CENTRAL INSTITUTE OF PETROCHEMICALS ENGINEERING &

TECHNOLOGY (CIPET): CENTRE FOR SKILLING & TECHNICAL

SUPPORT (CSTS)
(Department of Chemicals & Petrochemicals, Ministry of Chemicals & fertilizers, Govt. of India)

A Project/ In-Plant Train in Report On

“PROJECT REPORT ON INCREASE PRODUCTIVITY IN IMM FOR
THREAD PROTECTOR ( 8 INCH )”
Submitted in partial fulfilment of curriculum prescribed for the award of the

DIPLOMA IN PLASTICS TECHNOLOGY

Submitted by
Name:- ASHUTOSH DIKHIT Hall ticket no:-170416229
Academic Year:- 2022-23 Semester:-VI

Carried out at

CIPET:CSTS,BALASORE
Plot No. A, IDCO, Bampada Industrial
Area, Balasore-756056
Under the Guidance of

Internal Guide External Guide

(CIPET: CSTS-Balasore) (CIPET: CSTS-Balasore)

Name :- MS. MIR JESHMIN Name:-MR. DEEPAK RANJAN SWAIN

Designation:- Skill Instructor Designation :-Technician Grade III

Submitted to
Department of Plastics Technology,
CIPET: CSTS-Balasore
Plot No. A, IDCO, Bampada Industrial Area, Balasore-756056
 CERTIFICATE

This is to certify that the work entitled “PROJECT ON INCREASE PRODUCTIVITY IN

IMM FOR THREAD PROTECTOR(8 INCH )” is a bonafied work carried out by ASHUTOSH
DIKHIT at CIPET:CSTS-Balasore for a period of 06.02.2023 to 16.06.2023 in partial fulfilment of the
award of the DPT of CIPET: CSTS-Balasore during the year 2023. It is certified that all corrections /
suggestions indicated during CIE have been incorporated in the report. The project report has been
approved as it satisfies the academic requirements in respect of work prescribed for the DPT.

He is well disciplined in his behavior, hard working and dedicated towards assigned tasks.

Internal Project Guide External Project Guide

(MS. MIR JESHMIN (MR. DEEPAK RANJAN SWAIN
CIPET: CSTS-Balasore) CIPET: CSTS-Balasore)

Course In-Charge
(MR. MONOJ DEBNATH
CIPET : CSTS-Balasore) External Examiner

Head of the Department

(MS. NIHARIKA PARIDA
CIPET: CSTS-Balasore)

Place: Balasore
Date: 17.06.2023
 ACKNOWLEDGEMENT

It is our esteemed pleasure to present the project/In-plant Training on “PROJECT ON INCREASE

PRODUCTIVITY IN IMM FOR THREAD PROTECTOR (8 INCH )” is carried out at
CIPET:CSTS,Balasore under the guidance of Mr. Deepak Ranjan Swain. I would like to take this
opportunity to express my humble gratitude towards all those who are directly or indirectly connected to
this project.
I am highly thankful to Ms.Mir Jeshmin, CIPET: CSTS-Balasore, for her constant guidance and support
which eased the execution of this project.
I am highly thankful to Ms.Niharika Parida, Head of Department of Plastics Technology, CIPET: CSTS-
Balasore, for her constant guidance and support which eased the execution of this project.
I remain indebted for the constant guidance and support of Ms. Mir Jeshmin , Practical In-charge and
Mr.Monoj Debnath, Course In-charge, CIPET: CSTS-Balasore.

I am grateful to CIPET;CSTS,Balasore for letting me carry out our project at their premises for a duration
of 06.02.2023 to 16.06.2023. My heartfelt gratitude to Mr. Deepak Ranjan Swain, Production head for
being the guide of the “PROJECT ON INCREASE PRODUCTIVITY IN IMM FOR THREAD
PROTECTOR(8 INCH )” and been there as a constant support and motivating us throughout.
We thank the teaching and non-teaching staff of department of Plastics Technology for providing us the
support and guidance without which the execution of the project would have been very difficult.
We appreciate our classmates for all their help in every situation possible.
Although there may be many who remain unacknowledged in this humble note of gratitude but there
are none who remain unappreciated.

Signature of the student

Name: Ashutosh Dikhit
Hall ticket No.: 170416229
Course: DPT
Semester: VI
 CONTENT

Sl No Chapters Page No.

1 Abstract 1

2 Introduction
2.1 About CIPET:CSTS,BALASORE 2
2.2 Injection moulding Techniques 3- 5
2.2.1 Historical Background
2.2.2 Basic process principals
2.2.3 Types of Injection moulding Machine
2.3 Injection Moulding Machine 5–8
2.3.1 Parts of Injection Moulding machine
2.4 Injection Moulding Process 8 –10
2.4.1 Process Variables
2.4.2 Advantages of Injection Moulding Process
2.4.3 Limitations of Injection Moulding Process
2.4.4 Troubleshooting in Injection Moulding Process
2.5 Steps in Taguchi Parameter Design 11-12
2.5.1 Selection of Quality Characteristics
3 Literature Survey 13 – 14

4 Experimental Work/working procedure 15 - 17

4.1 Product
4.2 Procedure
4.3 Cooling
4.4 Closing Time
4.5 Dosing
4.6 Cycle Time
4.7 Data Backup
4.8 Long Time Monitoring
4.9 Responsibility

5 Result 18

6 Conclusion 19

7 Bibliography/Reference 20

8 List of Figures Annexure-I

9 List of Tables Annexure-II

 1
ABSTRACT

Injection molding is an important polymer processing operation in the plastic industry. In this process,
polymer is injected into a mold cavity, and solidifies to the shape of the mold. Optimizing the
parameters of the injection molding process is critical to enhance productivity. For process optimization,
parameters must operate at optimum levels for acceptable performance. Taguchi method is one of the
methods of optimization, in which orthogonal array is generated based on experimental design.
Optimization of injection molding process parameters will be carried out using Polypropylene (PP) as
the molding material Injection moulding has been a challenging process for many plastic components
manufacturers and researchers to produce plastics products meeting the requirements at very economical
cost. Since there is global competition in injection moulding industry, so using trial and error approach
to determine process parameters for injection moulding is no longer hold good enough. Since plastic is
widely used polymer due to its high
production rate, low cost and capability to produce intricate parts with high precision. It is much difficult
to set optimal process parameter levels which may cause defects in articles, such as shrinkage, warpage,
line defects. Determining optimal process parameter setting critically influences productivity, quality
and cost of production in plastic injection moulding (PIM) industry. In this paper optimal injection
moulding condition for minimum shrinkage were determined by the DOE technique of Taguchi
methods. The various observation has been taken for material namely PP. The determination of optimal
process parameters were based on S/N ratios.

1
 2
INTRODUCTION
2.1 ABOUT CIPET-CSTS, BALASORE:-
Plastic processing technology centre (APPTC) – A specialized unit of CIPET for Plastics processing
was established in the sand advanced city of Balasore in the state of Odisha with the joint efforts of
Govt. of India and Govt. of Odisha.
APPTC Balasore is an ISO 9001:2008 certified institute for processing and testing of plastic material
equipped with the latest state- of- art High end processing and testing machines to cater the needs of
the industries in eastern region of India in the areas of plastics and its allied areas.

Fig-1. (CIPET: CSTS, BALASORE)

CENTRAL INSTITUTE OF PETROCHEMICAL ENGINEERING AND TECHNOLOGY is an

autonomous institute under the department of Chemicals & Petrochemicals, Govt. of India. This is the
only institute of this kind in INDIA where all facilities like design, tooling, processing and testing of
plastics are available under one roof. CIPET caters to the needs of plastics industries through
manpower training, processing, design, and CAD/CAM/CAE, testing, consultancy, advisory and
developmental service.

To meet the needs of plastics conversion industry, CIPET has established extension centre in many
states of the country. Each centre of the CIPET has been equipped with machinery in the area of
mould/ product design and developments, CAD, plastic processing and testing/ quality control. Apart
from developing training manpower and technical services for plastics industries, each centre has been
entrusted with a specific trusted area for development.

2
 2.2
INJECTION MOLDING TECHNIQUES

2.2.1 Historical Background:-

A single-action hydraulic injection machine was designed in the U.S.A. in 1870 by
Hyatt. Heating-cylinder design was first recognized in a patent issued to Adam Gastron in
1932(1).

2.2.2 Basic process principle:

Injection molding process is mainly used for thermoplastic materials. Now a day,thermoset
materials are also used in injection molding process.

Injection means, to inject‟. The plastic melt is injected into the mold by force with the help of
rotating screw.

The pre-dried plastic material is fed into the hopper. The material enters into the barrel through
hopper. The barrel consists of one rotating screw. The heaters are also mounted on the outer
wall of the barrel.

The plastic material melted due to both type of heat-frictional heat and conventional heat.
Frictional heat is generated by screw rotation and conventional heat is given by external heaters.

The melted plastic material then fed into the close mold through nozzle with force. The mold is
filled completely with plastic material.

The material is cool down & rigidify inside the mold. Then the product is ejected from the
mold.

2.2.3 Types of injection molding machines :

• Hand Injection Moulding M/c.
• Plunger type Injection Moulding M/c.
• Reciprocating Screw Type Injection Moulding M/c.

1. Hand Injection Molding Machine:

Fig-2. Hand Injection Molding Machine.

3
  Hand injection molding machines are mostly used in small industries.
 By this machine, we can produce small-small products, for e.g. body & parts of fountain
pen, different parts of radio, automobiles, camera, soap stand, etc.
 Vertical machine consists of Barrel, Plunger, Band Heaters along with energy regulator,
Rack & Pinion system for injecting the material by the plunger, a torpedo and nozzle.
 The machine operates manually by pushing the plunger downwards, the material is fed
into the barrel.
 Material melts inside the barrel due to band heaters. The melted material is injecting
inside closed mold.
 Material melts inside the barrel due to band heaters. The melted material is injecting
inside closed mold.
 Then mold is cooled by water or in open air. Then mold is open and product is ejected
from mold. In this type of machine, the mold is clamp manually.

2) Plunger Type Injection Molding Machine:

Fig3. Plunger Type Injection Molding Machine (Vertical & Horizontal).

The machine operates in semi-automatic mode. Machine consist the barrel, torpedo, heaters, plunger,
hopper, clamping system, etc. The material is fed into the hopper. Material melts inside the barrel due
to band heaters. The melted material injected inside the closed mold with the help of plunger. Plunger
actuates by hydraulic cylinder and pushes material forward. The mold is clamped either hydraulically
or by toggle system. Then mold is cooled by water or in open air. Then mold is open and product is
ejected from mold.

4
 3) Reciprocating Screw Type Injection Molding Machine:

In this type of machine, the plunger and torpedo that are the key components of plunger-type
machines are replaced by a rotating screw that moves back and forth like a plunger within the
heating cylinder. As the screw rotates, the flights pick up the feed of granular material dropping
from the hopper and force it along the heated wall of the barrel, thereby increasing the rate of
heat transfer and also generating considerable heat by its mechanical work. The screw, moreover,
promotes mixing and homogenization of the plastic material.

Fig 4. Reciprocating Screw Type Injection Molding Machine

2.3 INJECTION MOULDING MACHINE

As the molten plastic comes at the end of the screw inside the barrel, the screw moves
back to permit the melt to accumulate. At the proper time the screw is pushed forward without
rotation, acting just like a plunger and forcing the melt through the nozzle into the mold. The size
of the charge per shot is regulated by the back travel of the screw. The heating and
homogenization of the plastics material are controlled by the screw rotation speed and wall
temperatures.

2.3.1 Parts of Injection Moulding Machine

Injection moulding machine majorly can be divided in to two units.1) Clamping Unit 2) Injection
Unit

1) Clamping Units:

The clamping unit keeps the mold closed while plasticized material is injected into it and opens
the mold when the molded article is ejected. The pressure produced by the injection plunger in
the cylinder is transmitted through the column of plasticized material and then through the nozzle

5
into the mold. The unlocking force, that is, the force which tends to open the mold, is given by
the product of the injection pressure and the projected area of the molding. Obviously, the
clamping force must be greater than the unlocking force to hold the mold halves closed
during injection.

1) Tie Bar:
Four numbers of tie bars are provided in the machine to align the movement of the Mould.

2) Moving Platen:
It is a platen which moves backward and forward depending upon the thickness of the
mould, the half part of the mould i.e core is fixed on this platen on the side of the clamping
unit.

3) Stationary/Fixed Platen:
It is a platen where the half part of the mould i.e. cavity is fixed and it is located beside the
injection unit. It is also responsible for the opening and closing of the mold.

4) Ejection System:
Ejection system will push the part out of the mould when it is opened.
There are some ejection systems used in order to eject the article.
1. Air ejection.
2. Knockout pins.
3. Blades.
4. Stripper plate, rings.
5. Ejector Sleeves.

2) INJECTION UNIT:
Purpose: to liquify the plastic materials and then inject the liquid into mold
 Resin is introduced through hopper
 Some machines can have several hoppers (to fed filler, colorants, other additives) Injection
molding act as mixer
 However, due to limited size of barrel, mixing capability is poor.
Screw Used in Injection Moulding Machines

Fig 5. Screw Used in Injection Moulding Machines

6
The screw has three zones with a ring-plunger assembly. The Feed Zone, where the plastic first
enters the screw and is conveyed along a root diameter the Transition Zone, where the plastic is
conveyed, compressed and melted along a root diameter that increases with a constant taper; and the
Metering Zone, where the melting of the plastic is completed and the melt is conveyed for ward
along a constant root diameter reaching a temperature and viscosity to parts.

Hydraulic system and electrical control system

 it is to ensure that pre-injection molding machine according to process requirements (such
as pressure, speed, temperature, time, etc.) and action program to work effectively and
accurately set the power and control systems.
Hopper
 A large, funnel-shaped device located on the top of the barrel in injection molding
machines. The hopper serves as the entryway for the raw material into the barrel.
Barrel
 The barrel of the injection molding machine supports the reciprocating plasticizing screw. It
is heated by the electric heater bands.
Reciprocating Screw
 The reciprocating screw is used to compress, melt, and convey the material.
 The reciprocating screw consists of three zones (illustrated below):
1. Feeding zone.(50%)
2. Compressing (or transition) zone.(25%)
3. Metering zone.(25%)

Fig 6. Reciprocating Screw

Band Heaters
 Bracelet shaped electrical heater that are placed around the outside circumference of barrel.

Fig 7 Electric Heating.

 Induction Heating
 Cast in Heaters.
 Band Heaters
1. Mica Insulated.
2. Ceramic Insulated.

7
Nozzle

 The nozzle connects the barrel to the sprue bushing of the mold and forms a seal between the barrel
and the mold

Fig 8 Nozzle
2.4 INJECTION MOLDING PROCESS:
1. The mould closes and the screw begins moving forward for injection.

Fig 9
2. The cavity fills as the reciprocating screw moves forward, as a plunger.

Fig 10
3. The cavity is packed as the screw continuously moves forward.

Fig 11

4. The cavity cools as the gate freezes off and the screw begins to retract to plasticize material
for the next shot.

Fig 12
5. The mould opens for part ejection

Fig 13

8
 6. The mould closes and the next cycle begins

Fig 14
2.4.1 Process Variables:
In injection moulding machine there are mainly 5 process variables which affect the
outcome of injection moulding through which one can have much or more impact on the
success of this process. They are:
1. Injection Speed.
2. Plastic temperature.
3. Plastic Pressure.
4. Cooling Temperature and
5. Cooling Time.
Control on this variable during each of the four phases of the injection moulding process
can help improve part quality, reduce part variation and increase overall productivity.

Materials recommended: PS, PP, PE.

Clamp Force :
Clamping force is important attribute of the clamping unit of an Injection Moulding
machine.
Clamping Force= Projected Area ˟ 5.
 Whereas, [Projected Area= length˟ width]
Shot Weight :
 Shot weight is the weight of the plastic injected when the nozzle is free standing.
 Usually PS (polystyrene) material is used with a specific gravity of 1.05.
Shot Weight in terms of a resin= ˚C ˟ b/ 1.05
Where, b = Specific gravity of the resin,
˚C= Shot weight in terms of PS (S.G=1.05)
2.4.2 Advantages of Injection Molding Process
 Minimal scrap loss results runners, gates, and rejects can be reground and reused.
 Same items can be molded in different materials, without changing the machine or maudlin
some cases.
 Close dimensional tolerances can be maintained.
 Parts can be moulded with metallic and non-metallic inserts.
 The inherent properties of the material give many advantages such as high strength-weight
rates, corrosion resistance, strength and clarity.
 Large volume production is possible.
 Relatively low labour cost per unit is obtainable.

2.4.3 Limitations of Injection Moulding Process:-

 Intense industry competition often results in low profit margins.
 Mould costs are high.
 Moulding machinery and auxiliary equipment costs are high.

9
  Lack of knowledge about the long term properties of the materials may result in long-
term failures.

2.4.4 Troubleshooting. In Injection Moulding Process :-

Sr. Molding Alternative

Descriptions Causes
No. Defects name
Tool or material is too hot, often
1. Blister Blistering Raised or layered zone
caused by a lack of cooling
on surface of the part
around the tool or a faulty
heater
Black or brown burnt
2. Burn marks Air burn/gas Tool lacks venting, injection
areas on the part located
burn/dieseling speed is too high
at furthest points from
gate or where air is
trapped
Masterbatch isn't mixing
3. properly, or the material has run
out and it's starting to come
Color streaks Colour Localized change of
color/colour through as natural only.
streaks
Previous colored material
"dragging" in nozzle or check
valve.
Contamination of the material
4. e.g. PP mixed with ABS, very
dangerous if the part is being
used for a safety critical
Delamination Delamination Thin mica like layers application as the material has
formed in part wall very little strength when
delaminated as the materials
cannot bond.
Mold is over packed or parting
line on the tool is damaged, too
much injection speed/material
Excess material in thin
Flash Burrs injected, clamping force too
5. layer exceeding normal
low. Can also be caused by dirt
part geometry
and contaminants around
tooling surfaces.
6. Flow marks Flow lines Directionally "off tone" Injection speeds too slow (the
wavy lines or patterns plastic has cooled down too
much during injection, injection
speeds should be set as fast as is
appropriate for the process and
material used)
Tab 1

10
2.5 Steps in Taguchi Parameter Design:-
Taguchi parameter design was used for identifying the significant processing parameters and
optimizing the minimum shrinkage. Two important tools used in parameter design are orthogonal
arrays and signal-to-noise (S/N) ratios. Fig.8 . demonstrates the steps of Taguchi parameter
design (2).

Fig 15 Steps in Taguchi Parameter Design

2.5.1 Selection of the quality characteristic:-

There are three types of quality characteristics in the Taguchi methodology such as the-
smaller-thebetter,the-larger the-better, and the-nominal-the-best. Signal to Noise analysis is
designed to measure quality characteristic. It is given
S/N = -10 log10 (MSD)
Where MSD = Mean Square Deviation

For the smaller the better characteristic,

MSD = ( Y1 2 + Y 2 2 + Y 3 2 + ………..) /n,

For the larger the better characteristic,

MSD = ( 1/ Y1 2 + 1/ Y 2 2 + 1/ Y 3 2 + ………)/n

For the nominal the best characteristic

Where Y1, Y2, Y3 are the responses and n is the number of tests in a trial and m is the target
value of the result. Smaller shrinkage values represent better or improved minimum shrinkage.

In product or process design of Taguchi method, there are three steps:

i. System design: selection of system for given objective function.

ii. Parameter design: selection of optimum levels of parameter

iii. Tolerance design: determination of tolerance (3).

11
Taguchi method uses the signal-to-noise (S/N) ratio instead of average. The S/N ratio reflects
both the average and the variation of the quality characteristics[4].As discussed by Oktem el
at.[5] the S/N ratio is a measure of performance aimed at developing products and processes
insensitive to noise factors. The standard S/N ratio used is as follows: Nominal is best (NB),
lower the better (LB) and higher the better (HB) [6]. In this study lower value of shrinkage
behavior is expected. Thus S/N ratio characteristics the lower – the- better is applied in the
analysis which is given in table 4 and can be calculated by using

S/N=-log10 (1/n∑yi2)

Where yi is the value of the quality characteristics for the ith trials, n are number of repetitions. The
response table of the S/N ratio is given in Tab 2 , and the best set of combination parameter can be
determined by selecting the level with highest value for each factor. As a result, the optimal process
parameter combination for. Packing pressure was found most effective factor for PP followed by
packing time, injection pressure and melt temperature.

Shrinkage is the difference between the size of a mold cavity and the size of the finished part divided
by the size of a mold. Usually it is expressed in percentage. Four points were marked on the
specimen, and measurements were made with micrometer screw gauge (with an accuracy of
0.01mm). For each specimen, the average thickness was calculated.

Sl. No A B C D Shrinkage S/N Ratio

1 1 1 1 1 3.242 -10.2163
2 1 1 1 1 3.545 -10.9923
3 1 1 1 1 3.151 -9.969
4 1 2 2 2 3.757 -11.4968
5 1 2 2 2 4.242 -12.5514
6 1 2 2 2 4.06 -12.1705
7 1 3 3 3 3.848 -11.7047
8 1 3 3 3 4.454 -12.975
9 1 3 3 3 4.545 -13.1507
10 2 1 2 3 4.242 -12.5514
11 2 1 2 3 4.545 -13.1507
12 2 1 2 3 4.848 -13.7113
13 2 2 3 1 4.666 -13.3789
14 2 2 3 1 4.666 -13.3789
15 2 2 3 1 4.545 -13.1507
16 2 3 1 2 4.151 -12.3631
17 2 3 1 2 3.636 -11.2125
18 2 3 1 2 2.848 -9.0908
19 3 1 3 2 3.545 -19.9923
20 3 1 3 2 3.242 -10.2163
21 3 1 3 2 3.454 -10.7664
22 3 2 1 3 3.151 -9.969
23 3 2 1 3 2.03 -6.1499
24 3 2 1 3 1.727 -4.7548
25 3 3 2 1 2.242 -7.0127
26 3 3 2 1 0.515 5.7639
27 3 3 2 1 0.515 5.7639

Tab 2. The Orthogonal Array

12
 3.
Literature review

Taguchi method contains system design, parameters design and tolerance design to achieve a robust
design in order to enhance practical product quality [7-8]. Taguchi design provides a powerful and
efficient method for designing processes that operate consistently and optimally over a variety of
conditions [9]. The use of Taguchi Method involves with following step [10] ; a) Identify the main
function and it side effects, b) Identify the noise factors, testing conditions, and quality characteristics,
c) Identify the objective function to be optimized, d) Identify the control factors and their levels, e)
Select the orthogonal array matrix experiment, f) Conduct the matrix experiment, g) Analyze the data,
IOP Conf. Series: Journal of Physics: Conf. Series 1026 (2018) 012018 doi :10.1088/1742-
6596/1026/1/012018 predict the optimum levels and performance, and h) Perform the verification
experiment and plan the future action. The application of Taguchi approach is widely used in various
industries [11-12].

Chang and Tsaur (1995). Based on the rheological properties of polymers, an integrated theory and
computer program was developed in this study for simulation of such behavior. Hybrid finite-element
and finite-difference methods were employed for simulating the injection moulding filling, packing,
and cooling processes. A control volume method was applied towards both finding the melt front
position and also calculating the temperature and pressure profile at any instant during the filling
process. A modified Tait equation provides a description of the pressure-volume-temperature
relationship of crystalline polymers. The Malkin’s kinetics model was employed to describe the
behavior of polymer crystallization. The flow induced and thermal induced-residual stresses employed
as the initial conditions in the solid mechanics analysis were obtained with the linear
thermoviscoelastic model. The displacements, including the thickness direction of part, which could
not be calculated by the traditional bending moment method, were solved by using the numerical solid
mechanics analysis with the three-dimensional finite element methods. The theoretical results were also
correlated using commercial FE flow simulation software. Though the integrated program was able to
simulate shrinkage and warpage on moulded products, the sink simulation was not modelled
conclusively. Substantial numbers of research studies, using physical experiments, were made to
understand the injection moulding process for various objectives. Some of which are meant to validate
the FE flow simulations. Practical experimental studies on injection moulding process are prohibitively
costly and time consuming. Complexity and cost increases, if one needs modification on moulds on a
continuous basis to conduct any useful study. Hence, practical studies had rather limited scopes.
However, few investigators conducted practical experimental studies for the study of sink marks.(13)

Dan and Bistany (2000) investigated the possibility of reducing sinks with beryllium copper as mould
material using laboratory level experiments. It was found that material with higher thermal
conductivity aids in the reduction of sink.(14)

Ernst et al (2003), An approach for design of mould elements like core and cavity inserts of the
injection moulds was attempted by iteratively coupling structural analysis with FE flow simulations.
The developed approach was reported to have resulted in quicker realization of the parts. Using
suitable rheological data even new materials can be simulated in FE flow simulation packages.(15)

Dubey et al (2005), a unique cooling control system was developed and implemented to control the

13
plastic part average cavity temperature inside the mold cavity on plastic injection molding machine by
utilizing coolant flow as the manipulated variable. An algorithm was developed to automatically
conduct open loop experiments, perform system identification, controller tuning and perform control
simulations. The tuning parameters were then downloaded to another controller for real time control of
part cavity temperature. The PI controller demonstrated good performance for both control simulations
and when implemented practically on machine. This approach can be readily applied on industrial
machines and it creates the foundation for implementing more advanced control schemes such as
model based predictive control and quadratic regulator types.(16)
Erzurumlu and Ozcelik (2006), he objective of this paper consists of minimization of the warpage and
sink index in terms of process parameters of the plastic parts have different rib cross-section types, and
rib layout angle using Taguchi optimization method. Considering the process parameters such as mold
temperature, melt temperature, packing pressure, in addition to rib cross-section types, and rib layout
angle, a series of mold analyses are performed to exploite the warpage and sink index data.(17)

Meiabadi et al (2013), he purpose of this research was to obtain the process parameters that ensure the
accurate part weight, less process cycle time, and injection pressure. The research results indicate that
the proposed approach can effectively help engineers determine optimal process parameters setting and
achieve competitive advantages of product quality and costs. The efficiency of the method depends on
the selection of appropriate process parameters, process parameter ranges and accuracy of Moldflow
simulations and neural network predictions. In this study, the process parameters were determined
within constraints of machine tools and mold steel. Thus, some parameters could not be considered as
the parameters for optimizing the injection process. Because of the fixed mold constraint, the gate
location and coolant point could not change their locations. For future study, the researcher should
perform the experiments using this methodology before producing new products and its mold.(18)

Bharti and Khan (2010), his article presents a review of research in the determination of the process
parameters for injection molding. A number of research works based on various approaches including
mathematical model, Taguchi technique, Artificial Neural Networks (ANN), Fuzzy logic, Case Based
Reasoning (CBR), Genetic Algorithms (GA), Finite Element Method(FEM), Non-Linear Modeling,
Response Surface Methodology, Linear Regression Analysis, Grey Rational Analysis and Principle
Component Analysis using cavity pressure signals have been described. A review of literature on
optimization techniques has revealed that there are, in particular, successful industrial applications of
design of experiment-based approaches for optimal settings of process variables. Taguchi methods and
response surface methodology are robust design techniques widely used in industries for making the
product/process insensitive to any uncontrollable factors such as environmental variables. Taguchi
approach has potential for savings in experimental time and cost on product or process development
and quality improvement. There is general agreement that off-line experiments during product or
process design stage are of great value. Reducing quality loss by designing the products and processes
to be insensitive to variation in noise variables is a novel concept to statisticians and quality engineers.
ANN, GA, and CBR are emerging as the new approaches in the determination of the process
parameters for injection molding. A trained neural network system can quickly provide a set of
molding parameters according to the results of the predicted quality of molded parts. However, the time
required in the training and retraining for a neural network could be very long. By using GA approach,
the system can locally optimize the molding parameters even without the knowledge about the process.
In practical use, the convergence rate to an optimal set of process parameters could be very slow in
some occasion. CBR systems can determine a set of initial process parameters for injection molding
quickly based on the similar case(s) without relying heavily on the expert molding personnel.(19)

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 4.
EXPERIMENTALAL WORK
Before begins with optimizing, the injection molding machine (IMM) must necessarily be in the
balance. The parameters are to choose, that the process is stable and does not lead to minor external
disturbance to committee, for example variation in the production hall.

Machine Spec- FUTURA 90

 Manufacturer Name : ELECTRONICA PLASTICS MACHINE LTD

 Model No : FUTURA – 90
 Clamping Force : 90 Ton
 Shot Capacity : 123 gms.
 Distance Between Tie Bar : 360 mm × 360 mm
 Mould Height (Min./Max.) : 100 mm/350 mm
 No. of Barrel : 1

4.1 PRODUCT :- Thread Protector (8 INCH )

Specifications
 Raw material- Poly propylene
 Density of PP-0.91 grams per cubic centimetre (g/cm3).

Fig 16 :- Raw material-Poly propylene.

Before begins with optimizing, the injection molding machine (IMM) must necessarily be in the
balance. The parameters are to choose, that the process is stable and does not lead to minor external
disturbance to committee, for example variation in the production hall.

Fig 17 :- Thread Protector

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4.2 Procedure :-
Temperature check
 Past- Barrel and melted material
 Target temp. are reached
 The malt temp. is in order
 The friction in nozzle, dispenser and sprue is in order Tools.
 Set temperature is reached (also hot runner)
 Mould cavity surface temperature and temp distribution in order.

Inject
Select injection program with at least 3 stages(more better)
Begin with slow moderate speeds for the respective material(prevent from jetting)
In middle area moderate to fast inject speed (adapted to the part geometry and material)
For wall thickness transition and geometry and geometry changes is the injection speed
adjusted (a constant flow front speed is desirable)
 Shortly before volumetric filling point moderate to slow injection speed, last speed very slow
(avoid overfeeding and peak pressure)

Switch over to holding pressure

Aim at soft- switching to volumetric filling, displacement or pressure dependent, depending on the
application (travel dependent in packaging, pressure dependent at about 80% for technical
application)

Pressure holding level- In thick walled parts with large cross-sectional and with low viscosity
plastics some amount of injection pressure is adopted Pressure holding periods Choose so long that
the sealing time is certainly exceeded.
Holding pressure profile- select slightly sloping profile, to machine and material compatibility as
possible.
 A falling over time pressure profile can especially bring advantages in semi crystalline
polymers.

4.3 Cooling time-

 Incorporate calculation. However as long as necessary, but as short as possible, so that the total
cycle time be short as possible.
 DE moulding deformation must be avoided.

4.4 Closing time

 High enough that flash are avoided but not too much high so that the mould is not unnecessarily
loaded.(wear and tear)
 About 10% higher than the minimum required closing force (determined by the stable injection
process)
4.5 Dosing
 Use rest cooling time for dosing
 Note the screw RPM speed depending on the material
 Note exceed critical dwell time
 Check intake behaviour (plasticizing time constant)
 Set back pressure to the material and the metering accordingly
4.6 Cycle time
 Idle times are to be kept as short as possible so that a minimum cycle time results
 For example open forms closer close form closer, press down nozzle/relieve, dosing delay,
injection start behaviour.

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4.7 Data back up
 Afar completion of the optimization phase if necessary fills the notebook with important data
(for example material MFI, drying time, water temp. etc.) Afterwards the machine data must
necessary be protected. Also a hardcopy should be created.

4.8 Long-time monitoring

 The optimized setting can be considered as safe, if within two production hours no more
changes must be made.
4.9 Reproducibility
 Ensure optimizes data when restart qualitative reproducibility.
 If unexpected errors occur the following point must be clarified.
 The temp. Conditions in the production hall.
 Is the humidity for example different seasonally was the mold in the meantime in revision?

Tab 3 OPTIMIZE COOLING TIME

DE molding
Cooling time Cycle time
Shot no. Temperature Remark
(second) (second)
(oC)
1 7.5 24.5 115 GP not proper
2 8 25 110 GP not proper
3 8.5 25.5 115 GP not proper
4 9 26 115 GP not proper
5 9.5 26.5 115 GP not proper
6 10 27 114 GP not proper
7 10.5 27.5 110 GP not proper
8 11 28 115 GP not proper
9 11.5 28.5 115 GP not proper
10 12 29 115 GP Ok

*GP – Gate point.

With the DE molding temperature we must be pay attention primarily to two things:
 Part must be not be damaged when thrown from the mould..
 Part must be in good shape when is ejected from the mould..

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 5
RESULT
1. Taguchi and ANOVA methods were used to investigate the effects of melt temperature,
injection pressure, packing pressure, packing time and cooling time on the shrinkage of
the PP material.
2. In Taguchi method, S/N ratios were used for determining the optimal set of process
parameters. ANOVA method gave the significance degree of the each process
parameter.
3. Melt temperature is the most effective parameter.

Fig 18 Product cycle time.

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 6
CONCLUSION

This paper contents the analytical and experiment data which are collected by performing on IIM
Milacron 80ton. In this paper the cycle time is optimized for the card holder by changing the cooling
time. Best cycle time for the product is found 29 sec. This paper also represents the procedure for
the optimization of cycle time. Cooling time, hold time and robot take out time are most effective
parameters to reduce the cycle time. But in this paper the main focus is on the cooling time that is
about 50% responsible for the cycle time. Optimization in cycle is most useful and important to
reduce cost as well increase the quality of the product.

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 7
Bibliography/Reference

1. Course material- sponsored by Gail

2. Study and Optimization of Process Parameters in Plastic Injection Moulding- A- Review Y. P.
Tidke1, A.V.Dhote2, Dr.C.R.Patil3 1PRMIT&R,Badnera 2Associate Professor,
PRMIT&R,Badnera 3Professor, PRMIT&R,Badnera
3. D.V. Rosato, M.G. Rosato, “Injection moulding handbook” Massachusetts: Kluwer Academic
Publishers, 2000.
4. Sajjan Kumar Lal, Dr. Hari Vasudevan,” Optimization of injection molding process parameter
in the molding of Low Density polyethylene (LDPE)”,International journal of Engineering
Research and Development,e-ISSN:2278- 067X,p-ISSN:2278-800X,volume 7,issue 5,pp.35-39.
5. M.C. Huang and C.C. Tai, “The effective factors in the warpage problem of an injection-
moulded part with a thin shell feature”, J. Mat. Proc. Tech., vol. 110, 2001, pp. 1–9.
6. K. Krishnaiah, P. Shahabudeen,”Applied design of experiment and Taguchi method”, PHI
learning private limited.Delhi-110092.2013.
7. Taguchi G and Konishi S 1987 Taguchi Methods, Orthogonal Arrays and Linear Graphs, Tools
for Quality Engineer American Supplier Institute p 8-35
8. Foster W T 2000 Basic Taguchi Design of Experiments, Proc. National Association of
Industrial Technology Conference Pittsburgh USA
9. Athreya1 S and Venkatesh Y D 2012 Application of Taguchi Method for Optimization of
Process Parameters in Improving the Surface Roughness of Lathe Facing Operation
International Refereed Journal of Engineering and Science (IRJES) Volume 1 Issue 3 p 13-19
10. Karna S K and Sahai R 2012 An Overview on Taguchi Method International Journal of
Engineering and Mathematical Sciences Volume 1 p11-18
11. Prashar A 2016 A Conceptual Hybrid Framework for Industrial Process Improvement :
Integrating Taguchi Methods, Shainin System and Six Sigma Production Planning and Control
Volume 27 issue 16 p1389-1404
12. Xu Y, Lu H, Zhou D, Zheng J and Zhang J 2017 Image Matching Optimization Based on
Taguchi Method and Adaptive Spatial Clustering with SIFT International Journal of Pattern
Recognition and Artificial Intelligence Volume 31 Issue 11
13. Chang R.Y. and Tsaur B. D. (1995), ‘Experimental and theoretical studies of shrinkage,
warpage, and sink marks of crystalline polymer injection molded parts’, Polymer Engineering
and Science, Vol.35, No.15, pp.1222-1230.
14. Dan T. and Bistany S. P. (2000), ‘Process and tooling factors affecting sink marks for
amorphous and crystalline resins’, Journal of Injection Molding Technology, Vol. 4,
15. Ernst S. and Marco T. (2003), ‘Approach for a mechanical design of plastics injection molds by
means of FEA’, SPE ANTEC Tech. Papers, pp.915-918.
16. Dubay R., Pramujati B. and Hernandez J. (2005), ‘Cavity temperature control in plastic
injection molding’, International Conference on Mechatronics and Automation, Vol. 2, 2005.
17. Erzurumlu T. and Ozcelik B. (2006), ‘Minimization of warpage and sink index in injection-
molded thermoplastics parts using Taguchi optimization method’, Materials and Design, Vol.
27, pp.853–861.
18. Mohammad Saleh Meiabadi, Abbas Vafaeesefat, Fatemeh Sharifi, “Optimization of Plastic
Injection Molding Process by Combination of Artificial Neural Network and Genetic
Algorithm”, Journal of Optimization in Industrial Engineering, Vol. 13, pp 49-54, 2013
19. Bharti, P.K. and Khan. , M. I. (2010). Recent methods for optimization of plastic injection
molding process –a retrospective and literature review. International Journal of Engineering
Science and Technology, 2(9), 4540-4554.

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LIST OF FIGURES (ANNEXTURE – I )

SL.NO FIG.NO Topic Page No

1. Fig 1 CIPET:CSTS,BALASORE 2

2. Fig 2 Hand injection moulding machine. 3

3. Fig 3 Plunger type injection moulding machine ( 4

vertical & horizontal )
4. Fig 4 Reciprocating screw type injection moulding 5
machine.
5. Fig 5 Screw used in injection moulding machine 6

6. Fig 6 Reciprocating screw 7

7. Fig 7 Electric heating 7

8. Fig 8 Nozzle 8

9. Fig 9 Injection moulding process 8

10. Fig 10 Injection moulding process 8

11. Fig 11 Injection moulding process 8

12. Fig 12 Injection moulding process 8

13. Fig 13 Injection moulding process 8

14. Fig 14 Injection moulding process 9

15. Fig 15 Steps of Taguchi Parameter Design 11

16. Fig 16 Raw material Polypropylene 15

17. Fig 17 Thread Protector 15

18. Fig 18 Product cycle time 18

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 9
List of Tables (ANNEXTURE – II )

Sl. No Table no. Topic Page No

1. Table No. 1 Trouble shooting in Injection moulding 10

process
2. Tab 2 The Orthogonal Array 12

3. Tab 3 Optimize Cooling Time 17

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