A Project Report on

DESIGNING, DEVELOPING &

MANUFACTURING AN INJECTION MOULD FOR
COMB

Submitted by Under the guidance of

DEBASIS SWAIN [Link] CHANDRA JENA
Membership No: ST7053520 Membership No: M-1617898

In partial fulfillment for the requirement of passing Section B

Examination
In Mechanical Engineering Branch

The Institution of Engineers (India)

An ISO 9001: 2008 CERTIFIED ORGANISATION
(ESTABLISHED 1920, INCORPORATED BY ROYAL CHARTER 1935)
8 Gokhale Road, Kolkata 700020
 ACKNOWLEDGEMENT

This project would have been difficult for me to complete without the help of

people who supported me. First of all I would like to thank my guide Mr. Madhab

Chandra Jena, M-1617898, for his guidance & encouragement. I would also like

to thank my mother, father, for all their support and inspiration throughout my

A.M.I.E. career.

Finally I would like to thank all the persons who have directly or indirectly helped

me to complete this project and prepare this report.

DEBASIS SWAIN
Membership no: ST-7053520
 CERTIFICATE

This is hereby declare that the project work on “DESIGNING, DEVELOPING &

MANUFACTURING AND INJECTION MOULD FOR COMB” undertaken by

Mr. Debasis Swain, Membership No– ST-7053520 is an authenticated work for

the partial fulfillment of the requirements of passing Section B examination in

Mechanical Engineering under “Institution of Engineers (India)” is a record of his

own work carried out by him under my supervision and guidance.

To the best of my knowledge and belief, this work has not

been submitted to any other University or Institution for the award of any degree.

In my opinion, this content fulfils the requirement of the regulations relating to the

nature and standard of work for of passing Section B Examination in Mechanical

Engineering.

I wish him all success for his future endeavor.

Submitted by Project Guide

DEBASIS SAWIN MR. MADHAB CHANDRA JENA

Membership No: ST-7053520 Membership No: M-1617898

 DECLARATION
“I, Sri Debasis Swain , S/O Mr. Mahendra Swain, do hereby declare that the

project work entitled “DESIGNING, DEVELOPING & MANUFACTURING

AND INJECTION MOULD FOR COMB” submitted by me is original one & has

not been submitted earlier to any other Institution for fulfillment of the

requirement of a course of study.

The reference which has been reflected in this report has been acknowledged

properly.

Submitted by Project Guide

DEBASIS SWAIN MR. MADHAB CHANDRA JENA

Membership No: ST-7053520 Membership No: M-1617898

 SYNOPSIS
Title of the Project:
DESIGNING, DEVELOPING & MANUFACTURING AND INJECTION MOULD FOR
COMB.
Objective:
The prime objective is to design, develop and manufacture a COMB by the
injection moulding process using composite material and testing the component
for mechanical strengths which will lead to produce a good quality product and of
economical cost.
Scope of the Project:
This dissertation work covers the injection mould design, develop, analysis and
manufacturing of COMB and is aimed at a high quality. A new tool with higher
productivity and quality parts are the primary requirements. Geometric profiles,
surface quality, material specification, in-service condition were the first step.
Design exercise involves choice of parting surface, allowance for shrinkage, draft,
gate location, venting, balancing of the mould and choice of ejection system.
Three-plate mould design has been employed to produce the component as it
facilitates square gate feeding into the cavity mould and the component is ejected
along with gate system after ejection.

The Technical Approach:

❖ Study of component
❖ Concept design
❖ Design calculation
❖ Core & cavity extraction
❖ Preparation of assembly drawing & mould base drawing
❖ Preparation of detailed drawing of core and cavity
❖ Preparations of detailed drawing of all other items
❖ Tool manufacturing, Tool assembling & Tryout.
About Component & it’s history:

A COMB is a tool consisting of a shaft that holds a row of teeth for pulling
through the hair to clean, untangle or style it. COMB have been used since
prehistoric times, having been discovered in very refined forms from settlements
dating back to 5000 years ago in Persia.

The prime activities of the project are as follows:

❖ Design of the component.

❖ Design consideration

❖ Design of the mould for the component.

❖ Manufacturing of the mould.

❖ Development of the mould.

❖ Final Inspection & Tool trial.

❖ Trial of COMB mould.

❖ Finally testing and cost estimation of the product.

Activity Schedule:
 CERTIFICATE OF ORIGINALITY

This is to certify that the project report entitled “DESIGNING, DEVELOPING

& MANUFACTURING AND INJECTION MOULD FOR COMB” submitted

to Institution of Engineers (India) is original work carried out by Debasis Swain

(ST-7053520) an aspirant of Grad. I.E. (I) in the partial fulfillment of Section –B

examinations –Mechanical Engineering under my guidance. The matter embodied

in this project is genuine work done by the student and has not been submitted

whether to this University or to any other University/ Institute for the fulfillment

of the requirement of any course of study.

Submitted by Project Guide

DEBASIS SWAIN MR. MADHAB CHANDRA JENA

Membership No: ST-7053520 Membership No: M-1617898

 CONTENTS

Sl. No. Description

1 Component drawing
2 Introduction on moulding
3 Moulding Processes
4 Design Consideration
5 Assembly drawing
6 Nomenclature of mould base
7 Detail drawing of each mould part
8 13 steps of Perfect mould design
9 Design calculation
10 Methodology
11 Tool Manufacturing
12 Tool Assembly
13 Tool Try-Out
14 Pre-loading checklist for trials
15 Bill of material
16 Cost estimation of tool
17 Cost Estimation of component
18 Mould trial report
19 Bibliography
20 Conclusion
 INTRODUCTION ON MOULDING
➢ PLASTIC MATERIALS:-

❖ Plastic is a unique class of materials, came into existence by the virtue of

their superior properties and cost performance balance over to conventional
materials like wood, ceramics & materials.

❖ Plastic materials based on their characteristics performance were classified

as thermoplastics and thermosetting materials.

❖ It is the well-known that the former class of materials distinguished from the
latter by their processing behavior and characteristics properties.

❖ Example for thermo plastic includes PS, PP, PVC, PET, PA, and POM.
❖ Example of thermo-sets includes PF, UF, &MF etc.
BASED ON APPLICATIONS PLASTICS ARE CLASSIFIED AS :

1. Commodity plastics
2. Engineering plastics
3. Specialty plastics

COMMODITY PLASTIC
These are low performance, high volume resins, characterized by ≤ 100°C and
tensile strength i.e. < 50 MPa. Two of them PE and PP are semi crystalline, thus
their properties depends on nucleation and annealing. The glossy resins (PC, PVC
and PMMA) are available as either rigid or impact modified varieties, viz. GPPS,
PVCR and PMM or HIPS, PVCF and HI-PMMA. All these polymers can be
formulated as field and reinforced grades excellent for film blowing or blow
moulding.
ENGINEERING PLASTIC
Five types of resins belongs to this category polyamides (PA), polyesters

(PEST), polycarbonates (PC), polyoxymethylene (POM) and modified

polyphenylene ether (PPE).They can be formed to precise and stable dimensions

.Their consumption is about 12% of total plastic. There is a great diversity of

performance within each of this type, especially considering the great chemical

verity within the PA, PEST & PC type as well as profusion of blends, filled and

reinforced systems comprising engineering resins.

SPECIALITY PLASTIC

To the category belong low volume, high performance, high temperature and

high cost polymers. Their consumption amount to less than 0.1% of total

plastics. By definitions, the resins are characterized by high modulus, tensile and

impact strength.
 MOULDING PROCESSES: -

The process of injection moulding essentially consists of plasticize the raw

material in a cylinder by the application of heat and then injecting it under
pressure through a nozzle by means of a ram into a closed mould.
➢ TYPES OF MOULDING:-
❖ Injection moulding
❖ Blow moulding
❖ Compression moulding
❖ Film insert moulding
❖ Gas assist moulding
❖ Rotational moulding
❖ Structural moulding
❖ Thermoforming
➢ INJECTION MOULDING:-
❖ Injection moulding is one of the most versatile processing methods by
means for manufacturing small clips to large industrial crate.
❖ From a practical point of view, a classification of injection mould should
be based on the main design features and manner of operation.
➢ TYPES OF INJECTION MOULDING:-

2-PLATE MOULD
❖ The 2 plate mould is very simple to design because the cold runner
and mould cavities are on the same part line surface which means they are
machined into the same plate.
❖ In a two plate mould with hot runners, the material remains in a
molten state through the sprue, runners, and gates and only starts to freeze
when it enters the cavity.
3 PLATE MOULD
❖ The principle of one of the numerous varieties of the 3 plate mould
construction. The third plate of floating plate is located between the top clamping
plate and the cavity back up plate. The material from the nozzle is forced through
the primary sprue , into the runner system , into the secondary sprues , and into the
cavity .
INJECTION Moulding PROCESS

Figure 3.1 Schematic representations of the injection moulding machine

process
The injection moulding process is used to turn plastic stock into finished
product.

The process involves many steps:

A. FEEDING THE RAW MATERIAL
B. PLASTICIZE THE RAW MATERIAL
C. FILL THE MOULD
D. PACK THE MOULD
E. HOLD PRESSURE
F. COOLING OF MOULD
G. OPENING OF MOULD AND PART EJECTION

The main factors in the injection moulding are the temperature and pressure
history during the process, the orientation of flowing material and the shrinkage
of the material. This means that the structure and the properties of injection
moulded parts are inhomogeneous and the products have always internal
stresses.
 A. FEEDING THE RAW MATERIAL
First the mould receives plastic resin in the form of small
chopped pellets. These are fed into the hopper of an injection-
moulding machine, where they fall into an augur-type screw channel,
which feeds the pellets forward inside the heated barrel as shown in
figure 3.2.

Figure. 3.2 Feeding the raw material

B. PLASTICIZE THE RAW MATERIAL

The cycle begins with the extruder plasticizing the resin and accumulating it in the
forward section of the barrel. The heater bands maintain the melt's temperature
as the shot it built up. The mould is closed. The cycle is typically timed so that
there is minimal time between the closing of the mould and the next shot.
Injection of the resin into the closed Mould as shown in figure 3.3.

Figure 3.3 Plasticizing the raw material

C. FILL THE MOULD
After the mould closes, the entire screw moves forward
(usually driven by a hydraulic mechanism at the drive end of the
machine) and pushes the molten resin out through the end of the barrel
and inject melt into the cooled mould. The air inside the mould will
be pushed out through small vents at the furthest extremities of the
melt flow path. This phase takes time from tenth of seconds to few
seconds depending on the plastics grade, wall thickness and the shape
of the part. This phase fills about 95% of the mould cavity.

Figure 3.4 Mould filling

D. PACK THE MOULD
After filling the mould with resin reduce the pressure to the
pack value and maintain it for a specified time to assure the mould is
full. Normally the screw will stay in the forward position until the
resin begins to harden in the mould. This creates the pressure in the
mould, thus ensuring that the mould fills completely.
E. HOLD PRESSURE
When the cavity is filled, the screw continues to push forward
to apply a holding pressure. This has the effect of squeezing extra
melt into the cavity to compensate for the shrinkage of the plastic as it
cools. This holding pressure is only effective as long as the gate(s)
remain open.

F. COOLING OF MOULD
The cooling process starts immediately upon the injection of
the molten polymer, but the cooling time is referred to as the time
from the solidification of the gate, when the holding step is finished,
to the ejection of the part, when it has reached a temperature low
enough to withstand the forces during ejection.

Critical dimensions, surface finish, cycle time, etc., are all

affected by mould cooling. Hence mould cooling is a decisive factor
if a product will be manufactured with good quality and at a
competitive cost.

Figure 3.4 Solidification, Cooling

G. OPENING OF MOULD AND PART EJECTION
When the cooling phase is complete the mould is opened and
the moulding is ejected. This is usually carried out with ejector pins in
the tool, which are coupled via an ejector plate to a hydraulic actuator,
or by an air operated ejector valve on the face of the mould tool.
Ejection is the removal of the cooled moulded
part from the mould cavity and from any cores or inserts. Once the
moulding is clear from the mould tool, the complete moulding cycle can
be repeated.

Figure 3.5 Mould open and Part ejection

 DESIGN CONSIDERATIONS IN INJECTION
MOULDING
The critical items to be considered while designing an
injection mould tool are,
❖ Shrinkage.
❖ Draft angle.
❖ Selection of Parting Surface.
❖ Number of Cavities.
❖ Feed System.
❖ Ejection System.

SHRINKAGE
Shrinkage is the geometric reduction in the size of the part. It is volumetric
reduction. If the shrinkage is same in all direction, (i.e. direction of thickness,
direction of flow and perpendicular to melt flow) then the part would shrink by
the same proportion and hence we would get a part of reduced size.

PROBLEMS CAUSED DUE TO PART SHRINKAGE

Uncompensated volumetric contraction leads to either sink marks or voids
in the moulding interior. Controlling part shrinkage is important in part, mould
and process designs, particularly in applications requiring tight tolerances.
Shrinkage that leads to sink marks or voids can be reduced or eliminated by
packing the cavity after filling. Also, the mould design should take shrinkage into
account in order to conform to the part dimension.
DESIGN CONSIDERATIONS FOR SHRINKAGE
During injection filling phase melt is compressed (10-15%) in the barrel. At
the end of the filling phase, the melt expands due to relaxation of pressure.
Therefore end of filling phase should not be at zero position but at 10% of
injection stroke. The mould fills up due to expanding melt. Therefore changeover
from filling to packing phase is smooth.

Hold on pressure and hold on time provides melt to compensate the void created
due to shrinkage. Therefore hold on pressure as well as hold on time has great
influence on the shrinkage of part.

DRAFT
To aid in the release of the part from the mould, parts are usually
designed with a taper in the direction of mould movement The taper creates a
clearance as soon as the mould begins to move, allowing the part to break free
The taper is commonly referred to as “draft,” and the amount of taper referred to
as “draft angle” As a rule [2], the draft on injection mould for sulfone resins
should be 1° to 2° .

PARTING SURFACE
The parting surface of a mould are those surfaces of both mould plates
adjacent to the impressions which butt together to form a seal and prevent the
loss of plastic material from the impression.

The various factors to be considered while selecting the parting surface are:

❖ Ease of ejection.
❖ Ease of machining.
❖ Ease of trimming de-gating .
❖ Location of side cores & no of side cores.
❖ Dimensional relationship or tolerance.
❖ Type of machine or feed system.
❖ Limitation of locking force.
 In general the parting surface is classified as,
❖ Flat parting surface.
❖ Non-flat parting surface.
❖ Profile parting surface.
❖ Angled parting surface.

FLAT PARTING SURFACE

Parting surface having only one plane is termed as Flat parting
surface. The position of the parting surface will therefore be at the top
of the moulding.

NON-FLAT PARTING SURFACE

Parting line which lies on a non-planar or curved
surface termed as non-flat parting surface.

NUMBER OF CAVITIES
Number of cavities is decided by,
❖ Size, Shape and Weight of the Component.
❖ Ease of Manufacturing.
❖ Machine capacity.
❖ Production Quantity.
In this dissertation work the two components are to be planned to
accommodate in single tool for ease of manufacture and production
wise. Hence 1+1 cavity to be considered for the design.

FEED SYSTEM
The feed system comprises of the following components
❖ Sprue.
❖ Runners.
❖ Gate.
THE SPRUE
The sprue is generally formed in the sprue bushing. This should
be tapered 3– 5 inclusive angle in order for it to be pulled out of the
tool more easily. It should also be highly polished in the line of draw
to assist withdrawal and in the direction of flow of the melt for more
efficient flow. The diameter at the narrow end should be larger than
the machine cylinder nozzle opening.

GATE DESIGN
Gate is the small orifice which connects the runner to the cavity.
It has a number of functions. Firstly, it provides a convenient weak link
by which the moulding can be broken off from the runner system. In
some mould the de-gating may be automatic when the mould opens.
The gate also acts like a valve in that it allows molten plastic to fill the
mould but being small it usually freezes off first. The cavity is thus
sealed off from the runner system which prevents material being
sucked out of the cavity during screw-back.

Gate locations should ensure following conditions:

❖ Ensure a balanced flow (rapid and uniform filling) in the
cavity so that certain areas of the part are not over packed.
❖ Ensure mould fills under realistic temperatures and pressures.
❖ Minimize weld lines as much as possible, or position them in
non-critical areas.
❖ Prevent "jetting" by positioning the gate so that the material
flow is smooth and uniform.
❖ Avoid air entrapment.
❖ Gate into the thickest section and direct material flow.
Gates are classified in two categories based on the method
of de-gating.
❖ Manually Trimmed Gates: Examples are Direct or sprue Gate,
Ring Gate, Edge Gate, Fan Gate, etc.
❖ Automatically Trimmed Gates: Examples are Pinpoint Gate,
Submarine or Tunnel Gate, etc.
❖ To fill the cavity sufficiently without any filling problems in
the components.
❖ The cross-sectional form is simple and, therefore cheap to machine.
❖ Close accuracy in the gate dimensions can be achieved.
❖ The filling rate of the impression can be controlled relatively
independently of the gate seal time.
❖ The edge gate is located so as it should be easily de-gated and it should
not affect the components aesthetic appearance. The below figure
shows gate used in this work.

Figure 3.5 Typical gating systems

In this tool edge gate is selected. The reason for selecting edge gate is as follows
EJECTON SYSTEM
After the moulding has solidified and cooled down, it has to
be removed from the mould. It would be ideal if gravity could separate
the part from cavity or core after mould opening. Mould opening
causes the mechanically actuated ejector system to be moved towards
the parting line thus ejecting the component.
Four factors should be considered in designing the ejection mechanism:
❖ Shape and geometry of the part.
❖ Type of material and wall thickness.
❖ Projected production volume.
❖ Component position relative to the parting line.

The basic ejection techniques are:

❖ Pin ejection.
❖ Blade ejection.
❖ Sleeve ejection.
❖ Valve ejection.
❖ Air ejection.
❖ Stripper plate ejection.
According to shape, material wall thickness, component position
relative to parting plane and aesthetic considerations the pin ejection
technique is chosen for the part ejection.

VENTING
Vent helps in evacuation of latent air that is in closed air. Allow
evacuation of gases produced by low molecular weight polymers and
additives. Vents in a mould cavity, as shown in Figure, allow the gas
(air) present in the cavity to escape from the cavity as the resin fills,
Inadequate venting may result in the gas being compressed in the
cavity, which may then heat up to the point of causing burn marks on
the part and a deposit on the mould surface. This is known as dieseling.
Poor venting may also result in poor weld line strength and the inability
to completely fill the cavity.
PROBLEMS ASSOCIATED WITH POOR VENTING:
1)Burn marks: High stress concentration
2)Weak weld lines: Poor mould filling
3)Internal bubbles and non-filling areas: Mould deposit buildup.
4)Adhesion problems: Longer cycle time Stress cracking in presence of chemicals.

STANDARD VENT DIMENSIONS:

1)Width: 3.2 mm minimum.
2)Land length:0.8 mm minimum to 1.6 mm
3)Relief channel depth: 1 mm minimum.
4)Vent depth will vary with melt flow. For high flow grades: Depth 0.08 mm to 0.10 mm.
For low flow grades: Depth 0.02 mm to 0.05 mm.
5)The relief channel should extend to the edge of the tool.

Vent in Mould
NOMENCLATURE OF MOULD BASE
➢ Top clamping plate/top plate
➢ Location ring or retainer ring
➢ Cavity plate
➢ Core plate
➢ Core back plate
➢ Spacer/Riser
➢ Bottom plate
➢ Ejector retainer plate
➢ Ejector back plate
➢ Guide pillars/leader pins
➢ Guide bush
➢ Auxiliary guide pillar & bush
➢ Sprue bush
➢ Feed button
➢ Leader pin
➢ Sprue puller
➢ Return pins/push back pins
➢ Parting surface
ASSEMBLY DRAWING OF COMB MOULD
2D DRAWING OF COMB
 Top plate: Holds the stationary part of the mould to the stationary platen of the injection
machine.

• PART NAME: Top plate

• MATERIAL: Mild steel

OPERATION SEQUENCE

CONVENTIONAL CNC DRILLING &

DEBURRING GRINDING DEBURRING CHAMFERING
MILLING MILLING BORING
 Locating ring: Fits into a counter bore in the top clamping plate and is used to locate the
mould on the platen of the press so the nozzle and sprue bushing are aligned automatically.

• PART NAME: Locating ring

• MATERIAL: Mild steel

OPERATION SEQUENCE

CONVENTIONAL CNC DRILLING &

DEBURRING GRINDING DEBURRING CHAMFERING
MILLING MILLING BORING
 Cavity: The female part of a mould which gives external shape of the component.

• PART NAME: Cavity plate

• MATERIAL: Mild steel
OPERATION SEQUENCE

DRILLING
CONVENTIONAL PROFILE
DEBURRING GRINDING & TAPPING POLISHING CHAMFERING
MILLING EDM
BOARING
 Core: The male portion of a mould which forms the internal shape of the moulding.

• PART NAME: Core plate

• MATERIAL: Mild steel

OPERATION SEQUENCE

DRILLING
CONVENTIONAL PROFILE
DEBURRING GRINDING & TAPPING POLISHING CHAMFERING
MILLING EDM
BORING
Core back plate
Top plate of the movable section of the mould. Forms the parting line of the mould with
cavity retainer plate. Used to hold the leader pin bushing as well as core and cavity blocks.

• PART NAME: Core retainer plate

• MATERIAL: Mild steel

OPERATION SEQUENCE

CONVENTIONAL
DEBURRING GRINDING DRILLING DEBURRING CHAMFERING
MILLING
Spacers
Mounted on the bottom clamping plate under the support plate to form a space which
allows the ejection bar to move when the piece parts are ejected.

• PART NAME: Spacer

• MATERIAL: Mild steel

OPERATION SEQUENCE

CONVENTIONAL
DEBURRING GRINDING DRILLING DEBURRING CHAMFERING
MILLING
 Bottom plate
Holds the moving portion of the mould to the movable platen of the injection machine.

• PART NAME: Bottom plate

• MATERIAL: Mild steel

OPERATION SEQUENCE

DEBURRIN CONVENTIONAL
GRINDING DRILLING BORING DEBURRING CHAMFERING
G MILLING
 Ejector retainer plate
Counter bored for the heads of ejector pins, ejector return pins, and sprue puller pin.

• PART NAME: Ejector retainer plate

• MATERIAL: Mild steel

OPERATION SEQUENCE

CONVENTIONAL
DEBURRING GRINDING DRILLING BORING DEBURRING CHAMFERING
MILLING
Ejector back plate
Bolted together with the ejector retainer plate to form a unit. Acts as a backup plate for the pins in
the ejector retainer plate.

• PART NAME: Ejector back plate

• MATERIAL: Mild steel
OPERATION SEQUENCE

DRILLING
CONVENTIONAL
DEBURRING GRINDING & REAMING DEBURRING CHAMFERING
MILLING
BORING
Guide Pillar
Hardened and round steel pin pressed into one of the plates to align the two halves of the
mould.

• PART NAME: Guide pillar

• MATERIAL: EN 31

OPERATION SEQUENCE

CONVENTIONAL CENTRE CNC GROOVE

DEBURRING HARDENING CHAMFERING
TURNING GRINDING CUTTING
Guide bushes
Hardened and ground steel bushings which are pressed into one of the plates. Serve as
bearing surfaces for the leader pins.

• PART NAME: Guide bush

• MATERIAL: EN 31

OPERATION SEQUENCE

CONVENTIONAL CENTRE
DEBURRING HARDENING CNC BORING CHAMFERING
TURNING GRINDING
 Auxiliary guide pillar &
bush:
It gives additional support for core retainer
plate. Stepped bushes are placed between
ejector & ejector back plate for smooth
movement of ejector assembly during
component ejection.

Sprue bush:
A stepped cylindrical bush butts against the
nozzle of the injection machine. It has a
tapered hole through which the molten
plastic is forced into the mould through feed
system.

Feed Buttons:
Pressed into the bottom clamping plate, to reduce the ejection force.

Leader pin
Hardened and ground steel pins pressed into one of the plated. Align the two halves of the
mould base.
 Sprue puller pin: Pin located
directly under the taper hole of the sprue
bush. Used to pull the moulded sprue out
of bushing after shot has been made.

Push back pin : Located in the

ejector retainer plates force the
ejector plate and ejector retainer
plate, and therefore the ejector pins,
to the bottom position as the mould
closes.

Parting surface: That part of the mould plate, adjust to the impression, which butt
together to form a seal and prevent loss of plastic material from the impression.
13 STEPS FOR PERFECT MOULD
DESIG N
➢ Study of plastic component

➢ Study of moulding m/c to be used

➢ Method of construction of mould

➢ Determination of no. of cavity

➢ Selection of parting surface

➢ Types of layout of cavities

➢ Selection of runner

➢ Selection of gate

➢ Selection of type of mould

➢ Cooling system

➢ Types of ejector grid

➢ Ejection system

➢ Mould venting

➢ Check the final design with design check list

DESIGN CALCULATION
CALCULATION FOR CLAMPING FORCE
Projected area of the moulding = 6688.58mm²

No. Of cavity to be moulded = 2nos

So total projected area = 2x6688.58=13377.16mm²

1.1 x 13377.16 =14714.88mm2 = 147.15cm²

Clamping force for screw injection moulding machine =

Projected area of moulding including feed system (cm²) x

½ to ⅔ of mean injection pressure (kg f/cm2)

Mean injection pressure for polypropylene =

(700+1400)/2=1050kgf/cm².

Clamping pressure=147.15 x ½(1050)

=77253.75kgf=76.03 Ton.

CALCULATION FOR RUNNER DIAMETER

𝟒
√𝑾× √𝑳
Formula: - D = 𝟑.𝟕

Here, D=Diameter of the Runner in mm

W=Weight of the component in gm.

L= Length of runner

D= mm

=> = 2.5mm

CALCULATION FOR GATE SIZE:-

(RECTANGULAR EDGE GATE)

Length of the gate=1 mm

Depth of the gate h= n x t Here n=0.1

t=5mm

h=3.5mm (consider 2mm depth increase gradually)

Width of the gate (w) =

Here A, surface area of the cavity mm²=18161.65mm²

W mm

(Consider 2mm width increase gradually)

SUPPORT PLATE THICKNESS VERIFRICATION: -

Section modulus (Z) =

L=300mm=30cm (i.e. length of core back plate)

W=30mm=3cm (i.e. thickness of core back plate)

Z=

PERMISSIBLE LOAD ON SUPPORTBLOCK(W): -

W

Here,

Z=45cm³ (i.e. section modulus)

S=840kg/cm² (i.e. permissible working stress in kg/cm2)

 M=124mm=12.4cm (i.e. the gap between two spacer block in cm)

W=(8x45x840)/12.4=24387.09kg

PERMISSIBLE PROJECTED AREA OF

MOULDING/IMPRESSIONS

Here,

W=24387.09kg

P=630kg/cm² (i.e. maximum pressure on support)

So, A=24387.09/630=38.71cm2

But our exercise the projected Area of the moulding is 66.89cm², which is more than the permissible
projected Area of moulding (i.e 38.71cm2 ) .

But always the permissible projected area should be greater than the actual projected area so here
the support plate (or) core back plate cannot bear the load.

But in our core plate the impression depth is so less, then we use the extra thickness of the core
plate as support plate thickness. If we consider the core plate thickness with core back plate
thickness as support plate thickness i.e. 50mm (20+30) then the permissible projected area will
come 107. [Link] is more than the actual projected area. So our mould will work perfectly.

METHODOLOGY
The dissertation project work titled “Design, Analysis and
Manufacturing of automatic Injection moulding tool for the
component COMB MOULD. The injection moulding tool for the
production of these components is manufactured with the following
methodology.
Methodology is a systematic approach for the realization of total
 task. It consists of the following detail:

❖ Study of the Component.

❖ Plastic flow Analysis.
❖ Solid modelling of the tool.
❖ Selection of tooling materials.
❖ Tool manufacturing process.
❖ Tool assembly and tryout.

❖ Cost Estimation.

STUDY OF THE COMPONENT

The study of the component is the most important and the
first step for the designer. The component drawings are
carefully scrutinized to extract the maximum possible amount
of information. The important information available is the
critical dimensions, line of draw, parting line, suitable ejection
system, and required side cores.

PLASTIC FLOW ANALYSIS

Plastic flow analysis is done using AUTODESK
MOULDFLOW SYNERGY 2012, to know the optimum
gate location, temperature distribution, fill time, air traps,
weld lines etc. and also tool modelling environment used
being “CREO PARAMETRIC 2.0” Software.
SOLID MODELING OF THE TOOL
Solid modelling of the tool is done using CAD
 software “CREO PARAMETRIC 2.0”. The component
weight, volume and surface area, projected area, etc. were
determined using the same software package. This data is
helpful to do design calculation. 2D – drawings of the
mould parts are prepared for manufacturing purpose and
this is done in “AUTOCAD-2012/2015” software.

SELECTION OF THE TOOLING MATERIAL

Selection of tooling materials: The steel used in the
manufacture of mould varies depending on the
applications. Proper material selection and proper
combination of alloys in varying percentages are required
for finished mould. Characteristics of polishing ability,
high dimensional stability and harden ability are directly
introduced to the alloy steel.

TOOL MANUFACTURING PROCESS

Tool manufacturing has been done by referring
2D-drawings followed by the use of different
manufacturing techniques stage by stage. After
manufacturing all the tool parts the blue matching of
mating parts of core and cavity has been done and the final
assembling has been done.
TOOL ASSEMBLY AND TRYOUT
Tool tryout and troubleshooting: After the tool
 is manufactured and assembled, the tool is ‘tried’ to see
that component produced is true to the geometry and
dimensions specified by the customer. Tryout is a
procedure where the tool is subjected to actual working
condition and the performance of the tool is noted. After
the tool has been tried out, the component is thoroughly
inspected for various defects. If any defects are found, it is
suitably reworked.

COST ESTIMATION
Mould cost estimation is crucial especially for small
and medium batch of production runs where the cost of
a mould represents a significant percentage of the
product development cost. It is the probable cost of an
article before the manufacturing starts.

TOOL MANUFACTURING
According to process plan presented in the form process sheets, manufacturing
of each component was carried out. The machining operation can be classified
into the following categories.
❖ PRE-TOOLING: Raw material is cut to overall profile considering machining
allowances. This operation is carried out generally by sawing and flame cutting. This
is also called as pre-tooling.

❖ CONVENTIONAL MACHINING: According to drawing and process sheet the raw

material is rough machined to the geometric features and size of the part by providing
sufficient allowance for finishing. Conventional machining is generally carried out by
 Lathe, Milling and shaping machines.
❖ CNC MACHINING: After rough machining if part as features such as pockets.
Profiles, etc. are machined using CNC MACHINES (Turning or Machining
Centers).
❖ STAGE INSPECTION: After each operation stage inspection is carried out to check
the required profiles are having geometric accuracy or not
❖ BENCH WORK: Drilling, Tapping is done using drilling machines. Finishing,
corner radius, cavity profiles are done at this stage.
❖ HEAT TREATMENT: The parts that are subjected to wear and tear, also and
thermal fatigue are heat-treated to increase their properties. Some of items that are
heat-treated include dies (core and cavity insert), ejector guide pillars, guide bushes,
ejector pins, return pins, sprue bush, runner plate, stop pins, and return pins.
❖ FINISHING: This is the last stage in manufacturing done by Grinding, Polishing or
Lapping as required.
FINAL INSPECTION (CMM): Co-ordinate measuring machine is used to check complex

profiles, which require close tolerance.

TOOL ASSEMBLY
THE ASSEMBLY CAN BE DIVIDED INTO
FOLLOWING STAGES:
❖ Fitting the guide pillars and bushes into their respective position
and checking the movements of the two halves of the die set.
Assembly of the upper half consisting of cavity plate, guide
pillar, sprue bush and top bolster.
❖ Assembly of ejector pins, return pins in the ejector assembly.
Fitting ejector pins in their respective holes of core insert.
 ❖ Assembly of top half consisting of top bolster, cavity housing,
and cavity inserts, sprue bush, locating ring & guide pillar
Assembly of bottom half consisting of core housing, core inserts,
core back plate spacers, bottom bolster, ejector plate, ejector
back plate, rest pin, ejector pins, sprue puller, sprue puller bush
& guide bush.
❖ Assembly of top half and bottom half to check proper alignment
and fitting down of the halves for core cavity match.
❖ Checking the mating surfaces by applying Persian blue (blue
matching).
The assembly starts with the final inspection of each and every
part that contributes to the making of the tool. All parts which
required to be suited in their respective housings are checked for
their functional aspects. The total assembly of the die is made in the
following stages.
COMPILATION OF THE ASSEMBLY

Assembly Of Tool Can Be Complied Into Two Major Concepts.

• Assembly of top or fixed half.
• Assembly of bottom or moving half.
ASSEMBLY OF FIXED HALF
❖ All parts are cleaned & deburred for fitting into their respective
positions.
❖ All cavity inserts and finger cams are assembled into the cavity plate.
❖ Guide pillars and stoppers are fitted at the four corners of the plate.
❖ Fitting of cavity plate in the pocket of the retainer plate by
means of screws.
❖ Fitting of sprue bush in the cavity plate.
❖ Fitting and clamping of locating ring in the top plate by
means of Allen screws.
ASSEMBLY OF MOVING HALF
❖ All parts are cleaned & deburred for fitting into their respective
positions.
❖ Guide bushes are fitted at the four corners of the plate.
❖ All core inserts, side cores and cam guides are assembled into
the core plate.
❖ Fitting of core plate in the pocket of the retainer plate by means of
screws.
❖ All ejector pins & push back pins are fitted and clamped with
Allen screws into the ejector grid.
❖ Spacers are fitted into their respective position.
❖ Rest buttons are fixed in the bottom plate.
❖ Finally, the bottom plate is fixed in the whole assembly with the help
of Allen screws.

MOULD FINAL ASSEMBLY

❖ The bottom half is placed on tool making bench later top of is

lifted by providing mechanism of chain and laid on the moving
half.
❖ The reference edge were confirmed and respective, guiding
elements for fool proofing before assembling or may lead to
eruptive damages to tool.
❖ The tool is checked for blue match and gap created in parting line.
After placing top half it is slightly tapped to confirm the matching
surfaces.
BLUE MATCHING
This is the process of checking the gap between the matching parts,
wedges and core pins in the assembly. A thin film of Persian blue
applied to the core pins angles and surface of the core plate
including push back pins. Then close the two halves and press for a
certain period, then open the two halves and check the impression in
cavity half. If the entire surface is blued, then the tool is ready for
tryout.

TOOL TRYOUT
After the assembly of the tool, before it sends to customer
the tool should be tried out for efficient production and quality
of the component produced.
The mould is manufactured and assembled in the workshop is
tried out on suitable injection moulding machine. This process
is called as a Try-out.
If any problem arises then those defects have to be rectified and
reworked and then dispatch it to the customer. The component
produced should be of acceptable quality and within specific
tolerance limits
The mould was tried out on Endura-220 tones machine.

PROCEDURE FOR TOOL TRY OUT

Firstly the mould assembly is mounted in between the platens
of the moulding machine. Then the two halves of the mould are
clamped firmly when they are in perfect alignment. The tool is
then preheated with the help of heat controllers so that the
temperature of the tool is about 900 c. The plastic raw material
is preheated in a preheating chamber up to about 285 ºc and
poured into the machine hopper. The material is plasticized
inside the cylinder of the machine and kept ready for injection.

The two halves of the mould are closed

and opened for several times. The movement of the ejector
assembly is checked and removing oil and dust cleans the
mould.
Movement of platens then closed the
mould and clamping force is selected depending on type of
material and amount of filling. The injection pressure and the
amount of material per shot are set in the machine as per
requirement. These machine variables are set by mere
calculations or through experimentation method. The material
is then injected into the mould and is allowed to cool hard and
set. The mould is opened and the ejector assembly is then
 actuated to eject the component. The components and the
runner system and thus the cycle repeats.

PRELOADING CHECK LIST FOR TRAILS (Mould)

CMPONENT NAME- COMB O.C. No. TOOL No.04

Sl
CHECKPOINT YES/NO SPEC. TRIAL DETAIL
N0.

MOULD NUMBER/NAME IS MATCHING WITH ORDER

1 Yes 4
CONFIRMATION NOTE

MOULD ALLIGNMENT IS ALRIGHT (SMOOTH MOVING

2 Yes
OF TWO HALVES IS PILLAR /BUSH)

3 DO THE EJECTOR ASSEMBLY WORK PROPERLY Yes

4 DO SPRING IN EJECTOR ASSEMBLY WORK PROPERLY NA

ARE THE MOULD HALVES PROVIDED WITH SAFETY M8 SCREW(CAVITY &

5 Yes
LINK CORE)

SAFETYLINK PROVIDED ARE WITH IN TOP AND M8 SCREW(CAVITY &

6 Yes
BOTTOM SURFACES OF THE MOULD CORE)

M12 AT CORE PLATE

7 MOULD LIFTING PROVISION IS AVAILABLE Yes M12 AND CORE BACK
PLATE

INSIDE DISTANCE BETWEEN THE TIE BARS IS 350X350(MOULD SIZE-

8 Yes
ENOUGH TO ACCOMMODATE THE MOULD 300X250)
 OUTSIDE DIEMETER OF THE LOCATING RING IS
9 Yes Ø125
MATCHING WITH M/C PLATEN OPENING DIAMETER

SPRUEBUSH SPHERICAL RADIUS IS MATCHING WITH

10 Yes R11
NOZZLE RADIUS OF THE MACHINE

CLEAR HOLES IS PROVIDED IN THE BOTTOM PLATE

11 Yes Ø32
FOR EJECTOR ROD

12 COOLING IS RIGHT AND LEAK PROOF NA

DO THE COOLING HOLE NIPPLES MATCH WITH THE

13 NA
MACHINE HOSE PIPE

14 SUFFICIENT AIR VENT IS PROVIDED NA

(IN THREE PALTE MOULD) ALL THE LINKS AND LIMIT

15 NA
BOLTS ARE FITTED

(IN THREE PLATE MOULD) ALL THE PLATES MOVE

16 NA
PARRALEL TO EACH OTHER

(IN SPLITE AND SIDE CORE MOULD) DO THE

17 NA
SPLITS/SIDE CORE LOCK IN THE OPEN CONDITION

After trial air vent to be

18 SPECIAL INSTRUCTIONS IF ANY NA provided

BILL OF MATERIAL
21 BUTTOM PLATE 1 256 X246 X26 MS -

20 LOCATING RING 1 Ø126p6X14 EN31 HRc 42-45

19 EJECTOR GUIDE BUSH 2 Ø24H7X26 EN31 HRc 45-48

18 EJECTOR GUIDE PILLAR 2 Ø24g6X81 EN31 HRc 45-48

17 ALLEN SCREW 4 M6X25 STD -

STD -
16 ALLEN SCREW 4 M10X150
15 ALLEN SCREW 4 M10X50 STD -

14 EJECTOR PIN 1 Ø8X190 D2 HRc 42-45

13 EJECTOR PIN 3 Ø6X190 D2 HRc 42-45

12 PUSH BACK PIN 4 Ø12g6X160 MS -

11 FEED BUTTOM 4 Ø6k6X16 MS

-
10 EJECTOR PLATE 1 246X120X16 MS -

9 EJECTOR RETAINER PLATE 1 246X120X12 MS -

8 SPACER/RAISER 2 246X66X31 MS -

7 CORE BACK PLATE 1 246X196X26 MS -

6 GUIDE PILLAR 4 Ø33X70 EN31 HRc 45-48

5 GUIDE BUSH 4 Ø33X35 EN31 HRc 45-48

4 CORE PLATE 1 246X196X36 MS -

3 CAVITY PLATE 1 246X196X36 MS -

2 SPRUE BUSH 1 Ø33X62 EN31 HRc 42-45

1 TOP PLATE 1 256 X246 X26 MS -

PART
NO DESCRIPTION QTY. SIZE MATERIAL REMARK

COST Estimation
INTRODUCTION
Cost estimation may be defined as the process of
forecasting the expenses that must be incurred to manufacture a
product. These expenses take into consideration all
expenditures involved in design and manufacturing with all the
related service facilities such as pattern making, tool making as
well as portion of the general administrative and selling costs.
Cost estimates are the joint product of the engineer and the cost
accountant.
Estimating is the calculation of the costs which are
expected to be incurred in manufacturing a component in
 advance before the component is actually manufactured. Costing
may be defined as a system of accounts which systematically
and accurately records every expenditure in order to determine
the cost of a product after knowing the different expenses
incurred in various department.

FUNCTIONS OF ESTIMATING
❖ To calculate the cost of new material needed to manufacture a
product.

❖ To calculate the cost of new material needed to manufacture a

product.
❖ To find the cost of parts to be purchased from outside vendors.
❖ To determine the most economical process, tooling or
material for making a product.
❖ To establish a standard of performance at the start of project.
❖ For feasibility studies on possible new products.
❖ To calculate the direct and indirect labor cost associated with the
manufacture of the product, based upon work study.
❖ To calculate various overhead charges associated with the
product.
❖ To decide about the profit to be charged, taking into
 consideration other manufacturers of same product in the market.
❖ To calculate the selling price of the product.
❖ To maintain records of previous estimating activities of the
company for future references.

❖ Todecide the most economical method of making the product.

To submit cost estimates with the competent authority for further

action.
 COMB MOULD OPERATION COSTING
EDM
SL CONV. CNC CONV. CNC EDM
MOULD PART GRINDING DRILLING DIESHINKIN FITTING TOTAL
NO. MILLING MILLING TURNING TURNING WIRECUT
G
TOP 3hrX100 3hrX100 1hrX700 1/2hrX50
1 1325/-
PLATE(01) =300 =300 =700 =25
1/2hrX10 1/2hrX70 1/2hrX70
1/2hrX700
2 SPRUE 0 0 0 1100/-
=350
BUSH(01) =50 =350 =350
CAVITY 3hrX100 3hrX100 3hrX700 8hrX700 1hrX50
3 8350/-
PLATE(01) =300 =300 =2100 =5600 =50

CORE 3hrX100 3hrX100 3.5hrX700 8hrX700 1hrX50

4 8700/-
PLATE(01) =300 =300 =2450 =5600 =50

GUIDE 2hrX100 6hr X700 1/2hrX50

5 4425/-
BUSH(04) =200 =4200 =25

GUIDE 2hrX100 6hr X700 1/2hrX50

6 4425/-
PILLAR(04) =200 =4200 =25

CORE BACK 3hrX100 2hrX100 1/2hrX700 1/2hrX50

7 875/-
PLATE(01) =300 =200 =350 =25
1/2hrX1
3hrX100 2hrX100 1/2hrX50
8 SPACER 00 575/-
=300 =200 =25
(02) =50
EJECTOR 1.5hrX10 1.5hrX10
2hrX100 1/3hrX700 1/2hrX50
9 RETAINER 0 0 755/-
=200 =230 =25
PLATE(01) =150 =150
1.5hrX10 1.5hrX10 1Hr&45
1/3hrX700 1/2hrX50
10 EJECTOR 0 0 MinX20 730/-
=230 =25
PLATE(01) =150 =150 0=175
 COMB MOULD OPERATION COSTING
CONV. CNC
SL GRINDI DRILLIN CONV. CNC EDM EDM
MOULD PART MILLIN FITTING TOTAL
NO. NG G TURNING TURNING WIRECUT DIESHINKING
G MILLING
FEED 1.5hrX100= 1/2hrX50
11 175/-
BUTTOM(04) 150 =25
PUSH BACK
12 242 X 4=968 968/-
PIN(04)
EJECTOR
13 (Ø6X190 per pin cost=39/-) 39 X 3=117 117/-
PIN(Ø6,03)
EJECTOR
14 (Ø8X190 per pin cost=75/-) 75X 1=75 75/-
PIN(Ø8,01)
ALLEN
15 SCREW(M10x50, (M10X50 per screw cost=17/-) 17X 4=52 52/-
4no's)
ALLEN
16 SCREW(M10x150 (M10X150 per screw cost=55/-) 55X 4=220 220/-
, 4no's)
ALLEN
17 SCREW(M6x25, (M6X25 per screw cost=5/-) 5X 4=20 20/-
4no's)
EJECTOR GUIDE 2hrX100
18 200/-
PILLAR(02) =200
EJECTOR GUIDE 1hrX100 1hrX700
19 800/-
BUSH(02) =100 =700
LOCATING
20 20/-
RING(01)
3hrX1 3hrX1 1hrX10
1/2hrX50
21 BUTTOM 00 00 0 725/-
=25
PLATE(01) =300 =300 =100

TOTAL COST OF MACHINING OPERATION =34,632

 COST OF RAW MATERIAL
VOLUME=L×B×H
WEIGHT=VOLUME×DENSITY (7.9)
COST=WEIGHT×COST PER Kg
{Cost of MS per kg=60/-} {Cost of EN 31 per kg=63/}

SL NO PART NAME PART SIZE COST

1 LOCATING RING Ø125×14 349/-

2 TOP PLATE 256×246×26 745/-
3 CAVITY PLATE 246×196×36 820/-
4 CORE PLATE 246×196×36 820/-
5 CORE BACK PLATE 246×196×26 594/-
6 SPACER(02) 246×66×31 477/-
7 EJECTOR RETAINER PLATE 246×10×12 167/-
8 EJECTOR PLATE 246×120×16 223/-
9 SPRUE BRUSH Ø33×62 105/-
10 GUIDE PILLAR(04) Ø33×70 128/-
11 GUIDE BUSH(04) Ø33×35 116/-
12 FEED BUTTOM(04) Ø10×16 12/-
13 EJECTOR GUIDE BUSH(02) Ø33×26 21/-
14 EJECTOR GUIDE PILLAR(02) Ø24×86 37/-

15 BOTTOM PLATE 256×246×26 745/-

Heat treatment cost for all part 125/-

5484/-
SO TOTAL COST OF RAW MATERIAL =5484/-
SINGLE PIECE COMPONENT COSTING
DETAILS:
➢ COST OF COMB MOULD=40116/-
{Operation cost (34632) +Raw material cost (5484)}

➢ COST OF VIRGIN POLYPROPYLENE

GRAIN=22,40,000/-
1. One kg of polypropylene=80/-
2. One component having weight=14gm
3. No of component from mould life having=20Laks
4. Amount of virgin PP material required for 20Laks
component =20Laks ×14gm=28000Kg
5. Total cost of Polypropylene= 28000×80= 22,40,000/-

➢ USABLE MOLDING MACHINE EXPENDITURE

=19,44,445/-
1. One hour machine cost=250/-
2. One component processing time=14Sec
3. For 20Laks component machining time will be
=20Laks×14Sec=7778 Hour
4. Total machining cost =7778×250=19,44,445/-

➢ COST OF ONE COMPONENT=

{[40,116+22,40,000+19,44,445]/20Laks]}=2.12/-
 Mould Trail Report
Tool No. : 04 W.O. No. : 04/2020-2021 Trail No. : 01 Date: 17-01-2021

Product and Material

Name: COMB Material: Polypropylene Manufacture: DEBASIS SWAIN(ST 705352-0)

Virgin: ___✓ Reground: _________________ MFI : __________________

Pigment: Dry Colour: _______________ Master batch: ______✓______ Liquid: ________________

Preheating/Pre drying: ✓ Yes ✓ No Temp: ________ C Time: ________Hrs

Injection Mould:

No. of Cavities: 02 Shot Weight: 40gms Article weight: 34gms

Clamping: Direct Clamping ✓ Clamps

Runner System: ✓ Cold Runner 3Plate Insulated Runner

Hot Runner Other: ______________________

Gating: Pin Point Submarine ✓ Other (Rectangular Edge

Gate)
✓
Knockout bar: Coupled Not Coupled

Injection Mould Machine:

Make & Size: L&T 85 D&MAC, SHORT WT.125gm Screw diameter: 38 mm

Locking System: ✓ Toggle Hydraulic

Nozzle: ✓ Open Needle valve Special

Temperature:

1850c 1900c 2000c _______◦c ________◦c 1850c

Zone1 Zone2 Zone3 Zone4 Zone5 Nozzle

Pressure: Injection: 72bar Holding: 26 bar Back:1bar

Speeds: Injection: 25mm/sec Feed Screw:

Time: Injection: 1.40sec Holding:1.40sec Cooling: 25sec Pause:40 sec

Total cycle: 40sec

Bibliography:

❖ Injection mould design-R.G.W. PYE

❖ Injection moulding hand [Link]
❖ Standard mould base-Kalyani
❖ Plastic material-J A Bravdson
❖ Mould flow design –By Hanser
❖ Google search
 CONCLUSION
The job injection moulding for comp
mould which was a project work for the
requirement of passing Section B Examination
in Mechanical Engineering Branch is now
completed.
By maintaining the entire
requirement we became able to get good
technological skill. We came to know about
different types of tools and the function of each
and every parts of the “COMB MOULD”.
Hope this project will help me in future.