Materials and

Manufacturing
Processes
Industrial Tour
Nouman Plastics Pvt. limited
Rawalpindi
PRESENTORS:

• Muhammad Umar Farooq 18-MCT-12

• Hafiz Muhammad Nouman Waseem 18-MCT-18
• Muhammad Zawar Zahid 18-MCT-27
• Mohsan Abbas 18-MCT-32
About the industry:

Nouman plastics (Private) Limited is a small engineering manufacturing enterprise in Pakistan

located at Rawalpindi.
They have the resources to handle large projects with demanding delivery schedules. Being the
largest and most extensive fabrication and machining facility equipped with state of the art
technology. Industry provide manufacturing services both on there own or customers design.
Industry have gained rich experience in designing and manufacturing of small products through
collaboration with national reputed engineering organizations. All its processing facilities are in-
house including Designing, Machining, Heat Treatment etc.
Casting:

Casting is a manufacturing process in which a liquid material is usually

poured into a mold, which contains a hollow cavity of the desired
shape, and then allowed to solidify.
 Injection Molding

• Injection molding is a process in which raw material in the form of

granules is feed in to the hopper and plasticized by a reciprocating
screw with heat and injected into the close mold to get the optimum
shape of the required part.

• Materials such as polystyrene, nylon, polypropylene and polythene

can be used in a process called injection molding.
Injection molding machine is separated in two units namely.
Injection unit :
Injection unit can be described in four general steps regardless of the type of machine used.

1.Powder or pelletized polymer is loaded and heated to the molten state.

2. Under pressure, the molten polymer is forced into a mold through an opening called a sprue.

3. The pressurized material is held in the mold until it solidifies.

4. The mold is opened and the part removed by ejector Pins.

Clamping unit:
• The clamping unit must be able to keep the mold halves closed during the pressurized injection of plastic
and not allow flashing.
• Common clamping mechanisms are direct hydraulic clamping and mechanical toggle clamps, actuated by
hydraulic cylinders
• Toggle clamps make use of mechanical advantage but are opened and locked by use of a hydraulic cylinder
• Today, many injection molding machines use direct hydraulic clamping since it uses fewer moving parts and
is reliable and highly controllable
• The methods by which molds are attached to clamping unit include screw and bolt fixtures, key rods and
vacuum to hold the mold, magnetic force and friction or a combination of these.
REAL TIME PHOTOS
 Raw Materials
Generally Plastic is used for injection molding.
 Thermoplastics
 Thermosetting
 Operating principle of injection
molding machine

 A similar desk organizer can be manufactured through injection molding

with this process molten plastic is injected into a steel mold.

 The steel mold made to great accuracy and it can be reused thousands of times
it is made in two halves so that when the molten plastic has cooled, the two parts
can be separated and the plastic desk organizer removed.

 Thermoplastics such as polystyrene, nylon, polypropylene and polythene are ideal

plastics for this type of manufacturing process.
 Continue……………
• Although the desk organizer is manufactured in one piece, the tubes look as if
they are separate. However, if you look closely they are joined by small 'fillets' of
plastic. These can be cut, if each part of the desk organizer is to be used
separately, or the client wants to split the large desk organizer into a number of
smaller pieces (by cutting with a scissors or craft knife).
 Stages of Injection molding
Stage 1
Granulated or powdered thermoplastic plastic is fed from a hopper into the Injection Molding machine.

Stage 2
The Injection Molding machine consists of a hollow steel barrel, containing a rotating screw (Archemidial Screw). The
screw carries the plastic along the barrel to the mold.
Heaters surround the barrel melt the plastic as it travels along the barrel.
Stage 3
The screw is forced back as the melted plastic collects at the end of the barrel. Once enough plastic has collected a
hydraulic ram pushes the screw forward injecting the plastic through a sprue into a mold cavity.
The mold is warmed before injecting and the plastic is injected quickly to prevent it from hardening before the
mold is full.
Stage 4
Pressure is maintained for a short time (dwell time) to prevent the material creeping back during setting
(hardening). This prevents shrinkage and hollows, therefore giving a better quality product.
The molding is left to cool before removing (ejected) from the mold. The molding takes on the shape of
the mold cavity. The image below shows an Injection Molding machine.
 Molding Terminologies
• Pattern: A sample or prototype to make some design as is made by a dye.

• Mold: A mold or mold is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw
materials.

• Mold maker: The manufacturer who makes the molds is called mold maker.

• Release Agent : A release agent is typically used to make removal of the hardened/set substance from the mold
easier.
 The Injection Molding-Mold
• A mold used for Injection Molding may cost thousands of pounds to produce however it does turn out to be
economical as many thousands of moldings can be produced from a single mold. This results in the low cost of each
molding.

• It used to be in case that when a new type of casting was needed a brand new die had to be made. Modern dies and
molds are made from a number of interchangeable parts. This allows the shape of the mold to be altered.

• The dies or molds used in this process are made from alloy stainless steel. These special alloy steel molds are made
in a number of parts to allow the moldings to be easily removed.

• These steel molds are initially very expensive to make and are suited to production in quantity where accuracy of
size, shape and surface finish is essential.
Products
 Injection Molding Applications
• Injection molding is a manufacturing technique for making parts from plastic material.

• Heated, fluid plastic is injected at high pressure into a mold, which is the inverse of the desired shape.

• The steel or aluminum mold is machined with the contours of the final product.