MAHARASHTRA STATE BOARD OF

TECHNICAL EDUCATION
SHIVAJIRAO S. JONDHALE POLYTECHNIC

MICRO PROJECT
Academic Year: 2021-22

TITLE OF PROJET
PLASTIC MOULDING PROCESSES

Program: MECHANICAL ENGINEERING

Program code: ME4I
Course: Manufacturing Processes (MPR)
Course code: 22446
 MAHARASHTRA STATE

BOARD OF TECHNICAL EDUCATION

Certificate
This is to certify that

GANESH RAVI GOTHWAL

Roll No. 617 of 4th Semester of Diploma in Mechanical engineering of Institute,

Shivajirao S. Jondhale POLYTECHNIC (Code: 0147) has completed the Micro
Project satisfactorily in Subject –MPR (22446) for the academic year 2021 -
2022 as prescribed in the curriculum.

Place: AMBERNATH Enrollment No: 2101470003

Date: ……………………… Exam Seat No: …………………………………….

Subject Teacher Head of the Department Principal

 MAHARASHTRA STATE

BOARD OF TECHNICAL EDUCATION

Certificate
This is to certify that

SAGAR SHANKAR KEDAR

Roll No. 621 of 4th Semester of Diploma in Mechanical engineering of Institute,

Shivajirao S. Jondhale POLYTECHNIC (Code : 0147) has completed the Micro
Project satisfactorily in Subject –MPR (22446) for the academic year 2021-
2022 as prescribed in the curriculum.

Place: AMBERNATH Enrollment No: 2101470016

Date: ……………………… Exam Seat No: …………………………………….

Subject Teacher Head of the Department Principal

 GROUP MEMBERS

Roll Name of Members Enrollment No.

No.
617 GANESH RAVI 2101470003
GOTHWAL
621 SAGAR 2101470016
SHANKAR
KEDAR
TOPICS ASSIGNED FOR GROUP MEMBERS

1. SAGAR SHANKAR KEDAR 621 – Compression &

Blow moulding

2. GANESH RAVI GOTHWAL 617 – Injection &

Extrusion

moulding
PLASTIC MOULDING PROCESSES

1. COMPRESSION MOULDING
Compression molding is the process of molding in which a preheated polymer is placed into

an open, heated mould cavity. The mould is then closed with a top plug and compressed in
order to have the material contact all areas of the mold.

This process is able to produce parts with a wide array of lengths, thicknesses, and
complexities. The objects it produces are also high in strength, making it an attractive process
for a number of different industries.

Thermoset composites are the most common type of material used in compression moulding.

FOUR MAIN STEPS

There are four main steps to the thermoset composite compression molding process:

1. A high strength, two part metallic tool is created that exactly matches the dimensions
required to produce the desired part. The tool is then installed in a press and heated.

2. The desired composite is pre-formed into the shape of the tool. Pre-forming is a crucial step
that helps to improve the performance of the finished part.

3. The pre-formed part is inserted into the heated mold. The tool is then compressed under
very high pressure, usually ranging from 800psi to 2000psi (depending on the thickness of the
part and the type of material used).

4. The part is removed from the tool after the pressure is released. Any resin flash around the
edges is also removed at this time.
APPLICATIONS :

1. Outer envelopes of a washing machine

2. Refrigerators
3. Automotive Exterior Panels
4. Gaskets
5. Helmets
6. Automobile auto parts etc.
BLOW MOULDING :

 Blow molding is a molding process in which air pressure is used to inflate

soft plastic into a mold cavity.

 It is an important industrial process for making one-piece hollow plastic

parts with thin walls, such as bottles and similar containers.

 Since many of these items are used for consumer beverages for mass

markets, production is typically organized for very high quantities.

 The technology is borrowed from the glass industry with which plastics

compete in the disposable or recyclable bottle market.

 Blow molding is accomplished in two steps: (1) fabrication of a starting tube

of molten plastic, called a parison (same as in glass-blowing); and (2)

inflation of the tube to the desired final shape.

 Forming the parison is accomplished by either of two processes: extrusion

or injection molding.
I. EXTRUSION BLOW MOULDING :

1. This form of blow molding consists of the cycle illustrated below.

2. In most cases, the process is organized as a very high production operation

for making plastic bottles.

3. The sequence is automated and usually integrated with downstream

operations such as bottle filling and labeling.

4. It is usually a requirement that the blown container be rigid, and rigidity

depends on wall thickness among other factors.

5. Extrusion blow moulding: (1) extrusion of parison; (2) parison is pinches at

the top and sealed at the bottom around a metal blow pin as the two halves of the
mold come together; (3) the tube is inflated so that it takes the shape of the mold
cavity; and (4) mold is opened to remove the solidified part.
II. INJECTION BLOW MOULDING :

1. In this process, the starting parison is injection molded rather than extruded.

2. A simplified sequence is outlined in below. Compared to its extrusion-based

competitor, the injection blow-molding process has a lower production rate,

which explains why it is less widely used.

3. Injection blow molding: (1) parison is injection molded around a blowing rod;
(2) injection mold is opened and parison is transferred to a blow mold; (3) soft
polymer is inflated to conform to a blow mold; and (4) blow mold is opened and
blown product is removed.
3. INJECTION MOULDING :
Injection molding is a method to obtain molded products by injecting
plastic materials molten by heat into a mold, and then cooling and
solidifying them.

The method is suitable for the mass production of products with

complicated shapes, and takes a large part in the area of plastic
processing.

Injection molding machine is divided into 2 units i.e. a clamping unit

and an injection unit.
The functions of the clamping unit are opening and closing a die, and the
ejection of products. There are 2 types of clamping methods, namely the
toggle type shown in the figure below and the straight-hydraulic type in
which a mold is directly opened and closed with a hydraulic cylinder.
The functions of the injection unit are to melt plastic by heat and then
to inject molten plastic into a mould.
The screw is rotated to melt plastic introduced from the hopper and to
accumulate molten plastic in front of the screw ( to be called metering ) .
After the required amount of molten plastic is accumulated, injection
process is stared.
While molten plastic is flowing in a mold, the machine controls the
moving speed of the screw, or injection speed. On the other hand, it
controls dwell pressure after molten plastic fills out cavities.
The position of change from speed control to pressure control is set at
the point where either screw position or injection pressure reaches a
certain fixed value.
APPLICATIONS :
1. Food and Beverage
When it comes to injection molding, the food and beverage industry relies heavily on plastic
materials to create product packaging and containers. Since this industry must adhere to strict
sanitization and safety regulations, plastic injection molding is an obvious fit to ensure
various specifications are achieved, including BPA-free, FDA-certified, non-toxic and GMA-
safe regulations. From components as small as bottle caps to the trays used in TV dinners,
injection molding provides a one-stop-shop for all the food and beverage industry’s
packaging and container needs.

2. Automotive Parts

Many of the parts found on modern automobiles require a broad range of intricately designed
features to function correctly. For this reason, many of the leaders of the automotive industry
have turned to plastic injection molding to develop, plan, and manufacture the parts they need.
Typical injected molded elements include bumpers, dashboards, and smaller pieces, such as
cup holders and mirror housings.
4. EXTRUSION MOULDING
Extrusion moulding is used to form plastic or metal materials into a pre-defined shape.
During the process, the material is melted and pushed through an extrusion moulding
machine, forming a long, tube-like shape or rod. This is cooled and cut to the required length.
Often, extrusion moulding plastic products created in this way are used for wiring or
insulating applications.

The products’ cross-sections show uniformity throughout the length of the tubing, which is
highly prized for numerous projects. Extrude plastics can also be formed into other tubular
products, such as drinking straws. The plastic can also be shaped into thin sheeting or films
by being flattened out by a set of cooling rolls.

The plastic extrusion process is commonly used for projects requiring high-volume,
continuous manufacturing. It begins with plastic polymer pellets being fed into the main
barrel of the extrusion moulding machine from a hopper. Here, the pellets or granules melt
gradually as the plastic is put through a heater, pushed along by rotating screws. The heat is
created by the barrel’s heating profile, as well as added friction and pressure inside.

The molten plastic is then decontaminated by a screen pack before the liquid is forced through
a die. This has been carefully sized and shaped to create the required finished product. The
newly formed tube forms a solid shape that exactly matches the shape of the die. The
extrusion is then cooled by passing through a water bath and going under some powerful fans.
As plastic is an excellent insulator, it can take a long time before it cools and solidifies into
the final product. Once this is achieved, the completed product is extracted from the machine.
EXTRUSION MOULDING MATERIALS :
There are several plastic polymers and products that can be used in the
extrusion moulding process. These include, but are not limited to the
following:

1. Acetal

2. Acrylic

3. Acrylonitrile butadiene styrene (ABS)

4. Nylon (polyamides)

5. Polycarbonate (PC)

6. Polypropylene (PP)

7. Polyethylene (PE)

8. Polystyrene

9. Polyvinyl chloride (PVC)

These materials have excellent insulating properties, as well as

recyclability and versatility to create the required shapes. They can
withstand the heat and pressure of the extrusion moulding process and
offer strong resistance to chemicals, corrosion and general wear and tear.
APPLICATIONS :
There are a large number of extrusion moulding products manufactured
across different industries and sectors. For example, the process is ideal
for making hollow pipes and tubing. These include PVC water and
sewer pipes, which can have diameters of up to several feet. The
medical industry, on the other hand, requires very, very small tubes for
various diagnostic and surgical applications. Extrusion moulding can
provide both of these ranges of diameters without compromising on
performance. Other plastic extrusion moulding applications include
drinking straws
and fuel lines inside automotive engines. Another key application is
wiring insulation for electrical wires and cables.

The extrusion moulding process can also produce very thin plastic
sheeting and films. These are also highly versatile and used across many
different sectors. Some examples include window glazing and machine
guards, glass replacement materials and packaging, such as drinks
bottles or blister packs for medications. Finally, the process is ideal for
making long cross-section shapes, such as windscreen wiper blades or
vinyl signs and sidings.

Shivajirao S. Jondhale Polytechnic, Ambernath

 Academic year 2021-22

Teacher Evaluation Sheet for the Micro Project

Program Title: Mechanical engineering

Course Title and Code: Manufacturing Processes (22446)

Semester: Fourth

Name of Students:

1. GANESH RAVI GOTHWAL

2. SAGAR SHANKAR KEDAR

Title of the project :- PLASTIC MOULDING PROCESSES

Cos addressed by Micro project :

1. Students will come to know about the varieties of a mould cavity.

2. They will also learn about the gating systems for placing the mould.

Major learning outcomes achieved during making of this project:-

(A) Practical Outcomes :-

It will help us to know about the formation of a mould.

(B) Unit Outcomes :-

It will help us to know the ingredients included in mould.

(C) Outcomes in affective domain :-

Learning about moulding is necessary because we will know the proper

positioning of mould and also what methods are suitable for mould and at what
temperature mould cavity is suitable for it.
Comments/Suggestions about team work/leadership/inter-personal communication (if

any) Consistency in work, good co-ordination & involvement in team

Any Other Comment:

Roll No. Name of group Mark for group Marks obtained by Total
members work A the Individual Marks
based on viva B [A+B]
617 SAGAR SHANKAR
KEDAR
621 GANESH RAVI
GOTHWAL

Name and Designation of faculty member : AnoopKumar Sir (MPR)

 WEEKLY PROGRESS REPORT
MICROPROJECT
Semester I 2021-22
Program code – ME4I Course code 22446
SR.N WEEK ACTIVITY PERFORMED DATE SIGN OF
O GUIDE
1 1st Week of March Discussion & finalization of 01/03/2022
2022 topic
2 2nd Week of Preparation & submission of 05/03/2022
March 2022 abstract
3 3rd Week of March Collection of data 11/03/2022
2022
4 4th Week of March Collection of data 19/03/2022
2022
5 5th Week of March Discussion & outline of 26/03/2022
2022 content
6 1st Week of April Formulation of content 03/04/2022
2022
7 2nd Week of April Formulation of content 10/04/2022
2022 (contained)
8 3rd week of April Editing & proof reading of 16/04/2022
2022 content
9 4th Week of April Compilation of report & 24/04/2022
2022 presentation
10 5th Week of April Seminar 30/04/2022
2022
11 1st Week of May Viva voce & final submission 03/05/2022
2022 of Microproject