast.
5. Locking force:

PROJECT REPORT 24
GTTI PDTD 12-13

Locking force depends upon the locking

pressure, tie bar nut setting and temperature of the die
and surroundings. As the die heats up, locking force
increases, and unless an allowance has been made for
this increase, the machine will not be stable when
locking. The locking force, injection pressure and
projected area of casting together with the die face
deviations are the influencing factors in controlling
the flash. For the best result the force should always
act at the center.

6. Mode of injection:
The use of two stage injections with a slow
first stage allows the gases more time to escape from
the cavity during the initial fill period and then
increasing the speed. By changing mode of injection
the cavity filling speed can be increased or decreased.

7. Plunger diameter:
Plunger diameter refers to the diameter of the
plunger being used. To increase the amount
maximum material being pushed out of the nozzle in
one stroke large diameter plunger can be selected.
Increasing the plunger diameter also reduces the final
force on the metal and tends to reduce plunger speed
during injection. To reduce number of spare parts
small plunger are helpful.

 DIE

PROJECT REPORT 25
GTTI PDTD 12-13

1. Die Temperature:

Die temperature is governed by casting rate,

cooling water flow and molten metal temperature.
Die temperature is 340-355C for aluminum.
Cooling channels in the die do increase the tool cost
and the complexity of the die but they are cost
effective for high production rate, high volume
jobs. Dies are also cooled between shot by spraying
cooling solutions on the face of the die

2. Filling rate:

Filling rate is termed by these factors:

1. Cavity fills time: It can be raised from 20-60

milliseconds and most favorably 40 milliseconds.
2.Cavity filling rate: It is expressed in cc/seconds.
3.Gate velocity: The values of gate velocity can be
28- 55 meters/seconds.

3 Flow rate:

The flow rate Q is the amount of material

conveyed by the plunger per second.

Flow rate (Q) = Filling weight

Filling time

PROJECT REPORT 26
GTTI PDTD 12-13

DIE CASTING PROCESS

Die casting is a manufacturing process for

Producing accurately dimensioned, sharply defined,
smooth or textured surface metal parts. It is
accomplished by injecting liquid metals at fast
velocity and under high pressure into reusable steel
dies. Compared to other casting processes, die
casting is at the top end of both velocity and
pressure. .
The process is rapid and allows complex
shapes to be cast as almost finished parts, and many
thousands of castings can be produced from a set of
dies without significant changes in casting in casting
dimensions.

Types of Die casting processes;

 HOT CHAMBER PROCESS

 COLD CHAMBER PROCESS

 HOT CHAMBER PROCESS

PROJECT REPORT 27
GTTI PDTD 12-13

In a hot chamber process the plunger and

cylinder are submerged in the molten metal in the
holding furnace. The power to pump the material into
the cavity is provided by the hydraulic accumulator.
Oil is supplied to the accumulator by a rate that will
bring the accumulator pressure up to the desired
level. When a shot is made the control valve opens
allowing the shot cylinder to force the plunger down
and force molten metal through the nozzle to the
sprue and through the runners and gates into the
Cavity.
The gases that were in the system are taken
through the vent or into the over flows. After the
cavity is filled metal is allowed to solidify, the casting
is ejected.

 COLD CHAMBER PROCESS

PROJECT REPORT 28
GTTI PDTD 12-13

The material heated outside and poured into the

sleeve through which it reaches to the runner and
gate. The machine usually has a plunger that is
mounted horizontally in a sleeve. The plunger enters
part way in to the die pushing the molten material in
to the impression.
Any excess metal remains in the end of the shot
sleeve between the plunger and parting surface of the
die to solidified remaining metal is called the biscuit.
The component along with the biscuit is ejected out
of the die.

DESIGN CALCULATION
PROJECT REPORT 29
GTTI PDTD 12-13

 LOCKING TONNAGE

Locking force required = (A x P)/1000 TON

A = Projected area of casting including runner and

over flows in cm

P = Cavity pressure (400-600 kg/ cm²) for AL.

A = 137.04 cm²

P = 500

Therefore = (137.04×500)/1000

= 68.52 TON

PROJECT REPORT 30
GTTI PDTD 12-13

 PLUNGER VELOCITY

V = (4Q)/ ∏d²
d = plunger dia in cm
v = cavity filling rate in cm/sec
Q = Volume of casting / cavity filling time

 Plunger dia

(DC-180) = Ø40 or Ø50 or Ø 35

V = (4Q)/ ∏d²
Q = volume of casting / cavity filling
time

= 35.197cm³/0.13 sec

= 270.75

Therefore

V = (4×270.75)/3.14× (4)²
= 1083/50.24
= 21.55 cm/sec

PROJECT REPORT 31
GTTI PDTD 12-13

 FILLING TIME
`

ti = Metal injection temperature (º c)= 650 º c

tf = Minimum flow temperature(º c) = 570 º c

td= Temperature of cavity (º c) = 340 º c

S = Percent solidification factor allowable in the

metal at the end of the filling = 15 %

Z = Unit conversion factor (º c / %) = 3.8 º c / %

T = Average part thickness = 3mm

K= Derived constant (sec/mm) = 0.0346 sec/mm

t = 0.0346 x 2 (650 - 570) + 15 x 3

570 – 340
= 0.0692 (3600)
230
= 1.83 sec

 FILLING WEIGHT

PROJECT REPORT 32
GTTI PDTD 12-13

The Filling weight is the total weight of the

casting including runner and overflow.

Flow weight = Part weight + overflow X no. of CVT

= 3.59g + 0.70g X 1
= 4.24 g

 FLOW RATE

The flow rate Q is the amount of material

conveyed by the plunger per second.

Flow rate (Q) = Filling weight

Filling time
= 4.24
1.83
= 2.31 cm/sec

 FILLING VOLUME

Filling volume = Filling weight

Density of metal
= 4.24
2.74
= 1.54 cm²

 VENTILATION CROSS SECTION

PROJECT REPORT 33
GTTI PDTD 12-13

V air can equal a max 300 m/s. the ventilation

section is dependant on the roughening depth/section
configuration (gap thickness of ventilation). For
configuring the ventilation section, the speed of the
air should be selected from 150 – 200 m/s.

VCS = flow rate X 1000

200 m/s

= 3770
200
= 18. 85 mm²

 SHOT WEIGHT

Shot weight = part weight + feed system weight +

Overflow
= 3.59 g + 8.75 g + 1.75 g

= 14.09 g

FEED (GATING) SYSTEM DESIGN

AND CALCULATION

PROJECT REPORT 34
GTTI PDTD 12-13

The gating system is a combination of various

channels and pockets machined into the parting
surfaces of the die which allow the molten metal to
fill the impression. The metal enters the die through
sprue, runner and gate. The metal flows through the
cavity and out the opposite side through smaller gate
and into the pockets called overflows. Each flow
stream should travel the shortest possible, and also
should reach the opposite side. A shock absorber is
the part of the runner system provided at the end of
the gate runner. Its is to
1.Receive the cold metal and the impurities.
2.Trap air that will compress and thus absorb any
impact of the cold metal reaching the runner end.
3.Position an ejector pin.
The various steps involved in gating system design
are
1.Planning the flow patterns
2.Calculating filling time
3.Selecting gate velocity
4.Determining minimum and maximum gate depth
5.Striking a balance between machine power and
gate size
6.Calculating plunger size and speed
7.Calculating gate and runner area and geometry.
GATE PATTERN

1.DIAGRAM FOR RUNNER FLOW

PROJECT REPORT 35
GTTI PDTD 12-13

GATE CALCULATIONS
2.GATE DEPTH

PROJECT REPORT 36
GTTI PDTD 12-13

Gate depth depends upon the atomization of

metal flow required. For a lesser gate depth greater
velocity is required for atomization.

Maximum gate depth:

The maximum gate depth is generally taken as 80%
of the component thickness. It is one of the critical
dimensions that must be established by calculations.
The final selection of the gate must satisfy the
conditions such as atomization of metal flow, gate
vestige, degating easiness.
Minimum gate depth:

Msg x Gd x Gv1.71 = J
J = Gd where,
Msg x Gv1.71

Msg = Density of the alloy

Gd = Gate depth
Gv = Gate velocity
J = Derived constant for the alloy
525 = Gd where,
2.74 X 518.18

Gd = 0.36mm

3.GATE CROSS SECTION:

PROJECT REPORT 37
GTTI PDTD 12-13

The gate and the adjacent runner together are

known as gate runner.
Gate cross section = flow rate x 1000
Gate velocity
= 3.77 x 1000
50
= 75.44 cm²

4.RUNNER:

A runner is the part of the runner system

which begins from the sprue and ends at gate.

Runner cross section = flow rate x 1000

Runner velocity
= 3.77 x 10
50
= 1.07 mm²

Fan gate runner;

PROJECT REPORT 38
GTTI PDTD 12-13

The flow angle from a fan gate runner ranges

from a maximum angle at the left side to zero flow
angle at the centre and then to the maximum on the
right hand side. The average flow angle is only half
the maximum.

Fan gate runner dimensions:

Area of cross section method:

The fan gate runner is shown to be positioned

straight to the cavity. The gate runner is defined by
nine cross sections.

PROJECT REPORT 39
GTTI PDTD 12-13

Finding the area of each section:

Area of section 1 = 40% of runner cross section

= 40/100 X 103.14
= 41.25mm

Area of section 5 = 10 % less than sec 1

= 10/100 - 103.14
= 37.1mm

Area of section 3 = sec 1 + sec 5

2
= 41.25 + 37.1
2
= 39.17 mm

PROJECT REPORT 40
GTTI PDTD 12-13

Area of section 4 = sec 3+ sec 5

2
= 39.17 + 37.1
2
= 38.13 mm

Area of section 2 = sec 1 + sec 3

2
= 41.25 + 39.17
2
= 40.21 mm

Area of section 7 = sec 5 + sec 1

2
= 31.1 + 33.9
2
= 40.21 mm

Area of section 9 = sec 5 – actual gate area

= 37.1 – 0.83
= 28.27 mm

Area of section 8 = sec 7 + sec 9

2
= 35.5 + 28.27
2
= 31.88 mm

PROJECT REPORT 41
GTTI PDTD 12-13

Area of section 6 = sec 5 + sec 7

2
= 31.1 + 35.5
2
= 36.3 mm

Area of cross section:

Area of section 1 = 41.25mm

Area of section 5 = 37.1mm

Area of section 3 = 39.17 mm

Area of section 4 = 38.13 mm

Area of section 2 = 40.21 mm

Area of section 7 = 40.21 mm

Area of section 9 = 28.27 mm

Area of section 8 = 31.88 mm

Area of section 6 = 36.3 mm

PROJECT REPORT 42
GTTI PDTD 12-13

Depth of section:

The depth of section 1 is determined by the

depth to width ratio. A width of twice the depth and
then it is compared to the maximum runner depth
allowed. If the calculated depth is equal or less than
the maximum it is used.

Runner volumes:

The size and shape of the runner depends on

the design strategy used. The volume of the each
runner is simply the area times the length.

Biscuit volume:

The length of the biscuit depends on the die

caster. If he uses intensified plunger pressure to feed
shrinkage during the solidification of the die casting
will be probably kept 25mm long.
But such long biscuits will usually increase
the solidification time.

Biscuit volume =

= 3.14 X 40 X 20
4
= 628 mm²
DIECASTING DIE
PROJECT REPORT 43
GTTI PDTD 12-13

COOLING

CAVITY INSERT SPRUE SLEEVE

COOLING COOLING

CORE INSERT SPRUE SPREADER

COOLING COOLING

Factors to be considered while cooling:

PROJECT REPORT 44
GTTI PDTD 12-13

 Inlet-Outlet temperature difference

 Difference in temperature (coolant
temperature vs. plastic melt).
 Flow of coolant from in to out.
 Thermal conductivity of mold material
 Amount of heat to remove.
 Total area of core and cavity.
 Size and length of runner.
 Arrangement and size of cooling insert.
 Diameter and number of inlet and outlet.
 Type of runner system (hot or cold).
 Quality of coolant.

ADVANTAGES OF COOLING:

 Easy removal of moldings from core side.

 To reduce cycle time.
 Uniform temperature is maintained
throughout the die.
 To solidify molten material.

PROJECT REPORT 45
GTTI PDTD 12-13

SELECTION OF DIE
MATERIAL

PROJECT REPORT 46
GTTI PDTD 12-13

DIE CASTING DIE MOULD BASE

STANDARD : 35-35 ( DME )

PROJECT REPORT 47
GTTI PDTD 12-13

BOTTOM HALF:

Bottom half consists:

 Core plate,
 Core insert
 Guide pillar
 Spreader
 Bottom plate
 Ejection plate, Ejector plate
 Ejector pin
 Heel block
PROJECT REPORT 48
GTTI PDTD 12-13

TOP HALF:

Top half consists:

 Cavity plate,
 Cavity insert
 Guide bush
 Spreader sleeve
 Protecting cap

PROJECT REPORT 49
GTTI PDTD 12-13

LIST OF MATERIAL

PROJECT REPORT 50
GTTI PDTD 12-13

TOP VIEW OF CORE

PROJECT REPORT 51
GTTI PDTD 12-13

PROJECT REPORT 52
GTTI PDTD 12-13

PROJECT REPORT 53
GTTI PDTD 12-13

PROJECT REPORT 54
GTTI PDTD 12-13

PROJECT REPORT 55
 GTTI PDTD 12-13

DIE ELEMENTS

CAVITY PLATE:

A plate or block of steel, which contains the

cavity. The cavity may be directly sunk into the
plate.

CORE PLATE:

A plate or a block of steel, which incorporate the

core. The core may be machined directly from a solid
plate or be a two part of construction.

GUIDE PILLAR:

Hardened steel circular member incorporated in

the design to align the two mould halves.

GUIDE BUSHES:

Hardened steel bushes, which provide a wear

resting surface for the guide pillars in a mould plate.

EJECTORS:

Hardened elements of different shapes used to

eject the component from the core after molding.

PROJECT REPORT 56
 GTTI PDTD 12-13

EJECTOR PLATE:

The purpose is to transfer the ejector force form

the actuating system of the injection machine to the
mounding through an ejector element.

SPURE SPREADER:

The sprue spreader performs several functions.

The first is to spread the incoming stream of molten
metal and then same time, the mass of the flow stream
is reduced to runner thickness and turned in to a
direction of travel parallel to the parting plane. The next
function is to help remove heat to solidify the metal in
the sprue. Finally it acts to pull the sprue out of the
bushing as the die opens. An internal baffle or all
around cooling method can be used.

SPRUE BUSH;

Sprue bushings for zinc casting are made of heat

treated steels. They are made of two piece assembly,
brazed all-round for maximum water cooling capacity.
The spherical seating is polished and precision ground. .

PROJECT REPORT 57
GTTI PDTD 12-13

HEAT TREATMENT

Heat treatment is defined as an operation

or combination of operations involving heating and
cooling of a metal/alloy in solid state to obtain
desirable conditions and their properties.

HEAT TREATMENT PROCESS

Stress relieving
Annealing
Normalizing
Hardening
Tempering
Aus tempering

PURPOSE OF HEAT-TREATMENT
PROCESS

It Causes relief of internal stresses developed

during cold working, welding, casting, forging etc.
Harden and strengthen metals and it improves
machinability. Soften metals for further working and
to change grain size. Improve ductility, toughness,
electrical and magnetic properties. Increase heat,
wear and corrosion resistance of materials.

PROJECT REPORT 58
GTTI PDTD 12-13

ANNEALING:

Annealing primarily is the process of heating a

metal which is in a distorted structural state, to a
temperature which will remove the instability or
distortion and then cooling is (usually at a slow rate)
so that the room temperature structure is stable and/or
strain free.

The purpose of annealing is to:

Inducing a completely stable structure. (Full

annealing)
Improve mechanical, physical, electrical and
magnetic properties.
Removing residual stresses.

HARDENING:

Hardening is that heat treatment of steel which

increases its hardness by quenching. (And tempering)
Tools and machine parts required to undergo heavy
duty service are often hardened. Quench hardening
and tempering are confined in application to the so-
called heat treatable steels (i.e., steels containing
carbon in excess of 0.3% and alloy additions).

PROJECT REPORT 59
GTTI PDTD 12-13

TEMPERING:

After hardening, steels is usually re-heated to a

suitable temperature below the lower critical point
(heating) to improve its toughness and ductility but it
is done at the expense of hardness and strength.

The purpose of tempering is to

Relieves residual stress

Improve ductility
Improve toughness
Reduce hardness

PROJECT REPORT 60
GTTI PDTD 12-13

DIE CASTING DEFECTS CAUSE AND

REMEDIES

1. LAMINATIONS
2. DIE EROSION
3. FLASH
4. DEFORMATION FROM EJECTOR
PINS
5. DRAGS

LAMINATIONS

Layers of metal inside or outside of casting

Cause: Most common is poor metal flow control,

though there are other causes.

Remedies:
1. Gating: good flow patterns – no long flow
distance and mixing far from gate.
2. Good die temperature: should be consistent over
the trouble area best if on the high side.
3. Intensifier action proper and consistent.

PROJECT REPORT 61
GTTI PDTD 12-13

DIE EROSION

Die erosion, cavitations, and burn out. Die has worn

spots causing raised spots on the casting; can be small
deep cavities (cavitations), or larger erosion areas at
the gate.

Cause: High metal velocity, bubbles in incoming

metal, high oxide or silicon content in metal.

Remedies:
1. Check gate velocities.
2. Check metal temperature should not be high.
3. Check dies temperature in the gate area, reduce
with spray if possible.

FLASH

Excessive cast material often accompanied by

dimensional deviation.

Cause: High metal temperature and either poor die fit

or poor machine locking when high pressure is
applied.

Remedies:
1. Die fit
2. Machine locking conditions
3. Die opening force centered on machine
PROJECT REPORT 62
GTTI PDTD 12-13

DRAGS

Cause: Deformation of the casting by undercuts

encountered during ejection. Undercuts may be
caused buildup on the die or by die erosion of solder.

Remedies:
1. See corrections for build-up and check draft angle.
2. Make sure die surface is smooth, machining marks
have been completely polished out.
4. Reduce the temperature of the steel that has the
drag-this can be done with spray or with high heat
transfer die materials.

DEFORMATION FROM EJECTOR PINS

Cause: Caused when the casting is still soft and

sticks in the die; consequently the ejector pins bend
the casting trying to eject.

Remedies:
1.Casting stays in the die too long or too short (hold
or dwell time not correct for casting).
2.Short dwell time means the casting may be too soft
at ejector pin location and may deform.
3.Machine ejection system is “jerky”’ with high
impact on the casting.

PROJECT REPORT 63
GTTI PDTD 12-13

DESIGN
VERIFICATION
CHECKLIST

PROJECT REPORT 64
GTTI PDTD 12-13

VERIFICATION CHECK LIST FOR

INJECTION MOULD DESIGN

COMPONENT
SL.NO. DESCRIPTION YES NO

1 Whether latest issue part drawing used? ✔

2 Whether degating point acceptable? ✔

Whether wall-thickness reduction on the
3 product considered to warpage extended ✔
cooling time?

CONSTRUCTION AND ASSEMBLY

SL.NO. DESCRIPTION YES NO

Whether component drawing is scaled

1 ✔
and mirrored for core / cavity design?
Whether mould top is decided in such a
2 way that preferably side cores are not in ✔
the direction of gravity?
When using hydraulic / pneumatic /
motorized accessories check whether any
3 ✔
fouling is there for the mould with the
molding machine elements?
Whether bottom stock (0.2) considered in
4 ✔
core and cavity inserts?

COOLING

PROJECT REPORT 65
GTTI PDTD 12-13

SL.NO. DESCRIPTION YES NO

Whether cooling provided for plunger
1 ✔
bush and spreader?
Whether waterlines inlet / outlet are
2 ✔
to the opposite side of the operator?
Whether sufficient distance is
3 provided between cooling inlet and ✔
outlet?
Whether cooling diagram shown with
4 ✔
assembly drawing?

EJECTION
SL.NO. DESCRIPTION YES NO
Whether alignment bushes for sleeve
1 ✔
ejector moulds are provided
Whether sufficient ejector travel
2 ✔
provided to ensure ejection of part.
Whether ejector pins at bottom of
3 ✔
deep pockets or ribs provided.
Whether stripper plate ride on guide-
4 ✔
pillars for full ejection stroke
Whether ejector bumper and
5 retractable rod position & size ✔
provided.

Whether ejector pin shoulder

6 thickness is 0.02-0.03mm below the ✔
ejector plate level.

FEED SYSTEM
SL.NO. DESCRIPTION YES NO

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GTTI PDTD 12-13

1 Whether system is calculated? ✔

Whether runner balanced for multi
2 ✔
cavity dies?
Whether the runner is easy to break
3 ✔
and allows proper filling?
Whether sufficient over flow pads are
4 given to help easy air removal from ✔
cavity and to fill the cavity properly. ?
Whether slender core pins or sharp
edges available close to gate opening?
5 ✔
(to avoid deformation due to hitting of
metal flow)

TYPICAL
SL.NO. DESCRIPTION YES NO
Have you answered all general
1 ✔
questions?

MISCELLEANEOUS
SL.NO. DESCRIPTION YES NO
Whether date code provision given.
1 ✔
(To be permitted by customer).
Whether trade marks, customer logo
2 ✔
& cavity nos. specified.

PROJECT REPORT 67
GTTI PDTD 12-13

ESTIMATION
AND
COSTING

ESTIMATION AND COSTING

Estimation
Estimation is the calculation of the cost of a product before it
is actually manufactured.

PROJECT REPORT 68
GTTI PDTD 12-13

Costing

Costing is the determination of the actual cost of the product

after it has been manufactured.
Methods of costing are,
1. Feeling,
2. Educated guessing,
3. Traditional cost accounting and
4. Activity based costing.

Activity based costing

This is a method of allocating costs to products and services.

It is generally used as a tool for planning and control.

PROJECT REPORT 69
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CONCULSION

CONCLUSION

We feel great pleasure and satisfaction in

involving in our injection mould project. The most
important aspect of this project was that, they were

PROJECT REPORT 70
GTTI PDTD 12-13

designed to the industrial standards. This project has

been an opportunity to enhance our knowledge and
designing capabilities.

We ultimately attained our goal of designing

injection mould with the required standard and
talking into account of various manufacturing factors.
This project not only enhanced our designing skills
but also updated our awareness in different fields.

PROJECT REPORT 71
GTTI PDTD 12-13

BIBLIOGRAPHY

BIBLIOGRAPHY

INJECTION MOULD DESIGN – 4th edition- R.G.W PYE

DIE DESIGN HAND BOOK – 3rd edition – David. A. Smith

PROJECT REPORT 72
GTTI PDTD 12-13

TECHINICAL DIRECTORY _ CIPET

ON DESIGN AND TOOLING
FOR PLASTICS

HASCO - STANDARD MOULD

BASE BOOK

DME - STANDARD MOULD

BASE BOOK

www.siliconenosepad.com
www.wekipedia.com
www.diestandards.com
www.omnilexica.com
www.aluminiumalloys.com
www.ehow.com
www.keyprstengine.com
www.castalloys.com
www.alumascprecision.co.uk

PROJECT REPORT 73