Automatic Pneumatic Plastic Injection Molding

Machine
Injection molding process is a very fast and quick process to make things. The utilization of plastic is expanded
now a days in numerous commercial enterprises such as car, bundling, restorative, and so on. The purpose for
this is the plastic made things are calm simpler to fabricate, handle and solid to utilize. So the plastic
merchandise fabricating commercial ventures are endeavoring hard to deliver great quality items everywhere
scale and less expensive expense. The Hydraulic worked machines take care o

Introduction

Pneumatic System
A pneumatic system is a system that uses compressed air to transferred energy. It is a very cheap system,because air is
a free substance. These systems are used for opening doors, air brakes on buses and trucks, mechanical clamps etc.
Energy delivered by pneumatic framework can be more adaptable, less immoderate, more dependable and less unsafe
than a few actuators and electric motors. It is less expensive than pressure driven machine and more productive when
contrasted with manual machine. So it tackles the issue of little and medium scale commercial enterprises extremely well.
Automatic Die Opening
In this machine, two pneumatic cylinders are used. One for infusion of liquid plastic into the mold and other for automatic
opening of the die. The completed item is excessively hot, making it impossible to touch. So automatic opening
mechanism of the die will be required. The benefit of this machine is, efficiency is expanded when contrasted with manual
machine, space required is less when contrasted with other machine, there is no issue of oil spillage and fire perils and
the expense is less when contrasted with water powered machine (hydraulic system). In manual machine, there is an
issue of evacuation of complete item. This issue is understood in pneumatic machine by utilizing pneumatic cylinder.

List of Components
1. 2 Cylinders
2. 5/2 Direction control valve
3. FRL Unit (Filtraion, Regulation, Lubrication)
4. Flow control valve
5. Pressure Regulator
6. Die
7. Mounting table
8. Nuts and screws

Description
The pneumatically worked injection plastic molding machine is created utilizing different parts. The segments are
pneumatic chambers, upper cylinder(100160 mm) and lower cylinder(5080 mm), pressure controller, 5/2 direction
control valve, stream control valve, FRL unit, outline, barrel, temperature controller, compressor,table for mounting, point
plates, Allen jolts. The upper cylinder is utilized for up and down movement of the plunger which infuses the plastic
material into heated barrel. Lower cylinder is utilized for opening of the die. In manual machine the procurement for
automatic evacuation of item is not present. In pneumatic machine, it is made accessible utilizing lower barrel. The
compressor gives compacted air to both the cylinders, which causes motion of the plunger. FRL unit is utilized for filtration,
regulation, and oil of the compressed air. Air channel evacuates every single outside material and permit dry, clean air to
stream without any stoppage. Once the compressor air has been appropriately cleaned, it is important to direct it to the
required level of pressure regardless of fluctuations in packed air main line. Different pneumatic frameworks work
proficiently at various operating pressure. Henceforth choice of weight controller of right range is critical for proficient
working of pneumatic framework. Pneumatic automation components widely utilize sealing material made out of rubber
compounds. For productive and inconvenience free working of these seals, they should be oiled or greased up to diminish
friction and corrosion. To grease up compressed air actuated equipment, the most effective and prudent strategy is to
infuse the lubricant into the compressed air that powers this hardware. 5/2 heading control valve is utilized to control the
course of the air.

Design of components

Design of Cylinder
Following parameters must keep in mind while designing the cylinder.
1. Cylinder thrust.
2. Air consumption.
Cylinder Thrust
The cylinder push is an element of cylinder diameter, working pneumatic force and the frictional resistance (however on
account of static pressure), the frictional resistance is zero). Cylinder push can be obtained by following formula.
FW = Cylinder thrust for forward stroke in kg.
FR = Cylinder thrust for return stroke in kg.
D = Diameter of piston in cm.
d = Diameter of piston rod in cm.
P = Operating air pressure in ?bar?.
Thrust in Forward Stroke:-
Fw=(pi/4) x D^2 x p
Thrust in backstroke Stroke:-
Fr=(pi/4) x (D^2 - d^2) x p
Air consumption
The air utilization information for barrel is required to find the compressor limit. The estimations include air utilization
during forward and return stroke.The hypothetical air utilization calculated from following formula.
CW = Air consumption for forward stroke (liters).
CR = Air consumption for return stroke (liters).
D = Diameter of piston in cm.
d = diameter of piston rod in cm.
L = Stroke length in cm.
P = Air pressure in bar.
Air consumption for forward stroke:-
Cf= {(pi/4) x D^2 x (p+1) x L} / 1000
Air consumption for backstroke:-
Cr= {(pi/4) x (D^2 -d^2) x (p+1) x L} / 1000

Design of Barrel
Barrel is made of Nitride Steel which is used for Iupilon /Novarex plastic resins. The Barrel comprises of cooling
water channel, heater bands, Thermocouple whose work is to take note of the temperature in different segment of the
barrel.

Design of Nozzle
Nozzle is situated toward the end of barrel which gives the molten plastic to the mold. Material is heated by the heater
which is wrapped on the outside of the barrel.

Design of Heater
The molten plastic are shaped at high temperature. The heater with capacity is around 150-200C.

Design of Die
Die is made up of mildsteel. It is typically made in two parts and when closed it shapes a cavity just like to casting desired.
One portion of the die stays stationary is known as "die cover" and the other part is called "moving or ejector die ". The die
casting method is utilized for castings of non-ferrous metals of nearly low combination temperature and this procedure is
less expensive and faster than perpetual or sand mold casting. A large portion of the vehicles parts are made with this
procedure. Center is male segment of the mold frames the inward state of the embellishment. cavity is on the female
segment of the mold, gives the mold its outside type of the part.

Working of machine
image cutesy: self taken
Embed the plastic granules in the barrel from container. heating coil is given around the barrel which warms the plastic
granules. The temperature of this warming coil can be control by dimmer of 1 amp (100o c). The stopper is given at the
end of the barrel from its internal side to counteracting liquid material tumble down. The stopper is connected in a manner
that if weight is given because of the activity of plunger liquid material gets infused easily into the die. Spring is utilized to
give a clearance in the middle of barrel and the die. Compressor is connected to cylinder through 5/2 heading control
valve which operate the pneumatic cylinders. The 5/2 control valve is hand lever sort of valve. At first stroke compacted air
having weight of 3.2 bar goes into cylinder (100160) which pushes the plunger descending into barrel and liquid material
gets infused into the die. Plunger moves upward in the second stroke of cylinder (100160. Because of expulsion of
pressure from spring, some space is produce in the middle of barrel and die. By utilizing another barrel (8050) which
likewise worked by 5/2 D.C. valve at a pressure of 1.7 bar appended evenly at the base of frame. Die gets evacuated at
first stroke. Because of this mold tumbles down. Second stroke close the die and the process goes on.

Advantages of pneumatic systems

1. High Effectiveness
2. High durability and reliability
3. Simple design
4. Safety
5. Environmental friendly
6. Economical

Conclusion

Pneumatic operated machines are very suitable for the small and medium production quantity. It is tranquil less expensive
in light of the fact that the primary working substance is air and air is free in nature. By this machine the productivity is
increase, less labor require and the finish product is automatically remove from the die by the automatic opening die
mechanics. Hydraulic operated machine can also solve this problem but the cost will be too high.