ABRICATION OF PLASTIC INJECTION

MOULDING MACHINE

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA

IN MECHANICAL ENGINEERING {FOUNDRY}

SUBMITTED BY:

1. R. VINOTH KUMAR
2. L. PRAMOSH
3. C. N. SHANKARAN

4. S. SOLOMAN RAJ
5. K. NEDUMARAN
6. S. SARAVANAN

Under guidance of
Mr. N.RAMU, M.E

OCTOBER 2016.
DEPARTMENT OF MECHANICAL ENGINEERING{FOUNDRY}

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 600123

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 600123

BONAFIDE CERTIFICATE
This is to certify that this Project work on

FABRICATION OF PLASTIC INJECTION

MOULDING MACHINE
submitted by . Reg. No.
in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING{FOUNDRY}
This is the bonafide record of work carried out by him under
our supervision during the year 2016
Submitted for the Viva-voce exam held on ..

HEAD OF THE DEPARTMENT

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal
Mr. A.VIJEY KISOORE,M.TECH., encouragement and valuable advice.

We thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., Ph.D., for presenting his felicitations on us.
We are grateful on our Entourages Mr. N.RAMU, M.E., for guiding in
various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the Mechanical
Engineering (MTMR) Department.

Ultimately, we extend our thanks to all who had rendered their co-operation
for the success of the project.

CONTENTS

CONTENTS
1.

INTRODUCTION

2.

SYNOPSIS

3.

CONSTRUCTION DETAILS

4.

WORKING PRINCIPLE

5.

TEST PROCEDURE

6.

SPARE PARTS DRAWING

7.

SAFTY,CARE AND MAINTENANCE

8.

PAINTING AND FINISHING

9.

COST ESTIMATION

10.

CONCLUSION

11.

BIBLIOGRAPHY

12.

PHOTO VIEW

ABSTRACT

ABSTRACT

The project deals about the injection moulding machine. The main principle
is to compress the plastic material in a barrel and the compression motion is
developed by rotating the leadscrew and nut mechanism arrangement. The plastic
material is heated by the heater surrounding the barrel. Then it is converted into
molten state.

The molten plastic is injected through the nozzle in barrel to the die by the
compression force. After completing this process, we will get the product from the
die. Commercial products like bushes, couplings, switches etc, can be produced.

The leadscrew is coupled to the DC motor operated in 24VDC supply

which is supplied from the DC power source.Here the leadscrew is rotating and
fixed at two ends.and the nut is sliding with the plunger which is used to compress
plastic molten liquid.

INTRODUCTION

INTRODUCTION

The Polymer material are converted into plastic and used as tubes,
sheets, foans, rods, adhesives, etc. The theological properties, softening,
tempering, stability, the size and shape are important in describing the
method.

These methods are different kinds of plastics.

Broadly

speaking the method may be discussed under the following headings.

FABRICATION
TECHNIQUES

FABRICATION TECHNIQUES :

1. MOULDING PROCESS
2. FOAMING PROCESS

MOULDING PROCESS :
In this process the plastic are fabricated under the effect pressure and heat
and both thermoplastics and thermosetting plastics may be starting materials.

INJECTION MOULDING :

Thermoplastics are produced by this method. In this the material is softened

by heating and the hot softened plastic is forced under high pressure into the mold,
when it is set by cooling and the mold is ejected.

FOAMING PROCESS :

This involves the blowing of a volatile organic liquid. Which is entrapped

into a polymer network resulting in the formation of foamed plastics. Foamed
polystyrenes are produced in this process.

CONSTRUCTION

CONSTRUCTION

This project consists of

1.BARREL WITH HEATER AND PLUNGER
2.RELAY BOARD- - - - - 1No

In this project, the plunger is moved up and down into barrel with the
help of motor and leadscrew mechanism. This motor is controlled
through the relay and switch . The plunger is fitted with the leadscrew
slide .The slide with the motor is shown in below figure.

M.S.ROD

M.S.ROD

M.S.PLATE
M.S. PLATE FOR SCREW ROD
ASSEMBLY

WORKING PRINCIPLE

WORKING PRINCIPLE

The injection moulding process is best suited for producing articles

made of thermoplastic materials. Here the equipment cost is relatively
high but the main attraction is the amenability of the injection moulding
process to a high production rate. In injection moulding machine is
shown in the process consists of feeding the compounded plastic
material as granules, pellets or powder through the hopper at definite
time intervals into the hot vertical Cylinder where it gets softened.
Pressure is applied through a plunger driven by the manual to push the
molten material through a cylinder into a mould fitted at the end of the
cylinder. While moving through the hot zone of the cylinder, a device
called torpedo helps spread the plastic material uniformly around the
inside wall of the hot cylinder sand thus ensures uniform heat
distribution.

The molten plastic material from the cylinder is then

injected through a nozzle material from the cylinder in then injected

through a nozzle into the mould cavity.

. By using a mechanical locking device, the mould is proper held

in position as the molten plastic material is injected under a pressure as
high as 1500 kg/ cm. The locking device has to be very skillfully
designed in order to withstand high operating pressures. Further more, a
proper flow of the molten material to the interior regions of the mold is
achieved by preheating the mould to an appropriate temperature.
Usually this temperature is slightly lower than the softening temperature
of the plastic material under going moulding.

After the mould is filled with the molten material under pressure.
Then it is cooled by cold water circulation and then opened so as to eject
the molded articles. The whole cycle could be repeated several time
either manually of in an automated mode.

TEST PROCEDURE

TEST

PROCEDURE

The given die is placed in the vice .

The heater is on
The plastic ore is poured in the furnace
After melting the ore the handle is moved downward .
Now the molten plastic is fed in to the die
Wait for sometime in order to cool the liquid.
Now taken out the tie from the vice .
Check the plastic product after opening the die set.

SPARE PARTS DRAWING

SPARE PARTS DRAWING

M.S.ROD

M.S. PLATE FOR SCREW ROD

ASSEMBLY

SAFETY CARE AND

MAINTENANCE

SAFETY, CARE AND MAINTENANCE

Before starting the machine the operator should wear goggles &
gloves.
The depth of passing the plunger should be given gradually,
in order to prevent the overflow of melting plastic material
Protective guards should be provided in the machine.
Alignment of the

piston and die set

should be maintained

periodically.
Clean the machine table before starting the machine.
Always maintain the smooth feed from the motor.
Cleaning should be done periodically with filing tool.

FEATURES OF THE PLASTIC INJECTION

MOULDING MACHINE

FEATURES OF THE PLASTIC INJECTION

MOULDING MACHINE

It is compact in size
It can be move
The electrical power consumption is nil.
It can be utilized at our work shop
Loading and unloading the job is easy
It is simple in construction
Low cost

FINISHING AND PAINTING

FINISHING AND PAINTING

JOB PREPARATION;
Before welding, remove any bend in the L angle with the sludge
hammer on the anvil block. Then it is cut to the required length
with the hacksaw blade and fabricated to required dimensional
shape with arc welding.
FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the
chipping hammer and cleaned with the metal wire brush. Then all
the surfaces are rubbed with the emery sheet.
Metal primer is applied on the surfaces with the brush .After
drying the metal primer, the second coating is applied with the
paint.

COST ESTIMATION

COST ESTIMATION

1. M.S. Stand

1500.00

2. MOULDING DIE

1800.00

3. PAINT

100.00

4. Electrical heater & Switches

900.00

5. Transporting charges

200.00

6. REPORT

600.00
------------------5100.00
-------------------

CONCLUSION

CONCLUSION
By doing this project PLASTIC INJECTION
MOULDING MACHINE we have gained experience in fabrication
and we have gathered practical experience by welding the structures .we
did this project to our entire satisfaction.
By doing this project work, we understood the working principle and uses of
various diesets and polymers etc.
It will be of no doubt that plastic manufacturing system will be an integrated
part in any industry.
Once again we express our sincere thanks to our staff members.

BIBILOGRAPHY

BIBILOGRAPHY
1. WORKSHOP TECHNOLOGY

-HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY

-R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY

-S.S.MANIAN

4. JIG AND FIXTURE DESIGN

- R.K.JAIN

5.FLUID POWER BY

-E.SUNDRAMOORTHY

Photo view