DYNAMIC INDUSTRIES

Executive Summary
Manufacturing of an injection mould component as per customers requirement and comparison of conventional milling and CNC milling methods.
By Nitish Kumar Roll no. 322, GR no. 71122100019 Submitted for Technical internship programme Training Supervisor and Guide

Prof. Ravi Terkar Associate Professor, MPSTME Mr. Anup Parikh Chairman, Dynamic Industries Ltd.

MUKESH PATEL SCHOOL OF TECHNOLOGY MANAGEMENT & ENGINEERING SVKM's NARSEE MONJEE INSTITUTE OF MANAGEMENT STUDIES (Declared as Deemed-to-be University Under Section 3 of the UGC Act. 1956) Vile Parle (w), Mumbai-400 056.

DYNAMIC INDUSTRIES

ABSTRACT
Dynamic Industries is an upcoming mould making and moulding company specialized in Automobile, Air-conditioners, Water Purifier System, Bio-medical, Television and House Hold Industries. Dynamic Industries have the quality policy of achieving sustained, profitable growth by providing services which consistently satisfy the needs and expectation of the customers. Some of the customers are TVS Motor Company Ltd, Hitachi Home and Life Solution Ltd, TATA Auto-Components Pvt. Ltd. My project is related to the production, design & manufacturing of an injection mould component known as Shroud in this case. In my training here, Ill be monitoring and studying the mould making process starting from the product design to the final trial & correction, alongside with the use of CNC milling machines and its comparison with conventional milling so as to know which is better and what are their advantages and disadvantages.

DYNAMIC INDUSTRIES

Introduction
The following stages are involved in mould making:

DYNAMIC INDUSTRIES

Understanding the Basics of the Injection Mould: Mould Cavity Space:

The mould cavity space is a shape inside the mould, ``excavated'' in such a manner that when the moulding material is forced into this space it will take on the shape of the cavity space and, therefore, the desired product.

Number of Cavities:
Many moulds, particularly moulds for larger products, are built for only one cavity space but many moulds, especially large production moulds, are built with 2 or more cavities. The reason for this is purely economical. It takes only little more time to inject several cavities than to inject one.

Cavity Shape:
The shape of the cavity is essentially the ``negative'' of the shape of the desired product, with dimensional allowances added to allow for shrinking of the plastic.

Cavity and Core:

By convention, the hollow (concave) portion of the cavity space is called the cavity. The matching, often raised (or convex) portion of the cavity space is called the core.

The Parting Line:

To be able to produce a mould (and to remove the moulded pieces), we must have at least two separate mould halves, with the cavity in one side and the core in the other.

Runners and Gates:

We must add provisions for bringing the plastic into the cavity spaces. This must be done with enough pressure so that the cavity spaces are filled completely before the plastic ``freezes,'' that is, cools so much that the plastic cannot flow anymore. The flow passages are the sprue, from where the machine nozzle contacts the mould, the runners, which distribute the plastic to the individual cavities, and the gates, which are (usually) small openings leading from the runner into the cavity space.

DYNAMIC INDUSTRIES

Venting:
As the plastic flows from the gate into the cavity space, the air trapped in it as the mould closed must be permitted to escape and to do this venting is done.

Cooling:
Cooling and productivity are closely tied. In injection moulding, the plastic is heated in the moulding machine to its processing (melt) temperature by adding energy in the form of heat, which is mostly generated by the rotation (work) of the extruder screw. After injection, the plastic must be cooled; in other words, the heat energy in the plastic must be removed by cooling. Cooling of mould is done by cooling channels. Moulds are usually built with cooling channels. These channels are usually connected in series with one inlet and one outlet for water flow.

Ejection:
After the plastic in the cavity spaces has cooled sufficiently and is rigid enough and ready for removal, the mould halves move apart, allowing sufficient space between the mould halves for removal of the product.

DYNAMIC INDUSTRIES

Pre machining of raw material is done to get uniform surface for further machining in CNC and EDM.
Pre machining steps are:

Milling: A milling machine is a machine tool that removes metal as the work is
fed against a rotating multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges.

Shaping: Process of removing metal from surface by the use of a single point
cutting tool held in ram that reciprocates the tool in a linear direction across the work piece held on the table of the machine.

Grinding: Grinding is a metal cutting operation performed by means of a

rotating abrasive wheel that acts as a cutting tool. It is used to finish work pieces which must show a high surface quality, accuracy of shape and dimensions.

DYNAMIC INDUSTRIES

Machining and Finishing processes of mould

CNC:
CNC machining is done for roughing and semi finishing of mould. The insert pockets, the core and cavity pockets, interlock pockets, slide openings and many water-lines are all using CNC.

There are two types of CNC machine based on axes:

2 & 3 Axes CNC machines:

CNC lathes will be coming under 2 axes machines. There will be two axes along which motion takes place. The saddle will be moving longitudinally on the bed (Zaxis) and the cross slide moves transversely on the saddle (along X-axis). In 3-axes machines, there will be one more axis, perpendicular to the above two axes. By the simultaneous control of all the 3 axes, complex surfaces can be machined.

4 & 5 Axes CNC machines:

4 and 5 axes CNC machines provide multi-axis machining capabilities beyond the standard 3- axis CNC tool path movements. A 5-axis milling centre includes the three X, Y, Z axes, the A axis which is rotary tilting of the spindle and the B-axis, which can be a rotary index table. These machines provides improved access to under cuts and deep pockets. By tilting the tool, the tool can be made normal to the work surface and the errors may be reduced as the major component of cutting force will be along the tool axis.

DYNAMIC INDUSTRIES

ELECTRICAL DISCHARGE MACHINING (EDM):

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion. The EDM tool is usually made of copper. Typically thin ribs and walls need to be deeply cut into the mould so we use EDM. Standard CNC machining processes are unable to accomplish such deep cuts due to cutter limitations. With a combination of EDM and CNC machining, we can obtain injection moulds made of sharp and clear features.

Characteristics of EDM:
(a) The process can be used to machine any work material if it is electrically conductive (b) Material removal depends on mainly thermal properties of the work material rather than its strength, hardness etc. (c) In EDM there is a physical tool and geometry of the tool is the positive impression of the hole or geometric feature machined (d) The tool has to be electrically conductive as well. The tool wear once again depends on the thermal properties of the tool material

DYNAMIC INDUSTRIES

Mould of fan shroud of TATA Motors EURO V standard based car:

The Final Product:

DYNAMIC INDUSTRIES

MAIN PROJECT: Comparison of CNC milling and Conventional milling to know which is better.
Experimental Calculation to check whether CNC milling is better or conventional milling: 1. CNC:
Running cost per hour: Rs. 600/Labour cost: Rs. 30/- per hour Tool set up time: 10 mins. Machining Time: 4 Hours. The total cost of running the CNC for 4 hours is Rs. 2400/Here, in this case the labour cost will be considered for only one hour because the CNC is run by a computer program automatically so there is no need of any labour after setting up of CNC.

2. Conventional Milling:
Running cost per hour: Rs. 100/Labour cost: Rs. 25/- per hour Tool set up time: 20 mins. Machining Time: 8 Hours. The total cost of running the Conventional milling for 8 hours is Rs. 800/In Conventional milling a person is required to run the machine to get the desired output. So, the labour cost after 8 hours will be Rs. 800/-.

DYNAMIC INDUSTRIES

Observations:
We can observe that the tool set-up time and machining time on CNC is half of that of Conventional milling and the total running time of CNC is also half of Conventional milling. This shows that a lot of time is saved on CNC than Conventional Milling. The machining time of CNC is also half of Conventional Milling machine i.e. in CNC two jobs can be machined in 8 hours whereas in Conventional Milling machine only one can be completed. One of the main thing observed was the surface finishing on CNC milling was much better than Conventional milling machine. Another main thing observed is that the total cost of CNC milling is much higher than Conventional milling machine.

Result:
Profit earned by the manufacturer is more on CNC and the customers expense is more but at the same time the surface finish on CNC is also of high quality and as per customers requirement they want to have a good high quality product. So, CNC milling is a much better choice than using conventional milling because it will benefit both the manufacturer and the customer. CNC machining can be a cost efficient process, particularly for high volume production runs.

Conclusion:
After doing my Technical Internship at Dynamic Industries, I have understood how the moulds are manufactured and the various machines which are used in manufacturing of moulds like CNC, EDM etc. By comparing CNC and Conventional milling method, I found that the cost of machining of CNC is more than the Conventional milling so the manufacturer will earn more by using CNC milling machines instead of Conventional milling methods. But the customer wants that the product should be accurate and of a very high quality and this is achieved only in CNC milling so the CNC milling will benefit both the customer and manufacturer. So, the CNC milling method is much better than Conventional milling method.

10