GOVERNMENT TOOL ROOM AND TRAINING CENTRE

NEAR CLOCK TOWER BANGARPET-KGF ROAD,

KOLAR - 563101

IMPLANT TRAINING REPORT

ON
“GRILL PANEL BOTTOM LOWER RAIL ”

In partial fulfillment for the award of

“DIPLOMA IN TOOL AND DIE MAKING”

GUIDED BY:
SUBMITTEDBY:
Mr. ABHILASH V Name:MADHUSUDANA .S
HOD-DPM &Lecturer Reg no : 1221226
GTTC-Kolar Batch : 12th Batch
 GOVERNMENT TOOL ROOM & TRAINING CENTRE
NEAR CLOCK TOWER BANGARPET KGF ROAD,
KOLAR-563101

CERTIFICATE

This is to certify that Mr. MADHUSUDANA S Bearing

Reg No:1221226 has successfully completed the in-plant training
on “GRILL PANEL BOTTOM LOWER RAIL” for fulfillment for the
award of “DIPLOMA IN TOOL AND DIE MAKING” from
[Link] ROOM AND TRAINING CENTER- KOLAR,
during the year 2024-2025

PROJECT GUIDE PRINCIPAL

Mr. Abhilash V Mr. Vikas D

Date:
Place:
 PROJECT REPORT EVALUATION

NAME : MADHUSUDANA S
REG NO : 1221226
COURSE :DTDM
ACADEMIC YEAR : 2024-25

MAXIMUM MARKS
SL. DESCRIPTION
MARKS OBTAINED
NO

01 STUDY ABOUT CMM 20

02 DRAWING SHEET 20
ANALYSIS

03 ELECTRODE 30
INSPECTION

04 PLANNING 30

05 REPORT 80

06 PRESENTATION 20

TOTAL 200

Signature of The Evaluator

 ACKNOWLEDGEMENT

I am extremely thankful to Dr. DINESH KUMAR Y.K MD of Government Tool Room

and Training Centre, for providing me an opportunity to do Implant training.
I am grateful to Dr.N RAMESHA DGM, GTTC for me providing me an opportunity to
do Implant training.
I am grateful to [Link] NAIK S ZONAL HEAD for me providing mean
opportunity to do Implant training.
I express my deep sense of gratitude and Indebtedness to Mr. VIKAS D,
Principal GTTC KOLAR, for providing me an opportunity to fulfill my cherished desire of
completing the Implant training .
I am extremely thankful to [Link] V for his excellent co- operation,support,
skillful guidance and valuable suggestions.
I am also grateful to [Link] ,HR INDO-MIM for providing me an opportunity
required to complete this training successfully.
My sincere regards to all staff members of GTTC KOLAR and employees of INDO-
MIM who directly or indirectly helped me in carrying & completing my training successfully.

Signature of Student :

Register Number :1221226

 ABOUT GTTC

The Government Tool Room and Training Centre (GTTC), established in 1972 in Rajajinagar, Bangalore, is a technical
education institute under the Skill Development, Entrepreneurship and Livelihood Department of the Government of
Karnataka, offering diploma courses in various technical fields.
Here's a more detailed overview of GTTC:
Establishment and Collaboration:GTTC was founded in 1972 as a joint venture between the Government of
Karnataka and the Government of Denmark.
Mission: The institute's mission is to provide skilled human resources for existing and new industries, with a focus on
hands-on learning and practical training.
Diploma Courses:GTTC offers diploma courses in fields like Tool and Die Making, Artificial Intelligence, Electrical
and Electronics Engineering, and Mechatronics.
AICTE Approval:The diploma courses offered by GTTC are approved by the All India Council for Technical
Education (AICTE).
Placement:GTTC diploma holders are in high demand in industries and multinational companies, and the institute
boasts a strong placement record.
Infrastructure:GTTC has state-of-the-art laboratories and facilities, including high-speed CNC machines, CNC
lathes, CNC turn mills, and other precision manufacturing equipment.
Recognition:GTTC is a recognized Scientific & Industrial Research Organization (SIRO) under the Council for
Scientific and Industrial Research (CSIR).
Post Diploma in Tool Design:GTTC offers a Post Diploma in Tool Design course, which is industry-oriented and
designed in consultation with major industry partners.
GTTC Locations:GTTC has multiple locations across Karnataka, including Bangalore, Harihar, and Lingasugur.
Other Courses:Besides diploma courses, GTTC also offers short-term competency courses and skill training
programs.

5
 ABOUT GTTC-KOLAR

The Government Tool Room and Training Centre (GTTC) in Kolar, established in 2010 as a sub-center of the GTTC
Bangalore, focuses on providing skilled manpower and technical services to industries, offering long-term and
shortterm training programs.
Here's a more detailed overview:

BACKGROUND & PURPOSE:

 Joint Venture:GTTC is a joint venture between the Government of Karnataka and DANIDA, the Government of
Denmark, with the main GTTC in Bangalore established in 1972.
 Expansion:The Kolar sub-center was established in 2010 due to the excellent performance of the Bangalore
GTTC and the proactive government's need for expansion.

 Focus:The GTTC aims to provide skilled manpower and technical services to both existing and emerging
industries.

TRAINING PROGRAMS:
 Long-Term and Short-Term:The GTTC offers a range of training programs, including long-term and short-term
skill development courses.
 Hands-On Training:The programs emphasize hands-on training, combining theory and practical experience to
equip trainees with industry-relevant skills.

NEED-BASED TRAINING:

6
GTTC also offers tailor-made training programs to industries, designed to meet their specific needs and enhance
employee skills.

FACILITIES AND EXPERTISE:

 Sophisticated Facilities:The GTTC boasts state-of-the-art manufacturing facilities, including CNC machines,
grinders, and other advanced equipment.
 Design and Manufacturing:GTTC is involved in designing and manufacturing press tools, dies, jigs, fixtures,
and critical components for various sectors, including aeronautical and defense.

7
 ABOUT TAFE COMPANY

COMPANY PROFILE

TAFE has an exclusive division dedicated to engineering plastics and precision moulds. The
Engineering Plastics Division (EPD), at Doddaballapur, near Bangalore, has an active strategic
alliance with McKechnie Plastic Components, U.K. This collaboration enables EPD with not
just state-of-the-art technology but with developing marketing strategies as well, while
providing enhanced value and support to customers of both companies.

EPD has the flexibility to produce a range of engineering plastic components. It also has the
infrastructure to cope with large demands, with machines ranging from 40 T to 130 T
capacities. This, and EPD's constant eye on quality have won many prestigious clients in
InfoTech, automotive, consumer electronics, etc., both in India and abroad.

The Engineering Plastics Divisions of TAFE (TAFE-EPD) manufactures high precision tools
and custom moulded engineering plastics at it state-of-the-art facility in Bangalore District,
Karnataka. The facility comprises a sophisticated design centre, a tool room and two injection
moulding plants, equipped with the latest CNC machining centers and micro-processor
controlled injection moulding machines.

8
The imperatives of growth in the engineering plastics and tool making industries require
continuous improvement in technology and business practices. TAFE-EPF meets this
challenge by combining the most systems and dedicated customer service. From art to part, the
focus is on maximizing customer satisfaction. through the investment in technology, people
and processes, TAFE-EPD has consolidated its position at the leading edge of the engineering
plastics industry

TAFE COSTEMERS

9
TAFE ACHIVEMENTS

10
 CONTENTS
SL.N
INDEX PAGE NO.
O

1 INTRODUCTION 12-27

2 COMPONENT ANALYSIS 28-37

3 TOOL DESIGN ANALYSIS 38-48

4 RAW MATERIAL SELECTION 49-52

6 TOOL TERMINOLOGY 53-65

16 SAFETY 66-67
17 CONCLUSION 68-69
18 BIBLIOGRAPHY 70-72

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PROJECT REPORT
FOR

“GRILL PANEL
BOTTOM R/L”

INTRODUCTION OF PROJECT

During the course of in-plant training for a period of 1 year at TAFE-EPD I was
assigned manufacturing of injection mould tools successfully I completed plenty of moulds
were manufactured and the best among was selected for my project work.

The tool selected for my project work was “Two Cavity with Two Plate Injection mould”.
The component produced from this tool is called

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“GRILL PANEL BOTTOM RH-LH”. The material used for this component is (PP-E)
Poly Propylene. This component is used in “TVS VEHICLE” (To fill the gap between
floor board & panel front).

This injection mould tool is manufactured in TAFE-ENGINEERING PLASTICS &

TOOL ROOM DIVISION. Customer of this tool is “TVS” (MYSORE).

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BRIEF SPECIFICATION OF THE PROJECT

SL.
DESCRIPTION REMARKS
NO.
01 Type of mould Two Plate Mould
02 Surface finish Texture
03 Type of material Poly Propylene
04 Part shrinkage 1.5%
05 Type of machine SP 150
06 Number of cavities 02
Sleeve & Pin
07 Type of ejection
Ejectors
08 Type of runner Round
09 Type of gate Submarine
10 Feed system Sprue,Runner,Gate
11 Number of day 01
lights
12 Type of cooling Annual
13 Customer T VSM
COMPONENT PHOTO

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INTRODUCTION OF PLASTICS

Plastics are varied group of organic material having very high molecular compounds and
fillers plasticizers, hardness, strains and pigments, lubricating and other substances which are
derived from natural source like Petroleum, coal, cellulose, salts, water, air and natural gas.
They can be easily fabricated and formed under the effect of pressure and heat. Plastic differ
from other material in a way that provide a combination of properties rather than extremes of
a single property. Plastics can be flexible light, strong and transparent at the same time.
Plastics have a wide range of properties, and wide range of colours.

Some other properties are:

 It has low specific gravity i.e., from 0.9 to 1.8g/[Link].

 It has high resistance to corrosion.
 It has good dielectric property when used under D.C and A.C.
 It has anti-friction property. So it is widely used as material for bearings.
 Plastics are poor heat conductors. So it is widely used as thermo insulating
material.

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 It is easy for processing.

TYPES OF PLASTICS
By virtue of thermal characteristics plastics are usually divided into two groups,
 Thermo-plastics.
 Thermo set-plastics.

THERMO-PLASTICS
In the plastics the material has long linear molecular structure and will
repeatedly soft when heated and will become hard when cooled. Typical
members and of the family are polystyrene, polyethylene, amides, and vinyl’s.

Each thermoplastic polymer has certain inherent characteristics, which are due
to the chemical composition. Addition desired features can be generated by
compounding polymers with fillers, extenders and reinforcing with organic and
inorganic material.
Based on molecular structure, thermoplastics can be classified into two
groups: Amorphous and Crystalline.

Amorphous materials never really melt during processing. They just soften and are
formed under pressure. These materials posses close dimensional tolerances on the part
compared to crystalline materials. ABS, PS, PC, etc. are classified under this group.
Crystalline materials have a specific melt temperature and remain solid until this temperature
is reached. After the melt temperature is achieved, the materials flow very easily with very
low viscosity. When the material is cooled to a temperature below the melt temperature, the
material hardens to a solid form. Nylon, Polyethylene, PP, etc. are classified under this group.

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Different THERMOPLASTIC molding methods are:

a) Injection molding
b) Blow molding
c) Extrusion molding
d) Thermo Forming
e) Rotary molding or Centrifugal molding
f) Calendaring

THERMOSET-PLASTICS
In thermosetting plastics the resin undergoes a chemical reaction under the influence of heat,
catalysts, ultraviolet light etc. resulting in products that are relatively infusible in characters
and are cross linked material that are not reversible i,e. the application of heat will not cause
the material to soften and upon cooling it will not solidity. Some plastics which belong to the
category are Phenolix, Epoxies, Melamine, Urea formaldehyde etc.

Thermo set-plastics are the material that hardens by the application of heat and

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further heating has no softening effect on it. This plastics are strong hard and brittle. These
materials cannot be recycled.

Different THERMO SET PLASTIC molding methods:

a) Compression molding
b) Transfer molding
c) Injection molding
TOOLING:

Tool can be defined as hardware necessary to produce any article.

In large quantity it can be a jig or a fixture used for rapid machining of parts i.e.
a Press tool used for producing sheet metal components, Gauges used for rapid
and repetitive inspection, Mould tool used to produce plastic components or a
die casting tool used to produce metal casting rapidly.

INTRODUCTION TO MOULD
Mould is a hollow form of cavity in to which molten plastic materials is forced to give the
shape of the required components. The terms generally refers to the whole assemble of parts
which go to make up the section of the injection molding equipments in which plastics
components are moulded.

COMMONLY USED MOULDING METHODS:

 Compression molding
 Transfer Molding
 Injection Molding
 Extrusion molding
 Blow Molding
 Rotor Molding
 Calendering
 Thermo forming

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Injection Moulding:Molten plastic is injected under high pressure into a cooled, split mould
to produce a high precision moulding
UsesBuckets
Telephones
TV cabinets
Gears
Toys

Blow Moulding
A hot thermoplastic tube is inflated by compressed air into a cooled split-cavity mould to
produce a hollow moulding

Uses
Bottles
Drums
Carboys
Car fuel tanks

Transfer moulding:
It is a Closed Mold process in which a pre-weighed amount of a polymer is preheated in a
separate chamber (transfer pot) and then forced into a preheated mold filled with a

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reinforcing fibers, taking a shape of the mold cavity, impregnating the fibers and
performing curing due to heat and pressure applied to the material.

Compression Moulding
Thermosetting plastic powder is compressed and heated in a matched die-set to produce
a precision moulding Uses
Fuse boxes
Lamp holders
Saucepan handles
Insulators

Rotational Moulding
Thermoplastic powder is tumbled, heated and cooled in a split, hollow mould to produce a
hollow mouding of simple shape.

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Uses
Litterbins
Playballs
Traffic bollards

INJECTION MOULDING
The present time is considered to be the plastic age, where an unlimited number of plastics
are being made available which in turn broadens the avenues for a wide variety of
application. Injection is a process in which plastic material is heated and softened in one part
of machine. And then injected under high pressure into the mold where it is cooled and
hardened to form the component. In this type repeatedly accurate components can be molded.
It is constant process. Generally thermoplastics are used for injection.
An injection mould consists of two halves, namely top half and bottom half. The top half
consists of cavity, which gives the external profile to the component. The bottom half consists
of core, which gives the internal profile of the component.
When the mould is closed in an injection machine, two halves are aligned by the main guide
pillars and bushes provided in the tool. The melted plastic material is injected under pressure
and speed from the heated cylinder by a feeding device. The injected material passes through
the sprue, runner and gate to fills the cavity. The material is converted to a rigid state by the
water or oil circulated through the cooling holes in the tool. Then the mould is opened adn
ejector assembly is actuated to eject the component. Thus cycle is continued.

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Why is injection anexpensive?

mold

Injectio molds are made up of special, high quality materials that have a good
n machinability property. Some standard mould components such as springs, bolts,
and limit switch are prefabricated and costs lower.
Most standard components such as ejector pins, ejector sleeves, and sprue bushings are not
prefabricated which mean they will only be manufactured when you order them. They are
not mass produced thus they are expensive

ADVANTAGES OF INJECTION MOULD

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1. Parts can be produced at high production rate.

2. Large volume of production is possible.
3. Parts can be achieved with good surface finish.
4. Relatively low labour cost per unit is obtained.
5. For many shape this process is more economical tofabricate.
6. Close dimensional can be maintained.
7. Parts can be molded with metallic and nonmetallic inserts.
8. Different surface colours can be obtained.
9. Parts can be molded in combination of plastics and fillers of glass, asbestos, talc
and carbon.

DISADVANTAGES OF INJECTION MOLDING

1. Material wastage is high.
2. High tool cost.
3. Expensive equipments.
4. High maintenance cost.
5. High power consumption.
6. Skilled labour is required to manufacture the tool.
7. Handling of mould is difficult.

TYPE OF MOULDS
1. Cold Runner Single –Day Light Mould.
2. Cold Runner Multi- Day Light Mould.

3. Hot Runner Mould.

INJECTIOIN MOLDING MACHINES:
John and Isaiah Hyatt received a patent in 1872 for an injection moulding machine, which
they used to mould camphor- plasticized cellulose nitrate (celluloid). In 1878 John Hyatt
introduced the first multi cavity mould.

In 1909 Leo [Link] introduced phenol formaldehyde resins which are now injection
mould able with a screw moulding machine. The experimental and theoretical work of
Wallace H Carothers let to general theory of condensation of polymerization that provided the
impetus for the production of many polymers including nylon.

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LIMITATION OF INJECTION MOULDING:

 High tool cost

 Expensive moulding equipment
 Skilled labor required for making the tool
 High Maintenance cost
 Handling of mold is difficult
 High Power consumption

INJECTIOIN MOLDING MACHINES

There are mainly three type of injection machine.

 HAND INJECTION MACHINE.

 PISTON TYPE INJECTION MACHINE.
 MACHINES WITH RECIPROCATING SCREW CYLINDER.

THE SEQUENCE OF OPERATIOIN IS AS FOLLOWS:

The rotating screw transports the polymer granules from the hopper into the injection
cylinder, where they are heated, plasticized and vented. The screw deposits the melt in

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infant itself moving backward to accommodate the material as it builds up. To ensure
optimum plasticization a counter-pressure exerted on the screw usually shows this
backward movement down. As soon as sufficient polymer has been plasticized for one shot,
the screw stops its rotating movement and acting as a plunger, moves forward forcing the
melt into the mould. Machines operating on this principle are now most commonly used.
Ensure the maximum melt homogeneity, shorter cylinder dwell time and, in many cases, a
shorter cycle.

These are the following processes, whichoccurduringinjection:

1. Plasticizing

The granular moulding material is loaded into the hopper and

enters the injection moulding machine, passes into a heated cylinder and into
the mould by the mains of convening plunger or reciprocating screw. Heating
and melting of the granules of the plastics and venting of the melt.
2. Injection
The melt is injected into the relatively cold mould under high pressure while closed.
Solidification of the polymer begins during the injection, first at the cavity walls.

3. Cooling
Moulds are cooled in order to harden the material, which has been injected into the mould,
were the plastics material to be solidified to facilitate ejection .

4. Mould release
The mould will be opened, ejects the component & gets ready for the next cycle.

Brief specification of the tool:

SL.
DESCRIPTION REMARKS
NO.
01 Type of mould Two Plate Mould
02 Surface finish Texture
03 Type of runner Round
04 Type of gate Submarine gate
05 Number of cavity LH+RH

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06 Material Poly Propylene

Sleeve & Pin
07 Type of ejection
Ejectors
08 Cooling media Water
09 Machine name SP 150
10 Number of daylight 01
11 Shut height 480
12 Mould size 600*480*460
13 Clamping tonnage 32 TONS
14 Ejection stroke 45 mm
15 Mould temperature 65C
16 Melting temperature 225C
17 Shrinkage 1.50%

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COMPONENT PHOTO

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COMPONENT 3D DRAWING

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Front view

Front view Bottom view

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COMPONENT ANALYSIS

Before proceeding to the detailed to the tool design analysis component has to be
analyzed for its material properties and application of the component.
Component Name : Grill Panel Bottom
L/H Component Material : POLY PROPYLENE
Shrinkage : 1.5%.
Shot weight : 72
Grams. Color : Black.
Component Weight : 42 Grams.
FUNCTIONAL ASPECTS OF THE COMPONENT
 It’s used in TVS COMPANY BIKE near the head light for fill the
gap & for the aesthetic look of the Jupiter bike.

CUSTOMER REQUIREMENT:

The mould is designed and built according to the needs specified by the
customer. The customer may need some modifications in the component drawing
provided by him. The design is modified according to his needs and when approved the
tool design is completed.’

The requirements are: -

 Mould for : “GRILL PANEL BOTTOM L/H”

 No. of impression : TWO
 Type of mould : TWO PLATE INJECTION MOULD
 Type of ejection : SLEEVE & PIN EJECTION
 Moulding materiel : PP
 Moulding machine : SP150
 Preferred gate : Sub marine gate.
 Component finish : Textured finish
COMPONENT DETAILS

NAME : “GRILL PANEL BOTTOM L/H”

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MATERIAL : P.P (Poly Propylene)

SHRINKAGE : 1.5 %

COMPONENT WEIGHT : 42gms

WEIGHT OF MOULDING : 72gms

WITH RUNNER

MELT. TEMP : 180-2800C

MOLD TEMP : 25-800C

The component “GRILL PANEL BOTTOM” is used to cover gap near head light & for
the aesthetic look of the N251 bike. The projection which are provided on the “Grill
panel bottom” will get assembled in the corresponding part.

JUSTIFICATION FOR USING P.P:

The material used for component is (P.P.).Because excellent dimensional stability, high
impact strength & less hinge property.

PROPERTIES COMPONENT MATERIAL:

 Low density.
 High impact strength.
 Good dimensional stability.
 Less hinge property.
 Good electrical properties.
 High resistance to high-energy radiation.

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 Limited chemical resistance.

CRITICALDIMENSION
 Pitch between the projections.
 In locking area profile dimension.
 Length and width of the component.

FEATURES
Due to complicated profile of the housing the core and cavity profile of the component
has been design on both the halves of the mould.

IMPORTANT FACTORS OF THE COMPONENT

• The component produced should be as per dimensions specified and should
be within tolerance.
• The component should be free from flashes and flash should be within
tolerance.
• The component should be free from weld line, sink mark, short shot, flow
lines, flash,
etc

MATERIAL SELECTED FOR THE COMPONENT

Material selected for the component is an important factor as it gives life and functional
aspects of the component. Plastic material selected for this component is PP which is an
entirely new linear PP (Poly Propylene) resin.
The Inherent Characteristics Of PP Resin:
Mechanical Properties:
• Excellent stiffness and hardness.
• Good toughness.
• Good static and dynamic long-term behavior.

Physical Properties:
• Dimensional stability also at high temperature.

• High heat deflection temperature.

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• Good heat ageing resistance.

• Flame retardant grades.

• Good friction and wear properties.

Electrical Properties:

• Excellent electrical insulating properties.

• Special grades with a high arc resistance and Effect of environmental

exposure:

• High chemical resistance.

• Low risk of stress cracking.

• Low influence of humidity on mechanical and electrical properties.

Other Properties:
• Good surface finish.

• Fully compounded colours available.

Processing:

• Standard injection molding machines.

• Good flow properties.

Percentage of fillers filled:
Material Glass Filled

PP 0%

The Application of PP :
It is widely used in domestic equipment, electronics, electrical,
telecommunications and automotive markets, Eg: Pump housings,
Impellers, Gears etc… Glass fiber filled grades have V.O. ratings in sections
down to 0.7mm –used for oven handles as the material resists elevated
temperatures ( > 100C ), is non-flammable, heat insulating and resists
hydrocarbons, oils, grease and abrasive kitchen cleaners.

PART MATERIAL DETAILS

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COMPONENT ANALYSIS & FESIBILITY

DRAFT ANALYSIS PARTING LINE

ACCORDING TO
DRAFT

GATE POSITION

EJCTOR PIN MARK FOR

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APPROVAL

CAVITY SIDE PART SURFACE CORE SIDE PART SURFACE

35
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AIR TRAPS WELD LINES

36
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KASSEMBLY PICTURE OF COMPONENT

37
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SHRINKAGE

As the hot plastic material cools in the mould, it contracts towards the center and will
stick to core because of shrinkage factor. Thus while designing a tool, the shrinkage
allowance must be added to the core and cavity. Different materials will have different
shrinkage and the material manufactures supply them for the given material. The average
shrinkage is 0.55%
It is only possible to fix the shrinkage data for mold design for thermoplastic
polyurethanes within certain limits because e the shape of the article, its wall thickness
and the processing conditions all exert a significant influence on shrinkage. As a rough
guide for mold design, shrinkage of approx. 1 % can be assumed.

An example of shrinkage calculations

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TOOL EJECTOR ASSEMBLY

COOLING:

The fundamental principle of injection moulding is that, as the melt enters the cavity, it
should get cooled rapidly to a temperature at which it solidifies sufficiently to retain the
shape of impression and allow ejection. So melt plastic wants to solidify before ejection.
For this reason we use water cooling.

Factors that influence the cooling:

 Intake of heat from injected plastic material.

 Heat transfer from the plastic to the mould during the injection and cooling (due to
shrinkage).
 Heat transfer from the mould to coolant.
 Transportation of heat by the coolant.
Purpose of cooling:
 The temperature as to be control for two purposes:

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To keep the temperature of a mould at a constant level during the operation.
To heat the mould to the working temperature before the start of production.

Cooling takes a maximum portion to reduce the overall mould cycles.

There are different types of cooling namely

 "U" Circuit.
 Rectangular Cooling.
 "Z" Circuit.
 Angled hole system.
 Annular method.
 Baffle Cooling.
 Helical Cooling.

In this mould plate cooling is used to maintain a uniform mould temperature and to
maintain the required temperature between the mould and the plastic material

COOLING TIME: -

The minimum cooling time for a moulding may be from estimated.

A formulae derived by ballman and susman. This has been shown to give good results
with poly styrene, but is also useful as an approximate guide for other materials.
-t2 [∏ (Tx-Tm)]
S= ------- Loge ---------------
2∏α [4(Tc-Tm)]
Where,
S = minimum cooling time.
t = thickness of molding (in or cm) α =
thermal diffusivity of material (in²/s or
cm²/s)
Tx = ejection temperature of moulding 9often heat distortion temperature is used)
(°F or °C)
Tm = mould temperature (°F or °C)
Tc = cylinder temperature (°F or °C)

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efficient heat transfer from the mold to the coolant, design the cooling system to
achieve turbulent flow, that is, a Reynolds number sign For efficiently higher than
the turbulence onset value of about 2,500. Flow (see you can estimate Reynolds
number using the following formula...

Q = gallons per minute

Diameter = flow channel d

MOULDCOOLINGSYSTEM

A mold cooling system typically consists of the following items:

• Temperature controlling unit

• Pump
• Supply manifold
• Hoses
• Cooling channels in the mold

The mold itself can be considered as a heat exchanger, with heat from the hot polymer
melt taken away by the circulating coolant.

Figures 3 and 4 illustrate the components of a typical cooling system.

3. A typical cooling system for an injection molding machine.

4. A cooling channel assembly attached to the mold plates.

TOOL COOLING SYSTEM

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SIDE CORES (SLIDERS):

Side cores are employed where some feature of the moulding forms an undercut relative
to the line of draw (ejection). The mould must be parted in one or two directions before
the component can be the line of draw but this is the core is frequently at the angles to
the line of draw but this is dependent upon the component and in the splits, but in others
only certain portions, the whole form contained in the splits, but in others only certain
portions, the remainders of the form being extracted in the line of draw.

Types of actuation splits:

1. Finger cam method.
2. Dog leg cam method.

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3. Spring actuation method.

4. Cam tracks.
5. Hydraulic pneumatic cylinders.
6. Hydro motor actuation

The wedges do all these above method are used for actuation only while the final locking

of the side core.

This project tool has eight side cores. two side cores are actuated by finger cam two is
actuated by hydraulic cylinder and four are actuated by spring .

Finger cam actuation:

Hardened circular pins are mounted at an angle in the fixed mould plate, The side core
mounted in the guides on moving mould plate have corresponding angled circular cores
to accommodate these finger cams. As mould opens the finger cam cores forces the side
cores to move outwards, sliding in the plate.

The length and angle of the finger cam determine the distance traveled by the split
across the ace of the mould plat

Finger cam working length is determined by the following formulae:

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L = M/Sinø+2C/Sin2ø.

Where, M = Split movement. ø

= Angle of finger

cam.

L= Working length of finger cam.

C= Clearance.

LENGTH OF FINGE CAM

L = 27.48/Sin25 + 2 x 0.5/Sin 2 x 25
= 88.6+ 1.49
= 90.09
= 90.0mm
MOVEMENT OF SIDE CORE;
M = (L Sinθ) - (C/Cos θ)
M = 90x Sin25 - 0.5/Cos25
M= 28.03 - 0.55
M = 27.48

AIR VENTS:-
Air vents are provided on the parting surface of the core and cavity for escape of
trapped air inside the impression. Air vents have a cross-sectional rectangular profile
with depth of 0.03-0.05 mm and width of 5-10mm depending upon the area of the
impression and characteristic of plastic material.

In many moulds the air, which is in the cavity, escapes through the gaps formed where
two pieces of metal meet e.g. down the side of pins and across the parting lines. If the air
cannot escape easily then it may restrict mould filling and or cause polymer degradation
through air compression. Weld lines are often accentuated because there is inadequate
venting provided in the mould at the weld line site.

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The position of any weld lines or burn marks will then indicate the position where the
vents should be located.

Each vent should usually be 0.04mm (0.0015in) deep and at least 3mm (0.12in) wide.
The air vent should be provided at the point where the flow paths are likely to meet, thus
causing the air trap.

Advantages of venting:
• Avoids air traps  Easier cycle.
• Provides a way for escape of air or gas.

DETECTION OF AIR TRAPPING:

As the polymer melt flow in to the feed system and from there in to the cavity the
air that is contained in the system must be displaced at on adequate rate unless molding
problems are to result. The most common problems are burning.

If the air cannot escape then it will be compressed and as this happens its
temperature rises. This rise is sufficient to cause polymer blacking or burning in many
cases. With some materials e.g. polyformaldehyde, this characteristic blackening may
not be seen even through the venting is not in adequate.

If the mould is not vented the small amount of kerosene is compressed with the
air during the next cycle and ignites in the molding leaving black soot on the molding

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where air is trapped. If mould is vented the air and kerosene mixture escape from the
mould and no burning is seen.

DRAFT:
A draft is an intentional taper provided on the core as well as on the cavity inserts. It
permits for easy ejection of the component in this tool. A draft of 20 was provided in the
core and cavity insert respectively for easy assembly & dismantling the tool (inserts).

“O RINGS

When mould are cooled by methods different from continues channels such as the use of

baffle, some sort of gaskting is necessary to prevent leakage rings have a circular cross

section and are available in any thickness and diameters.

PLUGS:
Plugs are made from brass or lead. They are pushed into the channels against rod
acting as a strip which has been placed into a perpendicular channels Plugs are
properly placed to obtain desired flow pattern. All channels is must be free of chips
and other obstruction to ensure free passage of the cooling medium.

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RAW MATERIAL SELECTION FOR THIS TOOL

SL NO DESCRIPTION MATERIAL
1 TOP PLATE MS
2 BOTTOM PLATE MS
3 SPACER BLOCK MS
4 CORE HOUSING MS
5 EJECTOR BACK PLATE EN-8
6 EJECTOR PLATE MS
7 GUIDE PILLAR EN-36B
8 GUIDE BUSH EN-36B
9 GUIDE PLATE MS
10 EJECTOR GUIDE PILLAR EN-36B
11 EJECTOR GUIDE BUSH EN-36B
12 PUSH BACK PIN EN-24
13 WEAR BUTTON EN-24
14 SUPPORT PILLAR MS
15 MACHINE KNOCKOUT ROD MS
16 EJ. PLATE STOPPER ROD EN-24
17 LEG MS
18 LOCATING RING MS
19 EJECTOR GUIDE PLATE MS
20 LATCH PLATE MS
21 LIMIT SWITCH TAPER BLOCK MS
22 LIMIT SWITCH HOLDER MS
23 PRESSURE PAD EN24
24 PRESSURE PAD EN24

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25 LIFTING BLOCK 01/02 MS

26 SHOULDER SCREW EN24
27 CLAMPING PLATE MS
28 CAVITY PLATE P20 2738
29 CORE INSERT P20 2311
30 SIDE CORE P20 2311
31 SIDE CORE INSERT 32 P20 2311
32 WEAR PLATE 35 EN24
33 WEDGE PLATE 35 EN24
34 COUPLING BLOCK 35 MS
35 CYLINDER HOLDER PLATE 35 MS
36 CLAMPING WEDGE BLOCK EN24
37 CLAMPING WEDGE BLOCK EN24
38 CORE PIN PLATE MS
39 EJECTOR PIN GUIDE PLATE LH/RH EN24
40 HYDRAULIC MANIFOLD MS
41 PLUG INSERT P20 2311
42 PLUG INSERT P20 2311
43 PLUG INSERT P20 2311
44 SPRUE BUSH EN24
45 COUPLING ROD 35 EN24
46 SIDE CORE STOPPER 32 MS
47 SIDE CORE STOPPER 33 MS
48 SIDE CORE STOPPER 34 MS
49 CORE PIN H13
50 SLEEVE EJECTOR H13
51 EJECTOR PIN DIA4g6 H13
52 STEPPED EJECTOR PIN DIA2g6 H13
COSTOFTOOLSTEELS
# Material IS-Standards Cost(Rs/
kg)

1 HDS T35Cr5MoV1 250

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2 CHS 17Mn1Cr95 55

3 MS C-45 50

3 OHNS T110W2Cr1 70

4 Pre T55Ni2Cr65Mo3 200

Hardened 0

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TOOL TERMINOLOGY
1. Top plate:
This is the top most plate. The top position of the mould parts are clamped by
means of screws. This also used for clamping top assembly on to the machine platen.
This plate also act as back plate for the cavity inserts.

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2. Bottom Plate:
This plate is incorporated next to the spacer. The bottom position of the mould
parts are clamped by means of screws. It gives a cushioning effect to the die as well as
provides enough room for the tool to be clamped to the machine platen. It will be of
more thickness to prevent bending.
1.

[Link] plate:
This is a plate where core inserts is fixed by wedges and spacers in position or
in alignment with the cavity. It also incorporates guide bush and provision for push back
pins.

The side core unit is also fixed in this plate.

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4. Cavity and Core inserts:

Basically consists of two parts i.e., cavity and core. The part in which
external profile of the component formed is cavity and the internal profile of the
component is core. When the mould is closed the two inserts come together forming a
space between the cavity and core. The space is called IMPRESSION.

5. Side core:

Side core or a side core is a local core,

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which is normally mounted at right angle to the die axis for forming holes or recess in
the side face of a component.

1. Register ring:
This is a disk shaped component seated into a recess in the top plate on the
cavity half of the tool. It locates the mould on the fixed platen. Being an accurate size
ensures the sprue bush aligns on the center line of the injection unit.

2. Guide Pillar and Guide Bush

Guide pillar and guide bush is used for the proper alignment of top half and
bottom half of the mould.

Ejector guide pillar and guide bush are used for the proper alignment of ejector assembly
with respect to core.

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1. Spacers:
These blocks are used in the mould to facilitate the ejector assembly to be
positioned and actuated.

3. EJECTOR PLATE:
It is the part of ejector assembly. This houses the ejector pins return pins. It is
made from MS.

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4. EJECTOR BACK PLATE:

It is the part of ejector assembly. This houses the, friction puller (Nylon Bush). It
clamped with ejector plate. It is made up of EN-8 material.

[Link] BUSH:
It is made of HDS. It is fitted in the cavity insert H7/ m6 fit. It is the connecting
member between the nozzle of the machine & the runner. Sprue bush, have an internal
taper. (20 to 40) This taper provided in the sprue bush facilitates easy removal of the
sprue.

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[Link] PIN (Push back pin):

These pins are fitted in the ejector plate and end up on the mould parting line and retain the
ejector assembly to its original position. It is made up of OHNS material hardened up to
5456HRC.

1. SIDE CORE STOPPER

These are used in the mould to facilitate the actual movement of side
core in backward stroke. These are made of MS.
2. PIN & SLEEVE EJECTOR:
These are the most common type of ejection. It is the simplest
method to use to eject the component. The moulding is ejected by the

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application of force by a circular steel rod called Pin and sleeve

ejector. It is made up of HDS.

5. Screws and Dowels:

Screws are used to hold the die parts together and dowels are used to
align the different parts.

6. Supporting Pillar:
Support block are judiciously positioned and clamped to bottom plate by

means of screws. It is used for extra support for ejector assembly.

7. Guide rail:
Guide rails are used to guide the side core in mould, during front and back
movement of side core.

8. Sprue Puller Pin:

Sprue puller pin positively ejects out the sprue from the sprue puller bush.

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9. STRAIGHT LOCKS:
These are used to align and lock the two halves of mould positively.

10. Wear Plate:

These are hardened plates provided for enabling the proper and free
movement of the side core, thereby avoiding the wear of the core plate.

11. Wedge Plate:

This is the portion, which gives final locking for the side cores when the
mould is in closed condition.

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12. Latch:
This is the plate used to clamp the moving and fixed halves of mould in the
time of idle and while transporting.

13. Insulation sheet:

This is fixed between the machine platen and top plate. And also between
bottom plate and machine platen. This sheet does allow the heat to transmit from
mould to the machine plate

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BILL OF MATERIALS
DETAIL QT MATERI FINISH Raw Material REMAR
DESCRIPTION
NO. Y AL SIZE Size KS
1 TOP PLATE 1 MS 40*480*600 50*490*610

2 BOTTOM PLATE 1 MS 40*480*600 50*490*610

3 SPACER BLOCK 2 MS 110*90*520 120*100*530

4 CORE HOUSING 1 MS 110*400*520 120*410*530

6 EJECTOR BACK PLATE 1 EN-8 30*210*498 35*220*510

7 EJECTOR PLATE 1 MS 26*210*498 32*220*510

8 GUIDE PILLAR 4 EN-36B φ56*240 φ60*245 58~62HRC

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9 GUIDE BUSH 4 EN-36B φ65*90 φ70*95 58~62HRC

10 GUIDE PLATE 4 MS 18*80*80 25*85*85

EJECTOR GUIDE
11 6 EN-36B φ25*162 φ30*170 58~62HRC
PILLAR
12 EJECTOR GUIDE BUSH 6 EN-36B φ44*54 φ50*60 58~62HRC

13 PUSH BACK PIN 4 EN-24 φ28*192 φ35*200 40~48HRC

14 WEAR BUTTON 4 EN-24 φ28*20 φ30*25 40~48HRC

15 SUPPORT PILLAR 6 MS φ48*110 φ50*115

MACHINE KNOCKOUT
16 4 MS φ38*45 φ40*50
ROD
EJ. PLATE STOPPER
17 4 EN-24 φ30*20 φ35*25
ROD

18 LEG 4 MS φ90*180 φ95*185

19 LOCATING RING 1 MS φ149*25 φ155*30

EJECTOR GUIDE
20 4 MS 18*30*60 25*35*65
PLATE

21 LATCH PLATE 2 MS 20*36*70 25*40*65

LIMIT SWITCH TAPER

22 1 MS 22*25*30 30*30*35
BLOCK
LIMIT SWITCH
23 1 MS 12*50*60 15*55*65
HOLDER
24 PRESSURE PAD 2 EN24 20*38*58 30*45*65 40~48HRC

25 PRESSURE PAD 2 EN24 20*38*50 25*45*55 40~48HRC

26 LIFTING BLOCK 01/02 2 MS 60*110*120 65*115*125

27 SHOULDER SCREW 4 EN24 φ26*122 φ30*130 46~48HRC

28 CLAMPING PLATE 4 MS 10*40*150 15*45*160

29 CLAMPING PLATE 4 MS 10*40*150 15*45*160

5 CAVITY PLATE 1 P20 2738 190*400*520 200*410*530

31 CORE INSERT 2 P20 2311 170*180*200 180*190*210

32 SIDE CORE 2 MS 38*40*40 45*45*45

33 SIDE CORE 2 P20 2311 16*23*100 20*30*105

34 SIDE CORE 2 MS 38*40*45 45*45*50

35 SIDE CORE 2 P20 2311 38*43*65 45*50*70

36 SIDE CORE INSERT 32 2 P20 2311 20*20*41 25*25*45

37 SIDE CORE INSERT 33 2 P20 2311 20*20*41 25*25*45

SIDE CORE GUIDE

38 2 MS 55*60*64 60*65*70
HOLDER 32

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39 GUIDE RAIL 32 4 EN24 20*17*65 25*25*70 40~48HRC

40 WEAR PLATE 32 2 EN24 5*30*43 10*50*85 40~48HRC

41 WEDGE PLATE 32 2 EN24 5*26*28 10*30*32 40~48HRC

SIDE CORE HOLDER
42 2 MS 38*40*105 45*45*110
33
SIDE CORE GUIDE
43 2 MS 90*105*178 95*110*185
HOLDER 33
44 GUIDE RAIL 33 4 EN24 20*17*70 25*25*75 40~48HRC

45 WEAR PLATE 33 2 EN24 5*30*70 10*35*75 40~48HRC

46 WEDGE PLATE 33 2 EN24 5*26*28 10*30*35 40~48HRC

47 GUIDE RAIL 34 2 EN24 20*17*60 25*25*65 40~48HRC

48 WEAR PLATE 34 2 EN24 6*30*50 10*35*55 40~48HRC

49 WEDGE PLATE 34 2 EN24 5*26*28 10*30*32 40~48HRC

SIDE CORE HOLDER
50 2 MS 60*70*95 65*75*100
35
51 GUIDE RAIL 34/35 2 EN24 104*22*105 110*30*110 40~48HRC

52 GUIDE RAIL 35 2 EN24 50*18*100 55*25*105 40~48HRC

53 WEAR PLATE 35 2 EN24 6*45*80 10*50*85 40~48HRC

54 WEDGE PLATE 35 2 EN24 8*45*48 15*50*55 40~48HRC

55 COUPLING BLOCK 35 2 MS 33*45*50 40*50*55

CYLINDER HOLDER
57 2 MS 40*90*115 45*95*120
PLATE 35
CLAMPINGWEDGE
61 3 EN24 25*50*50 30*55*55 40~48HRC
BLOCK
CLAMPINGWEDGE
62 1 EN24 25*50*90 30*55*95 40~48HRC
BLOCK
65 CORE PIN PLATE 1 MS 14.5*20*90 20*25*95

EJECTOR PIN GUIDE

70 1+1 EN24 20*30*50 25*35*55 40~48HRC
PLATE LH/RH
EJECTOR PIN GUIDE
71 1+1 EN24 20*20*32 25*25*40 40~48HRC
PLATE LH/RH
HYDRAULIC
72 1 MS 50*75*125 55*80*130
MANIFOLD

73 PLUG INSERT 1 P20 2311 35*23*40 40*30*45

74 PLUG INSERT 1 P20 2311 25*10*21 30*15*25

75 PLUG INSERT 1 P20 2311 42*14*32 50*20*35

46~48
30 SPRUE BUSH 1 EN24
HRC
46~48
56 COUPLING ROD 35 2 EN24
HRC
SIDE CORE STOPPER
58 2 MS
32
SIDE CORE STOPPER
59 2 MS
33

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SIDE CORE STOPPER

60 2 MS
34

63 CORE PIN 2 H13

64 SLEEVE EJECTOR 2 H13

46~48
66 EJECTOR PIN DIA6g6 3 STD
HRC
46~48
67 EJECTOR PIN DIA6g6 2 STD
HRC
46~48
68 EJECTOR PIN DIA4g6 6 STD
HRC
STEPPEDEJECTOR PIN 46~48
69 2 STD
DIA2g6 HRC

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SAFETY RULES

• Following are the safety measure, which should be followed while

completing the mould.
• While assembling, care to be taken that all the parts are with out sharp edges
and fool proofing technique should be provided.
• The clearance between pillar and bush should be within tolerance specified.

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• The pillar and bush should be at the perfect right angle to the core and cavity.
• See whether pillar project out of the plates, if it projecting they won’t make
the tool to butt platen at the right angle.
• Both halves should be clamped rigidly.
• Care should be taken that stroke given is to much, which may result in
jamming of tool.
• Maximum and minimum shut height of the tool should be considered
according to the pillar length.

PERSONAL
• First and foremost and the least expensed is the breaking of sharp edges and
corners.
• Rigidity and fool proofing should be built in the tool.
• Safety glass to be worn in the working places when ever necessary.
• Care to be taken while assembling the sharp corner parts.

TOOL
 Safety of the operator and equipment should be considered while planning the
design and selection of feeding and ejecting mechanism.
 For manually feed operation it is usually an always preferable to design the safety
shield as a part of tool. Once the tool is set in the injection molding machine it is
completely self-guarded required no additional protection..
 Some sensors is also fixed as a fool proofing to the return of ejector plate, when
ever precise side core is used.
 The eyebolt should be rigid enough to lift the weight of the respective tool.

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By manufacturing this two plate mould, I have acquired knowledge regarding

mould manufacturing process, including design study, process planning and electrode
planning, defects and remedies and trail procedures. The problems which occurred while
manufacturing this tool where solved with help of my uncharged.

I am able to complete this tool because of my good

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training provided during my three years in GT&TC, one year in-plant training in TAFE
EPD Bangalore. In which I got opportunity to take up this tool as my project and built
my career.
This tool gave me a good exposure to modern industrial working atmosphere.

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BIBLIOGRAPHY
INJECTION MOULD DESIGN : [Link]
MOULD MAKING HAND BOOK : GUNTER MENNING
WESTERMANN TABLE : HERMANNJUTZ
TOOL DESIGN : MR. MURALI
INTERNET : [Link], [Link]
MANUAL : HASCO, DME,
MANUAL
THEORY OF MOULD : [Link]

INJECTION MOULD DESIGN : [Link]

ESTIMATION AND COSTING : [Link] AND

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[Link]

SOFTWARES USED :
TOOL DESIGN : CATIA V5
TOOL LAYOUT : AUTO CAD
MAKING OF BOM PR : MICROSOFT
EXCEL
MOULD BASE 3D : CERO 4.0

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