VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI - 590018, KARNATAKA

An Internship Report on

DESIGN AND MANUFACTURING OF INJECTION

MOULD
Submitted in partial fulfillment of the requirement for the award of degree
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

Submitted by:
RAHUL RATHOD
(1BY19ME031)
VIII Semester
Internship(18MEI85) carried out at
LAKSHMI TECHNOLOGIES
No. 13,12th cross, Doddanna industrial estate, Peenya 2nd Stage Bangalore-560091

Internal Guide External Guide

Name: Dr. Shripad Diwakar Name:Shivukumar Banakar
Designation: Assistant Professor Designation:Manager
Organization: BMSIT&M Organization:LakshmiTechnologies

B.M.S. INSTITUTE OF TECHNOLOGY AND MANAGEMENT

#6443, Doddaballapura Main Road, Avalahalli, Yelahanka, Bengaluru-560064
DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC YEAR: 2022 – 23

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B.M.S. INSTITUTE OF TECHNOLOGY AND MANAGEMENT
(Affiliated to Visvesvaraya Technological University, Belagavi, Karnataka)
#6443, Doddaballapura Main Road, Avalahalli, Yelahanka, Bengaluru-560064
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the Internship Report on “DESIGN AND MANUFACTURINGOF

INJECTION MOULD” submitted by “RAHUL RATHOD” bearing 1BY19ME031
respectively is a bonafide student of B.M.S. Institute of Technology And Management, has
successfully completed the Internship programme in partial fulfillment for the award of
Bachelor of Engineering in Mechanical Engineering prescribed by Visvesvaraya
Technological University, Belagavi during the academic year 2022 - 23. The Internship
report has been approved as it satisfies the academic requirements in respect of seminar
prescribed for the Bachelor of Engineering degree.

Signature of Internal Guide Signature of HoD

Dr. Shripad Diwakar Dr. H K Govindaraju
Assistant Professor Professor and Head
Dept. of Mech Engg, BMSIT&M Dept. of Mech Engg, BMSIT&M
Dr. Mohan Babu G N

PRINCIPAL

External Viva
Name of the Examiners: Signature with date

1.

2.

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Internship certificate

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 DECLARATION

I hereby declare that the Internship work entitled “DESIGN AND MANUFACTURING OF
INJECTION MOULD” has been independently carried out by me at LAKSHMI
TECHNOLOGIES, No. 13,12th cross, Doddanna industrial estate, Peenya 2nd Stage
Bangalore-560091 under the external guidance of SHIVUKUMAR BANAKAR, The
Manager, Lakshmi Technologies and under the internal guidance of DR SHRIPAD
DIWAKAR, Assistant Professor Department of Mechanical Engineering, BMS Institute of
Technology and Management in partial fulfillment of the requirement for the award of
Bachelor of Engineering in Mechanical Engineering prescribed by Visvesvaraya
Technological University, Belagavi during the academic year 2022-23.

I further declare that I have not submitted this report either in part or in full in any other
university for the award of any degree.

RAHUL RATHOD
1BY19ME031

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 ACKNOWLEDGEMENT
My sincerest gratitude to Mr. Shivukumar Banakar, manager, Lakshmi Technologies
for providing us with the opportunity to carry out the internship program.I am very thankful
to the company for providing me resources and facilities to help in the internship.I would
also take this opportunity to thank all the workers for their valuable guidance, support, and
inputs.
Last but not the least I also take this opportunity to express our sincere words of
gratitude to our Department of Mechanical Engineering, BMS INSTITUTE OF
TECHNOLOGY and MANAGEMENT, Bangalore, for helping us to carry out our internship
work.

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 ABSTRACT

This report provides an overview of the plastic injection moulding process based on my
internship experience at Lakshmi Technologies in Peenya, 2nd stage. The report covers the
various steps involved in the process, including material selection, melting, injection, cooling,
ejection, and finishing.

The report also discusses the working of the injection moulding machine, highlighting the
importance of maintaining proper temperature and pressure control, and the need for precise
tooling design. The report emphasizes the versatility and efficiency of the plastic injection
moulding process, which makes it a popular choice for many manufacturers across industries.

Overall, the author believes that their internship experience has provided them with a solid
foundation to pursue a successful career in the field of mechanical engineering. The report
concludes by discussing the my takeaways from their internship and the valuable skills they
have acquired.

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 TABLE OF CONTENTS
SLNO. DESCRIPTION PAGE NO

CHAPTER 1 INTRODUCTION 9-11

1.1 ABOUT LAKSHMI TECHNOLOGIES 9
1.2 QUALITY POLICY 9
1.3 CORE COMPETENCE 10
1.4 SERVICES 11
CHAPTER 2 ABOUT INTERNSHIP 12-27
2.1 INTRODUCTION TO INJECTION MOLDING 12
2.2 INJECTION MOLDING PROCESS 14
2.3 MANUFACTURING OPERATION 15
2.4 THE MOLD 22
2.5 INTRODUCTION TO RUBBER INJECTION MOLDING 25
2.6 WORKING PROCEDURE 27
CHAPTER 3 CONCLUSION 28

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 LIST OF FIGURES

Figure Figure Name Page No.

No.
1 INJECTION MOLDING MACHINE 13

2 INJECTION MOLDING 14
PROCESS
3 RECIPROCATING SCREW 17
INJECTION MOLDING UNIT
4 TYPICAL MOLD TOOL 21
ARRANGEMENT
5 INJECTION MOULD 26
BEFORE SHOT AND AFTER
FILLED

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CHAPTER 1

INTRODUCTION

1.1 ABOUT LAKSHMI TECHNOLOGIES

The company is located in Doddanna Industrial Estate in Bangalore and is in the

business of manufacture of high precision and critical industrial parts through
injection moulding process. The thrust is on continuous up- gradation of
infrastructure and machinery to meet ever-growing customer needs. We provide
end-to-end tooling solutions for a diverse range of industries. And we assure you
Quality on time delivery and cost effective.

VISION:

To Encourage as a Global One Stop Solution Partner in the field of Injection

Moulds and Moulded Parts by maximizing Efficency and Technological
Innovation.

MISSION:

At LT Tools we provide the Highest Quality Products - Competitively Priced

along with Services exceeding of Customers Expectations and build an
Environment that encourages Continuous Improvement and Upgrade Technology.

1.2 QUALITY POLICY

LT Tools is Committed to Provide Highest Quality to Design and Manufacture
Plastic Injection Products to exceed Customer Requirement

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and Enhance Customer Satisfaction by continuous Improvement of System and
Procedures.

1.3 CORE COMPETENCE

 Specialize in development & manufacturing of precision components
for Electrical, Electronic, Automobile Industries, etc.

 Specialist in design & manufacture of Plastic Injection Moulding

Tools, Components & Sub- Assemblies.

 Dedicated Tool room with adequate infrastructure.

 In-house production facility for Injection Moulded Components.

 Product development

 Proto moulds and components

An ISO 9001:2015 Company

 Good experience in New Product Development

 Good experience and expert in machining of good quality Core

,cavity ,electrodes, hard machining insert & mould base.

 Manufacturing of Jigs & Fixtures

 18 years experience in more then 800 injection molds it includes Two

plate mould, Three plate mould, Hot runner mould, Double ejection
mould, Gear mould, submarine slider mold ,rotatable core mold .

 18 years experience in VMC machine components. Aluminum parts

for Aerospace components, gear body& engine body for automotive
components.

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1.4 SERVICES
1) CNC Milling Job Work

2) CNC Wire EDM Machine Job Work

3) CNC Spark EDM Machine Job Work

4) Injection Moulds

5) Manufacturing of Jigs & Fixtures

6) Manufacturing of precision injection moulds

7) injection moulds modifications.

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 TASKS PERFORMED
CHAPTER 2
2.1Introduction to injection molding
The injection machine is a machine that melt plasticize the molding material inside the
heating cylinder and inject this into the mold tool to create the molded product by
solidifying inside it. The injection machine is constructed of a mold clamping device that
opens and closes the mold tool, and device that plasticize and inject the molding material.
There are several types in the injection machine, and the difference is made by how these
two devices are arranged.

1. Horizontal injection machine: Both mold clamping device and injection device
compounded horizontally.

2. Vertical injection machine: Both mold clamping device and injection device
compounded vertically.

3. Two-color injection machine.

4. Rotary injection machine.

5. Low foam injection machine.

6. Multi material injection machine.

7. Sandwich injection machine.

2.1Introduction to plastic injection molding process

One of the most common methods of converting plastics from the raw material form to
an article of use is the process of injection molding. This process is most typically used
for thermoplastic materials which may be successively melted, reshaped and cooled.
Injection molded components are a feature of almost every functional manufactured
article in the modern world, from automotive products through to food packaging. This
versatile process allows us to produce high quality, simple or complex components on a
fully automated basis at high speed with materials that have changed the face of
manufacturing technology over the last 50 years or so.

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 FIG 1:INJECTION MOLDING MACHINE

The large and rapidly growing plastics products industry has very little representation in
the Southeast. Since plastics materials were originally substitutes for other materials, they
were first introduced largely into those areas of the North with established manufacturing
shops and technical experience. Because of the requirements and economics of the
plastics products industry and the buying habits of its customers, there is a large number
of small manufacturers today. They are still concentrated in the North, although
California also has a substantial number. Unlike most other industries, the plastics
products industry has not established branch plants in the Southeast. In fact, the industry
has very few branch plants anywhere, primarily because the typical individual company
is too small and too concerned with day-to-day problems to consider the advantages of
another plant location. The Southeast does appear to be a good location for plastics
products manufacturing, however, principally because of its substantial markets and its
attractive labor relations and costs.

There are two approaches which Carroll County can take to develop a plastics products
industry. First, local entrepreneurs can set up plastics products operations, or existing
manufacturers can diversify into a plastics products line. While this approach perhaps
offers the most immediate opportunity, investment in new or additional plant facilities
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and production equipment should not be considered without first obtaining reasonably
thorough technological knowledge of plant operations and plastics applications. Because
of the preoccupation of most established manufacturers with operations in their present
locations, this approach would require extensive preparation and fact finding in order to
spark the interest of those companies which would profit from an expansion of
production facilities into the southeastern market. If this approach were pursued, Carroll
County's presentation should contain significant, well-documented advantages, not
marginal or theoretical ones. Before a substantial plastics products industry could be
attracted, for example, it would probably be necessary to train local workers in plastics
technology at technical schools and colleges in the area.

The rapid growth of the plastics products industry accounts in part for its attractiveness to
entrepreneurs. In 1938, suppliers to the fledgling plastics products industry produced 150
million pounds of synthetic resins and cellulosics. By 1954 the figure reached 2.9 billion
pounds. In the next seven years shipments grew by 130%. to 6.7 billion pounds. The
largest portion of recent consumption increases has been due to larger volume purchases
of thermoplastics -- the materials used in injection molding. Since 1950, about half of the
plastics products plants in the United States have used only injection-molding machinery;
a second large portion of the total has used injection-molding plus compression or
extrusion equipment.

2.2 INJECTION MOULDING PROCESS

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The detail of the process
During the molding process, the plastic pellets will be first delivered into the high-temperature
injection barrel through the hopper, where they are heated, melted and plasticized into a sticky
molten flow, which will then be injected into a lower temperature closed mold through the
injection nozzle at a high speed under the great pushing pressure exerted by the plunger or the
screw.

Under the great pressure, the molten plastic will fill the entire cavity and will also be
compacted. After that, the plunger or the screw will return after a period of pressure holding.
At this point, it is possible to flow back from the cavity into the sprue and runner system.

When the mold opens after cooling and forming, the product will be released from the mold
cavity.

2.3Manufacturing operation

The operations required to produce plastics products by injection molding include (1)
preparation of the molding material, (2) melting the material, (3) forcing the material through
a nozzle and into a mold, (4) ejecting the molded product, and (5) machining and finishing the
product. Operations 1 through 4 may be performed without interruption on a single
combination of processing machinery.

Molding materials are frequently ready for immediate use when they are delivered by the
supplier, but they may require pre-molding preparation. Plastic material fed to the

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injection machine must be reasonably free of moisture if internal voids and surface defects
are to be avoided. Consequently, drying may be necessary to remove moisture from the
surface of molding resins or, in the case of such hygroscopic materials as nylon, acrylics, and
styrene blends, to drive out adsorbed water. Pre-molding preparation may also require
addition of colorants, lubricants, other resins, and scrap material which is to be reworked.
These materials are generally blended into the virgin resin in some sort of tumbler. After any
necessary preparation, the molding material is transferred, either mechanically or manually, to
a hopper which feeds the material to the heating cylinder of the injection-molding machine.
Heat and mechanical agitation convert the cold, granular feed material into a homogeneous
plastic melt of controlled viscosity. Temperature in the cylinder is controlled by wraparound
electrical resistance heaters. Mixing action is provided by forcing the melt past baffles or
spreaders or by use of a rotating screw mechanism within the cylinder.

The plastic melt is forced through a nozzle and into the mold. Nozzle temperature is
controlled to allow continued clean shots of plastic into the mold without hardening and
breaking or drooling. The mold accepts a metered amount of plastic molding material and
cools it quickly and uniformly, usually by transferring the heat to water or some other medium
which is circulated through channels buried in the mold. When the molding compound has
set, the mold is opened and the molded part is forced out of the mold cavity. Some molded
articles require some form of machining or finishing. Thermoplastics products can be
machined with the same equipment used for wood or metals, except that allowance must be
made for the greater heat sensitivity of the plastics product. They may be sawed, routed,
drilled, turned, tapped, threaded, and sheared. Articles may be finished by buffing and
polishing if surfaces are cooled or kept in constant motion, by tumble finishing, and by
solvent polishing.

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 FIG 3: RECIPROCATING SCREW INJECTION MOLDING UNIT

At this stage in the machine cycle the helical form injection screw (Figure 1) is in a 'screwed
back' position with a charge of molten thermoplastic material in front of the screw tip roughly
equivalent to or slightly larger than that amount of molten material required to fill the mold
cavity. Injection molding screws are generally designed with length to diameter ratios in the
region of 15:1 to 20:1, and compression ratios from rear to front of around 2 : 1 to 4 : 1 in
order to allow for the gradual densification of the thermoplastic material as it melts. A check
valve is fitted to the front of the screw such as to let material pass through in front of the
screw tip on metering (material dosing), but not allow material to flow back over the screw
flights on injection. The screw is contained within a barrel which has a hardened abrasion
resistant inner surface.

Normally, ceramic resistance heaters are fitted around the barrel wall, these are used to
primarily heat the thermoplastic material in the barrel to the required processing temperature
and make up for heat loss through the barrel wall, due to the fact that, during processing most
of the heat required for processing is generated through shear imparted by the screw.
Thermocouple pockets are machined deep into the barrel wall so as to provide a reasonable
indication of melt temperature. Heat input can therefore be closed loop controlled with a
Proportional Integral and Derivative (PID) system. The screw (non-rotating) is driven forward
under hydraulic pressure to discharge the thermoplastic material out of the injection barrel
through the injection nozzle, which forms an interface between barrel and mold, and into the
molding tool itself.

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Holding Pressure and Cooling
The screw is held in the forward position for a set period of time, usually with a molten
'cushion' of thermoplastic material in front of the screw tip such that a 'holding' pressure may
be maintained on the solidifying material within the mold, thus allowing compensating
material to enter the mold as the molded part solidifies and shrinks. Holding pressure may be
initiated by one of three methods: by a set time in seconds from the start of the injection fill
phase; by the position of the screw in millimetres from the end of injection stroke; or by the
rise in hydraulic pressure as measured by a pressure transducer in the mold itself or in the
injection hydraulic system.

As the material solidifies to a point where hold pressure no longer has an effect on the
mold packing, the hold pressure may be decayed to zero, this will help minimise residual
stresses in the resultant molding. Once the hold pressure phase has been terminated the mold
must be held shut for a set period of cooling time. This time allows the heat in the molding to
dissipate into the mold tool such that the molding temperature falls to a level where the
molding can be ejected from the mold without excessive distortion or shrinkage. This usually
requires the molding to fall to a temperature below the rubbery transition temperature of the
thermoplastic or Tg (glass transition temperature). Depending on the type of plastic this can
be within a few degrees or over a temperature range. Mold temperature control is incorporated
into the tool usually via channels for pressurised water flow. The mold may be connected to a
cooling unit or water heater depending on the material being processed, type of component
and production rate required.

Material Dosing or Metering

During the cooling phase, the barrel is recharged with material for the next molding cycle.
The injection screw rotates and, due to its helical nature, material in granule or powder form is
drawn into the rear end of the barrel from a hopper feed. The throat connecting the hopper to
the injection barrel is usually water cooled to prevent early melting and subsequent material
bridging giving a disruption of feed. The screw rotation speed is usually set in rpm which is
measured using a proximity switch at the rear of the

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screw. Screw rotation may be set as one constant speed throughout metering or as several
speed stages.

The material is gradually transferred forward over the screw flights and progressively
melted such that when it arrives in front of the screw tip it should be fully molten and
homogenised. The molten material transferred in front of the tip progressively pushes the
screw back until the required shot size is reached. Increased shear is imparted to the material
by restricting the backward movement of the screw, this is done by restricting the flow of
hydraulic fluid leaving the injection cylinder. This is referred to as `back pressure' and it helps
to homogenise the material and reduce the possibility of unmelted material transferring to the
front of the screw.

Mold Open and Part Ejection

When the cooling phase is complete the mold is opened and the molding is ejected.
This is usually carried out with ejector pins in the tool which are coupled via an ejector
plate to a hydraulic actuator, or by an air operated ejector valve on the face of the mold tool.
The molding may free fall into a collection box or onto a transfer conveyer, or may be
removed by an automatic robot. In this latter case the molding cycle is fully automatic. In
semi-automatic mode, the operator may intervene at this point in the cycle to remove the
molding manually. Once the molding is clear from the mold tool, the complete molding cycle
can be repeated.

Mold Design
Mold design is in itself an extremely diverse and complicated subject. However, it is
useful to understand basic design features and construction of simple injection mold
tools.

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 FIG 4:TYPICAL MOLD TOOL ARRANGEMENT.

In this case the mold simply consists of two halves commonly referred to as the moving (core)
half and fixed (cavity) half. Starting from the injection side, a location ring is fitted to the back
of the rear backing plate, this locates and centralizes the mold into the fixed platen. Through
the locating ring a sprue bush can be seen. The sprue bush is profiled with a radius to
match up with the injection unit nozzle so that material can be directly transferred from the
injection unit through to the mold cavity. In the case of a single impression (cavity) mold, the
sprue may feed directly onto the component, in the case of a multi impression mold, the
sprue feeds onto a runner system machined into the tool face that acts as a transfer system to
the cavity for the molten material. Heated or hot runner systems may be incorporated in the
fixed half of the mold such that the sprue and runner feed system is constantly molten and
therefore not ejected at the end of the cycle. Instead the molten material remaining in the hot
runner system after injection of a component forms part of the next shot. Many different types
of gating may be used to connect the runner system to the mold cavities. Gates are preferably
as small as possible in order to minimize the potential ‗witness‘ mark on the component.

It can be seen that a sprue and a cavity form in the mold creates the component
shape,

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these may be machined directly into solid steel or aluminum plates, or made separately as
inserts which may be subsequently fitted to the core and cavity supporting plates. In this
particular example, hardened pins are used to eject the components from the mold, these are
fixed into a rear ejector plate which is connected to a hydraulic actuator behind the moving
platen. A profiled ejector pin behind the sprue bush ensures separation of sprue from sprue
bush when the mold opens and aids ejection of the runner system. Cooling channels are
machined into the core and cavity plates in order to remove the process heat from the tool.
The complete tool is held together with a system of spacer blocks, bolster and backing plates
such that it may be bolted directly to the machine platens and is completely rigid and able to
resist injection forces.

Injection Molding Machine Selection Criteria

Machine selection, particularly for a range of component types can be quite difficult. It
is always wise to talk to machine suppliers in depth regarding overall machine specifications.
Rough guidelines do however exist to enable an estimation of machine type and size
required.

2.4 The Mold

The mold must fit within the available clamping area. This is usually determined by the tie
bar spacing on the machine restricting mold fitting and removal. Some machines have
retractable tie bars to assist mold changing. The clamp stroke available must be able to
accommodate the mold height or depth of mold and the required opening stroke needed to
eject the plastic component. For free fall ejection, the daylight between platens must be
greater than mold height plus twice the depth of component to be ejected. It must be noted
that this dimension will need to be considerably greater if for instance, the component is
removed by a robot, so as to allow access for the removal head. It is always wise to allow
plenty of room for man oeuvre for later machine flexibility.

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The clamping unit

The clamping unit must be able to supply enough locking force to keep the mold shut during
the injection phase, otherwise the mold will part and molten material will flash over the mold
split line. As a rough guide of thumb, parts with thin wall sections and deep draw depths
require approximately 3-4 tonnes per square inch or 0.5-0.6 tonnes/cm2, and parts with thick
wall sections and shallow draw depths require approximately 2 tonnes per square inch or 0.3
tonnes/cm2. To calculate the locking force required for a particular component, this value
must be multiplied by the projected area of the component to obtain an overall value in
tonnes. The projected area of a component is taken as one side of the molding only,
perpendicular to the injection unit as oriented in the mold. For instance, a simple box housing
of 3 mm wall section having a top surface area of 120 cm2 will require at least 120 x 0.3 = 36
tonnes of locking force.

The Injection Unit

The injection unit must be capable of supplying the component shot weight (including the
sprue and runner system). The total shot weight should not exceed 90% of the injection
capacity of the machine. Injection capacities are usually quoted in grams of polystyrene at a
specific gravity of 1.03 g cm-3. If it is intended to process another material, the injection unit
shot weight should be recalculated using that particular material's specific gravity.As
metering or screw recovery must take place before cooling time has elapsed and the mold
opens, the injection unit (size of screw) must be sized to allow this to happen. If recovery
does not occur within the cooling period, the overall cycle time will be unnecessarily
increased. The maximum temperature possible on the barrel must be great enough to melt the
type of plastic being processed. The barrel and screw must be specially treated if particularly
abrasive materials are to be processed, such as glass fiber filled polyamide (nylon). Also, the
screw geometry must be correct for processing specific materials, although general purpose
designs are available to cater for a range of commodity thermoplastics

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Molding Quality
Thermoplastic moldings may contain many defects which are a result of bad mold design,
however, correct control of the injection molding process itself usually plays the major
part in achieving a good quality component. Basic part quality defects may be as follows.

Weld Lines
Weld lines are created when two or more cooling melt flow fronts meet within the mold.
This can be recognised on a molding as a hairline feature and occurs where melt flow has
been divided around an obstacle in the tool, such as a boss pin, and rejoins on the other side.
Weld lines locally reduce the mechanical properties of the material at that point and care
should be taken to position gating such that weld lines are minimised. If they are
unavoidable, they must be positioned in areas of least effect. Melt flow software packages
are of great assistance in this area for complex moldings. Modification of process conditions
such as increasing melt temperature, mold temperature or injection speed may improve the
situation but may create other problems.

Shrinkage
Shrinkage occurs as the thermoplastic cools in the mold. It is due, on a molecular level, to
the polymer chains relaxing (recoiling) and aligning themselves with adjacent chains.
Increased shrinkage occurs with more highly crystalline plastics (e.g. polybutylene
terephthalate, PBT) due to the formation of more dense crystal structures. Sink marks may
occur in plastic parts in areas of thicker cross section such as junctions between side wall and
base where the plastic is slower to cool. Higher mold temperatures will allow the plastic to
shrink more due to increased molecular energy and subsequent ability to recoil. Higher
packing pressures may compensate, as shrinkage can be taken up with new melt (assuming
the gate is still live).

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Splash Marks
Splash marks occur as silver streaks on the molding surface. If any moisture is present in the
material, it is heated and conveyed into the mold cavity. At the point where material enters
the cavity (gate) there is a sudden decompression of the material and the moisture will
volatilise off causing the splash effect. This occurs particularly in moisture attractive
thermoplastics such as nylon (polyamide, PA) and polyacetal (polyoxymethylene, POM).

Distortion and Molded in Stress

Distortion and molded in stress may occur in molded components due to molecular chain
orientation. As the polymer is forced along small channels or cross sections, the molecular
chains become aligned and stretched. As the polymer cools, the molecules try to relax to
their preferred coiled state. As the cooling process is generally fast, the extended molecular
chains become 'frozen' in their uncoiled state. After molding, the molecular chains still try to
recoil and as a result the component may distort, particularly in the case of semi-flexible
polymers such as polyethylene. With more rigid polymers, the distortion may not take place,
however, the residual stress in the plastic will lead to a reduction in important material
properties such as impact strength.

2.5 Introduction to rubber injection molding

Based off of a process intended for the molding of plastics, injection molding of rubber
began in the mid 1960s. Rubber injection molding successfully alters the plastics
process by heating the rubber and placing it under significantly more pressure per square
inch of cavity surface in molding. This is different from the plastic injection molding process
where the materials are cooled under less pressure. Through various innovations, injection
molding has become one of the most efficient ways to create molded rubber products in
many cases.

The process of injection and injection-transfer molding starts with efficient material
preparation. To begin, the material is mixed in bulk and then stripped immediately into

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continuous approx. 1.25" wide & .375" strips. These strips are then fed into a screw which,
in turn, fills a barrel with the appropriate predetermined amount of rubber.

FIG 5 : INJECTION MOULD BEFORE SHOT AND AFTER FILLED

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2.6 Working procedure

The rubber injection molding process starts with an uncured rubber ribbon stock that is fed
into a rotating screw of the injection unit. A controlled amount of material is pulled into the
injection unit. Here the material is plasticized to a target elevated temperature. The rubber
material is then injected into the mold cavity through a runner and gate system where it is
held in the mold under high pressure and elevated temperature to activate the cure system in
the rubber compound (rubber is vulcanized). The cycle time is established to reach an
optimal level of cure. At the end of the cycle, the parts are removed or ejected from the
cavities and the next cycle begins.

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CHAPTER 3
CONCLUSION

In conclusion, my internship at Lakshmi Technologies in Peenya, 2nd stage has provided me

with a comprehensive understanding of the plastic injection moulding process. During my
internship, I was able to gain hands-on experience working with injection moulding machines,
learning about different types of materials, and understanding the various steps involved in the
process.

Through this experience, I have gained valuable skills that will be useful in my future career as
a mechanical engineer. I have learned about the importance of selecting the appropriate
material, the significance of maintaining proper temperature and pressure control, and the need
for precise tooling design.

Overall, the plastic injection moulding process is a versatile and efficient manufacturing
process that is used in a wide range of industries. It has the potential to produce high-quality
parts and products quickly and at a low cost, making it a popular choice for many
manufacturers.

I am grateful for the opportunity to have completed my internship at Lakshmi Technologies,

and I believe that the experience has provided me with a solid foundation to pursue a successful
career in the field of mechanical engineering.

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 Programme Outcomes (PO):

PO1. Engineering knowledge: Apply the knowledge of Mathematics, Science Engineering

fundamentals and an engineering specialization to the solution of complex engineering problems.

PO2. Problem analysis: Identify, formulate, review research literature, and analyse complex
Engineering problems reaching substantiated conclusion using first principles of mathematics,
natural sciences and engineering sciences.

PO3. Design/development of solutions: Design solutions for complex engineering problems

and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
consideration.

PO4. Conduct investigation of complex problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of data, and
synthesis of the Information to provide valid conclusions.
PO5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern Engineering and IT tools including prediction and modelling to complex engineering
activities with an understanding of the limitations.

PO6. The engineer and society: Apply reasoning informed by the contextual knowledge to
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to
the professional engineering practice.

PO7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal environmental contexts, and demonstrate the knowledge of, and need for
Sustainable development.

PO8. Ethics: Applied ethics ex and commit to professional ethics and responsibilities and norms
of the engineering practice.

PO9. Individual and team work: Function effectively as a individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.

PO10. Communication: Communicate effectively on complex engineering activities with the

engineering Community and with society at large, such as being able to comprehend and write
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effective reports and design documentation mate effective presentations, and give and receive
clear instruction.

PO11. Project management and finance: Demonstrate knowledge and understanding of the
Engineering and management principles and apply these to one's own work, as a member and
Leader in a team to manage projects and in multidisciplinary environments.

PO12. Lifelong learning: Recognize the need for, and have the preparation and ability to engage
in independent and lifelong learning in the broadest context of technological.

Course Outcomes (CO):

CO1 Correlate the engineering concepts with the work being done in the respective industry

CO2 Describe the issues faced to get the product outcome in the respective industry

CO3 Interpret the engineering practice carried out during the internship

CO-PO MAPPING
PO1 PO2 PO3 PO4 PO5 PO6 PO8 PO9 PO10 PO11 PO12
CO1 3 2 3 3 3 3
CO2 3 2 3 3 3 3
CO3 3 2 3 3 3 3
Avg 3 2 3 3 3 3

CO-PSO MAPPING
PSO PSO
PSO 2 PSO 4
1 3
CO1 2 2 2
CO2 2 2 2 2
CO3 2 2 2 2
Avg 2 2 2 2

1: Slight (Low) 2: Moderate (Medium) 3: Substantial (High)

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