PRACTICAL TRAINING

At

S.P. ENTERPRISES
B-60, WARD NO.9, DABUA COLONY
NIT Faridabad-121001

Submitted in the partial fulfillment of

Bachelor of Technology Degree Of
Maharishi Dayanand University, Rohtak.
SUBMITTED TO :
Department of MECH. Engg.

SUBMITTED BY :
RAJAN(12ME081)

DEPARTMENT OF MECHANICAL ENGINEERING

Maharishi Dayanand UNIVERSITY, Rohtak(Haryana)

Declaration
I here by declare that the project work entitled Industrial Training Report
Submitted to the S.P. ENTERPRISES is a record of an original Work Done by
me under he guidance of Mr. Harinder sir & Mr. suresh Sharma sir . It has not been
altered or corrected as a result of assessment and it may contain errors and
omissions. The views expressed in it together with any Recommendations by me.

Rajan

Acknowledgement
A Project is a combination of views, ideas, suggestion and combination of many
people. The report is the opportunity to thank those who contributed towards its
fulfillment. Before we get those of things. I would like to add a few heartfelt
words for the people who work part of this training in humerous way people who
give unending supports.
I would like to extend my gratitude towards Mr. AJIT CHAUHAN for giving
considerate and helping.
I also wish to thank the chief manager at different department Akash Kumar
Tanwar (Sr. Manager) whose constant support held long way learning during my
training.
I am immensely thankful to all the employee of goel plastic industries who give the
precious time on providing the with valuable information and replying to my all
queries.

PREFACE
This is a report based on my experience at S.P. ENTERPISES. Being a student of
mechanical engineering, I wished to gain exposure to the various aspects of
working in an industry. This was a perfact opportunity for me . My primary goal
was to gain some insight into methods of manufacturing and design, and during my
time at the shop-floor, I have achieved it to some extent.
It was a good learning experience and will stand me in good stand me in good
stead in future.

Table Of Contents
Chapter 1.Introduction
1.1 Services And Major Functions
1.2 Various Department
1.3 Customers & Vendors
Chapter 2 Molding Process
2.1 Types Of Molding Process
2.2 Short Description Of Types Of Molding
Chapter 3 Brief Process Explanation
3.1 Injection Molding
3.2 Injection Molding Equipment
3.3 Mould
3.4 Mould Design
3.5 Tool Material
3.6 Machining
3.7 Cost
3.8 Injection Process
3.9 Injection Molding Cycle
3.10 Applications
Chapter 4 Material And Power Requirement
4.1 Thermoplastic Material
4.2 Molding Defects
4.3 Tolerances And Surfaces
4.4 Power Requirements

Chapter 1.Introduction

We are one of the leading manufacturers of proven quality plastic moulds components in
Faridabad, since 2008.The facility comprises of 2 workshops of sizes 400 sq.mts.
600 sq.mts.. With a complete standby power for the entire premises. We are constantly
undergoing expansion and introducing newer technologies and equipment. The
Manufacturing processes are : hand moulding of different sizes, automatic horizontal plastic
injection moulding machines, automatic vertical plastic injection moulding machines.all the
processes are carried out with hydraulic power.
We also have a TOOL ROOM for manufacture of jigs,fixtures, etc.

1.1

Services And Major Functions

The infrastructure of the Engineering Workshops could provide the following listed
services to its consumers both in academic and non-academic terms.
We produce more than 1,50,000 quality assured plastic items a month . We are certified to TS
16949 quality system requirements, from TUV.
Goel plastic industries manufactures components comprising of h-connectors, snap, pvc cap, left
right door lock, insulation cap,wire assembly male female parts all these are used in assembly of
different parts.

1.2 Various Department/Shop

New Production Development Department

Vendor Supplied Area / Raw material Storage
SCM department
Primary Inspection Department
Maintenance Department
Production Shop
Heat Treatment shop
Pre Dispatch Inspection Department
Final Inspection (Domestic/Export)

1.3 Customers & Vendors

Customers:

Sivani locks

Vendors:

P.K. Engineering Works

CHAPTER 2

MOULDING PROCESS:- Moulding is the process of manufacturing by shaping liquid

or pliable raw material using a rigid frame called a mold or matrix. This itself may have been
made using a pattern or model of the final object.
A mould is a hollowed-out block that is filled with a liquid or pliable material like plastic, glass,
metal or ceramic raw material. The liquid hardens or sets inside the molds,adopting its shape.a
mold is the counterpart to cast. The very common bivalve molding process uses two molds, one
for each half of the object. Piece molding uses a number of different molds, each creating a
section of a complicated object.this is generally only used for larger and more valuable objects.
The mfg who makes the molds is called the mold maker. A release agent is typically used to
make removal of hardened/set substance from the mold easier.
Typical uses for molded plastics include molde furniture, molded household goods, molded
cases, and structural materials.

2.1Types of molding includes:

BLOW MOLDING
POWDER METALLURGY PLUS SINTERING
COMPRESSION MOLDING
EXTRUSION MOLDING
INJECTION MOLDING
LAMINATING
MATRIX MOLDING
SPIN CASTING
ROTATION MOLDING
TRANSFER MOLDING

2.2 ABOUT SOME OF THE ABOVE MENTIONED TYPES A SHORT DESCRIPTION IS

GIVEN BELOW

Blow Molding Well suited for hollow objects, like bottles

The process follows the basic steps found in glass blowing. A parison (heated plastic mass,
generally a tube) is inflated by air. The air pushes the plastic against the mold to form the desired

shape. Once cooled, the plastic is ejected.

The blow molding process is designed to manufacture high volume, one-piece hollow objects. If
you need to make lots of bottles, this is the process for you. Blow molding creates very uniform,
thin walled containers. And, it can do so very economically.
Compression Molding Well suited for larger objects like auto parts.
The name of this molding method says everything. A heated plastic material is placed in a
heated mold and is then compressed into shape. The plastic can be in bulk but often comes in
sheets. The heating process, called curing, insures the final part will maintain its integrity. As
with other molding methods, once the part has been shaped, it is then removed from the mold. If
sheeting plastic material is used, the material is first trimmed in the mold before the part is
removed.
This method of molding is very suitable to high-strength compounds like thermosetting resins as
well as fiberglass and reinforced plastics. The superior strength properties of the materials used
in compression molding make it an invaluable process for the automotive industry.
Extrusion Molding Well suited for long hollow formed applications like tubing, pipes and
straws.
While other forms of molding uses extrusion to get the plastic resins into a mold, this process
extrudes the melted plastic directly into a die. The die shape, not a mold, determines the shape of
the final product. The extruded tubing is cooled and can be cut or rolled for shipment.

Rotational Molding (Rotomolding) Well suited for large, hollow, one-piece parts.
This process uses high temperatures and rotational movement to coat the inside of the mold and
form the part. The constant rotation of the mold creates centrifugal force forming even-walled
products. Because it is ideally suited to large hollow containers, such as tanks, it is not a fast

moving process. However, it is a very economical process for particular applications and can be
cheaper than other types of molding. Very little material is wasted using this process, and excess
material can often be re-used, making it an economical and environmentally viable
manufacturing process.

Chapter 3 Brief process explanation

3.1 INJECTION MOULDING (INJECTION MOLDING IN THE
USA) is a manufacturing process for producing parts by injecting material into a mould.
Injection moulding can be performed with a host of materials, including metals, glasses,

elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material

for the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools and
hardens to the configuration of the cavity. After a product is designed, usually by an industrial
designer or an engineer, moulds are made by a mouldmaker (or toolmaker) from metal, usually

either steel or aluminum, and precision-machined to form the features of the desired part. Injection
moulding is widely used for manufacturing a variety of parts, from the smallest components to
entirebody panels of cars. Advances in 3D printing technology, using photopolymers which do not

melt during the injection moulding of some lower temperature thermoplastics, can be used for
some simple injection moulds.
Parts to be injection moulded must be very carefully designed to facilitate the moulding process;
the material used for the part, the desired shape and features of the part, the material of the
mould, and the properties of the moulding machine must all be taken into account. The versatility
of injection moulding is facilitated by this breadth of design considerations and possibilities.

3.2 EQUIPMENTS

Main article: Injection molding machine

Injection moulding machines consist of a material hopper, an injection ram or screw-type

plunger, and a heating unit. Also known as presses, they hold the moulds in which the
components are shaped. Presses are rated by tonnage, which expresses the amount of clamping
force that the machine can exert. This force keeps the mould closed during the injection process.
Tonnage can vary from less than 5 tons to over 9,000 tons, with the higher figures used in
comparatively few manufacturing operations. The total clamp force needed is determined by the
projected area of the part being moulded. This projected area is multiplied by a clamp force of
from 1.8 to 7.2 tonsfor each square centimeter of the projected areas. As a rule of thumb, 4 or 5
tons/in2 can be used for most products. If the plastic material is very stiff, it will require more
injection pressure to fill the mould, and thus more clamp tonnage to hold the mould closed. The
required force can also be determined by the material used and the size of the part; larger parts
require higher clamping force.

3.3 MOULD
Mould or die are the common terms used to describe the tool used to produce plastic parts in
moulding.

1. Guide Pins fixed to one half of the mould and align the two halves by entering the holes
in the other half.
2. Runner passageways in the mould connecting the cavities to the sprue bush.
3. Gate Frequently the runner narrows as it enters the mould cavity. This is called a gate
and produces a weak point enabling the moulding to be easily broken or cut from the
runner.
4. Sprue Bush Tapered hole in the centre of the mould into which the molten plastic is first
injected.
5. Locating Ring Positions the mould on the fixed platen so that the injection nozzle lines
up with the sprue bush.
6. Mould Cavity The space in the mould shaped to produce the finished component(s).
7. Ejector Pins These pins push the moulding and sprue/runner out of the mould.
8. The Shot Total amount of plastic injected into mould.
9. Sprue Material which sets in the sprue bush.

Since moulds have been expensive to manufacture, they were usually only used in mass
production where thousands of parts were being produced. Typical moulds are constructed from
hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy. The choice of
material to build a mould from is primarily one of economics; in general, steel moulds cost more
to construct, but their longer lifespan will offset the higher initial cost over a higher number of
parts made before wearing out. Pre-hardened steel moulds are less wear-resistant and are used for
lower volume requirements or larger components; their typical steel hardness is 3845 on
the Rockwell-C scale. Hardened steel moulds are heat treated after machining; these are by far
superior in terms of wear resistance and lifespan. Typical hardness ranges between 50 and 60
Rockwell-C (HRC). Aluminum moulds can cost substantially less, and when designed and
machined with modern computerized equipment can be economical for moulding tens or even
hundreds of thousands of parts. Beryllium copper is used in areas of the mould that require fast
heat removal or areas that see the most shear heat generated. The moulds can be manufactured
either by CNC machining or by using electrical discharge machining processes.

Injection moulding die with ITS SAMPLE

3.4 MOULD DESIGN

Standard two plates tooling core and cavity are inserts in a mould base "family mould" of five different parts

The mould consists of two primary components, the injection mould (A plate) and the ejector
mould (B plate). These components are also referred to as moulder and mouldmakerPlastic resin
enters the mould through a sprue or gate in the injection mould; the sprue bushing is to seal
tightly against the nozzle of the injection barrel of the moulding machine and to allow molten
plastic to flow from the barrel into the mould, also known as the cavity. The sprue bushing directs
the molten plastic to the cavity images through channels that are machined into the faces of the A
and B plates. These channels allow plastic to run along them, so they are referred to asrunners.
The molten plastic flows through the runner and enters one or more specialized gates and into the
cavity geometry to form the desired part.

Sprue, runner and gates in actual injection moulding product

The amount of resin required to fill the sprue, runner and cavities of a mould comprises a "shot".
Trapped air in the mould can escape through air vents that are ground into the parting line of the
mould, or around ejector pins and slides that are slightly smaller than the holes retaining them. If
the trapped air is not allowed to escape, it is compressed by the pressure of the incoming material
and squeezed into the corners of the cavity, where it prevents filling and can also cause other
defects. The air can even become so compressed that it ignites and burns the surrounding plastic
material.
To allow for removal of the moulded part from the mould, the mould features must not overhang
one another in the direction that the mould opens, unless parts of the mould are designed to move
from between such overhangs when the mould opens (using components called Lifters).
Sides of the part that appear parallel with the direction of draw (the axis of the cored position
(hole) or insert is parallel to the up and down movement of the mould as it opens and closes) are
typically angled slightly, called draft, to ease release of the part from the mould. Insufficient draft
can cause deformation or damage. The draft required for mould release is primarily dependent on
the depth of the cavity: the deeper the cavity, the more draft necessary. Shrinkage must also be
taken into account when determining the draft required. If the skin is too thin, then the moulded
part will tend to shrink onto the cores that form while cooling and cling to those cores, or the part
may warp, twist, blister or crack when the cavity is pulled away.
A mould is usually designed so that the moulded part reliably remains on the ejector (B) side of
the mould when it opens, and draws the runner and the sprue out of the (A) side along with the
parts. The part then falls freely when ejected from the (B) side. Tunnel gates, also known as
submarine or mould gates, are located below the parting line or mould surface. An opening is
machined into the surface of the mould on the parting line. The moulded part is cut (by the
mould) from the runner system on ejection from the mould.[15]:288 Ejector pins, also known as
knockout pins, are circular pins placed in either half of the mould (usually the ejector half),
which push the finished moulded product, or runner system out of a mould. 3The ejection of the
article using pins, sleeves, strippers, etc. may cause undesirable impressions or distortion, so care
must be taken when designing the mould.
The standard method of cooling is passing a coolant (usually water) through a series of holes
drilled through the mould plates and connected by hoses to form a continuous pathway. The

coolant absorbs heat from the mould (which has absorbed heat from the hot plastic) and keeps
the mould at a proper temperature to solidify the plastic at the most efficient rate.
To ease maintenance and venting, cavities and cores are divided into pieces, called inserts, and
sub-assemblies, also called inserts, blocks, or chase blocks. By substituting interchangeable
inserts, one mould may make several variations of the same part.
More complex parts are formed using more complex moulds. These may have sections called
slides, that move into a cavity perpendicular to the draw direction, to form overhanging part
features. When the mould is opened, the slides are pulled away from the plastic part by using
stationary angle pins on the stationary mould half. These pins enter a slot in the slides and
cause the slides to move backward when the moving half of the mould opens. The part is then
ejected and the mould closes. The closing action of the mould causes the slides to move forward
along the angle pins.
A mould can produce several copies of the same parts in a single "shot". The number of
"impressions" in the mould of that part is often incorrectly referred to as cavitation. A tool with
one impression will often be called a single impression (cavity) mould. A mould with 2 or more
cavities of the same parts will likely be referred to as multiple impression (cavity) mould. Some
extremely high production volume moulds (like those for bottle caps) can have over 128 cavities.
In some cases multiple cavity tooling will mould a series of different parts in the same tool.
Some toolmakers call these moulds family moulds as all the parts are related. Examples include
plastic model kits.

3.5 TOOL MATERIALS

Tool steel or beryllium-copper are often used. Mild steel, aluminum, nickel or epoxy are suitable
only for prototype or very short production runs. Modern hard aluminum (7075 and 2024 alloys)
with proper mould design, can easily make moulds capable of 100,000 or more part life with
proper mould maintenance.

3.6 MACHINING
Moulds are built through two main methods: standard machining and EDM. Standard machining,
in its conventional form, has historically been the method of building injection moulds. With
technological development, CNC machining became the predominant means of making more
complex moulds with more accurate mould details in less time than traditional methods.
The electrical discharge machining-(EDM) or spark erosion process has become widely used in
mould making. As well as allowing the formation of shapes that are difficult to machine, the
process allows pre-hardened moulds to be shaped so that no heat treatment is required. Changes
to a hardened mould by conventional drilling and milling normally require annealing to soften
the mould, followed by heat treatment to harden it again. EDM is a simple process in which a
shaped electrode, usually made of copper or graphite, is very slowly lowered onto the mould
surface (over a period of many hours), which is immersed in paraffin oil (kerosene). A voltage
applied between tool and mould causes spark erosion of the mould surface in the inverse shape
of the electrode.

3.7 COST
The number of cavities incorporated into a mould will directly correlate in moulding costs.
Fewer cavities require far less tooling work, so limiting the number of cavities in-turn will result
in lower initial manufacturing costs to build an injection mould.
As the number of cavities play a vital role in moulding costs, so does the complexity of the part's
design. Complexity can be incorporated into many factors such as surface finishing, tolerance
requirements, internal or external threads, fine detailing or the number of undercuts that may be
incorporated.
Further details such as undercuts, or any feature causing additional tooling will increase the
mould cost. Surface finish of the core and cavity of molds will further influence the cost. Rubber
injection moulding process produces a high yield of durable products, making it the most

efficient and cost-effective method of moulding. Consistent vulcanization processes involving

precise temperature control significantly reduces all waste material

3.8 INJECTION PROCESS

With injection moulding, granular plastic is fed by gravity from a hopper into a heated barrel. As
the granules are slowly moved forward by a screw-type plunger, the plastic is forced into a
heated chamber, where it is melted. As the plunger advances, the melted plastic is forced through
a nozzle that rests against the mould, allowing it to enter the mould cavity through a gate and
runner system. The mould remains cold so the plastic solidifies almost as soon as the mould is
filled process then repeats.

CLAMPING the moving and fixed platens of the injection moulding machine holds
the mould tool together under pressure.

INJECTION the molten plastic that has been melted from pellet form in the barrel of
the moulding machine is injected under pressure into the mould.

DWELLING after the molten plastic has been injected into the mould pressure is applied to
ensure all cavities are filled.

COOLING the plastic parts are then allowed to solidify in the mould.

OPENING - the moving platen moves away from the fixed plates separating the mould tool.
EJECTION - A plate or air blast then aids ejection of the completed plastic moulding from
the injection mould tool.

3.9 INJECTION MOULDING CYCLE

The sequence of events during the injection mould of a plastic part is called the injection
moulding cycle. The cycle begins when the mould closes, followed by the injection of the
polymer into the mould cavity. Once the cavity is filled, a holding pressure is maintained to
compensate for material shrinkage. In the next step, the screw turns, feeding the next shot to the
front screw. This causes the screw to retract as the next shot is prepared. Once the part is
sufficiently cool, the mould opens and the part is ejected.

3.10 APPLICATIONS
Injection moulding is used to create many things such as wire spools, packaging, bottle caps,
automotive parts and components, Gameboys, pocket combs, some musical instruments (and
parts of them), one-piece chairs and small tables, storage containers, mechanical parts (including
gears), and most other plastic products available today. Injection moulding is the most common
modern method of manufacturing parts; it is ideal for producing high volumes of the same
object.

Chapter 4 Material And Power Requirement

4.1 THERMOPLASTIC MATERIALSALS
The table below provides some brief details on different thermoplastic materials used in
injection moulding. The list is by no means exhaustive and there are a number of blends of
different materials, e.g. PC/ABS, designed to achieve the best performance properties of the
two individual components. Within each group of plastics materials different levels of
performance are available. Additional strength may be gained through the addition of fillers,
such as talc or glass, in many cases. Also additives to improve UV stability or flame
retardancy or provide antimicrobial properties may also be used.

Material

Abbr.

Properties

Typical Applications

Polypropylene

PP

Good chemical resistance

Packaging, containers

PP

HPPP

Semi rigid, durable

Small domestic appliances

Homopolymer

Polyethylene

eg kettles
PE

PE Low Density LDPE/LLDP

E

PE

High HDPE

Density

Polystyrene

PS

General Purpose GPPS

Good

chemical

resistance, Low Density Packaging,

flexible or semi rigid depending containers. High Density

on grade. Weatherproof, good crates,

chemical

drums,

low temperature performance.

gas/water pipe and fittings,

Non toxic. Low cost

kitchenware

Brittle, transparent. Poor UV GPPS toys, packaging,

stability. HIPS up to 7x impact cosmetic packaging
strength of GPPS

High Impact

HIPS

HIPS

TV

cabinets,

refrigerator linings, toilet

seats
Acrylic

PMMA

Rigid,clear,

glossy,

weather resistance

good Lenses,

signs,

light

diffusers, point of purchase

displays

Acrylonitrile
Butadiene
Styrene

ABS

Rigid, opaque, tough, good Domestic appliances, car

gloss, texture possible

fascias, computer housings

Nylon

PA

Rigid, tough, hardwearing

(Polyamide)

Gears,

bearings,

automotive under bonnet

parts

4.2 MOULDING DEFECTS

Injection moulding is a complex technology with possible production problems. They can be
caused either by defects in the moulds, or more often by the moulding process itself.

Moulding
defects

Blister

Alternative
name

Blistering

Descriptions

Causes

Raised or layered

Tool or material is too hot, often

zone on surface of

caused by a lack of cooling around the

the part

tool or a faulty heater

Black or brown burnt

Burn marks

Air burn/gas
burn/dieseling

areas on the part

located at furthest
points from gate or

Tool lacks venting, injection speed is

too high

where air is trapped

Flash

Burrs

Excess material in

Mould is over packed or parting line

on the tool is damaged, too much

thin layer exceeding

injection speed/material injected,

normal part

clamping force too low. Can also be

geometry

caused by dirt and contaminants

around tooling surfaces.

Foreign particle
Embedded

Embedded

(burnt material or

contaminates

particulates

other) embedded in
the part

Part deformed by
Jetting

turbulent flow of
material.

Particles on the tool surface,

contaminated material or foreign
debris in the barrel, or too much shear
heat burning the material prior to
injection

Poor tool design, gate position or

runner. Injection speed set too high.
Poor design of gates which cause too
little die swelland result jetting.

Caused by the melt-front flowing

around an object standing proud in a
plastic part as well as at the end of fill
Small lines on the

where the melt-front comes together

backside of core pins again. Can be minimized or eliminated

Knit lines

Weld lines

or windows in parts

with a mould-flow study when the

that look like just

mould is in design phase. Once the

lines.

mould is made and the gate is placed,

one can minimize this flaw only by
changing the melt and the mould
temperature.

Sink marks

[sinks]

Localized depression Holding time/pressure too low,

cooling time too short, with sprueless

hot runners this can also be caused by
(In thicker zones)

the gate temperature being set too

high. Excessive material or walls too
thick.

Short shot

Non-fill or
short mould

Lack of material, injection speed or

Partial part

pressure too low, mould too cold, lack

of gas vents

Methods such as industrial CT scanning can help with finding these defects externally as well as
internally.

4.3 TOLERANCES AND SURFACES

Moulding tolerance is a specified allowance on the deviation in parameters such as dimensions,
weights, shapes, or angles, etc. To maximize control in setting tolerances there is usually a
minimum and maximum limit on thickness, based on the process used. Injection moulding
typically is capable of tolerances equivalent to an IT Grade of about 914. The possible tolerance
of a thermoplastic or a thermoset is 0.200 to 0.500 millimeters In specialised applications
tolerances as low as 5 m on both diameters and linear features are achieved in mass
production. Surface finishes of 0.0500 to 0.1000 m or better can be obtained. Rough or pebbled
surfaces are also possible.
Moulding Type

Typical [mm]

Possible [mm]

Thermoplastic

0.500

0.200

Thermoset

0.500

0.200

4.4 POWER REQUIREMENTS

The power required for this process of injection moulding depends on many things and varies
between materials used. Manufacturing Processes Reference Guide states that the power
requirements depend on "a material's specific gravity, melting point, thermal conductivity, part
size, and molding rate." Below is a table from page 243 of the same reference as previously
mentioned that best illustrates the characteristics relevant to the power required for the most
commonly used materials.

Material

Specific gravity

Melting point (F)

Melting point (C)

Epoxy

1.12 to 1.24

248

120

Phenolic

1.34 to 1.95

248

120

Nylon

1.01 to 1.15

381 to 509

194 to 265

Polyethylene

0.91 to 0.965

230 to 243

110 to 117

Polystyrene

1.04 to 1.07

338

170

References:
www.google.com
www.wikipedia.com
www.fadooengineers.com