CENTRAL INSTITUTE OF
PETROCHEMICALS ENGINEERING AND
TECHNOLOGY (CIPET LUCKNOW)
FINAL YEAR PROJECT
2021-2024
UNDER THE GUIDANCE OF
[Link] JAISWAL
[Link] BAHADUR
MAURYA
NAME: ANKUSH
VATS COURSE: DPMT
SEMESTER: VI
HALL TICKET NO.: 050322579
SUBMITTED TO: [Link] BAHADUR
MAURYA
TABLE OF CONTENTS
INTRODUCTION
PRODUCT DESIGN
PROCESS TYPE
MACHINE SELECTION
MOLD DESIGN
MOLD MATERIAL SELECTION
MACHINING PROCESS
MOLD COST ESTIMATION
MOLD ASSEMBLY AND FITTING
MOLD TRIAL ON SELECTED MACHINE
CONCLUSION
INTRODUCTION
Introduction to Spoon Mold Design
The manufacturing of plastic spoons via injection molding is a common
practice due to the efficiency, cost-effectiveness, and high-quality
output that this process offers. Injection molding is a versatile and
widely-used method for producing complex plastic parts with high
precision and repeatability. The final year project involves designing
and developing an injection mold for manufacturing plastic spoons,
focusing on the entire process from product design to mold trial and cost
estimation
Product Design
In this project, we will design a plastic spoon, which is a common and
essential kitchen utensil. The spoon will be made from Polypropylene
(PP), a widely used thermoplastic polymer in the plastic industry. The
design will include both 2D and 3D representations to ensure precision
and clarity in the manufacturing process
Material Selection: Polypropylene (PP)
Why Polypropylene?
Polypropylene is chosen for the following reasons:
1. **Cost-Effectiveness**: PP is relatively inexpensive compared to
other thermoplastics, making it ideal for producing high-volume, low-
cost items such as disposable spoons.
2. **Chemical Resistance**: PP exhibits excellent resistance to a wide
range of chemicals, including acids, bases, and organic solvents. This
property is essential for utensils that come into contact with various
foods and cleaning agents.
3. **Durability**: Despite being lightweight, PP has good tensile
strength and impact resistance, ensuring the spoon can withstand regular
use without breaking or deforming.
4. **Thermal Resistance**: PP has a high melting point (160-170°C),
making it suitable for use with hot foods and liquids without deforming
.
5. **Safety**: PP is non-toxic and safe for food contact, complying
with FDA regulations for food-grade plastics.
6. **Ease of Processing**: PP flows easily in the molten state,
allowing for efficient injection molding with minimal defects. It also has
a relatively low density, which helps reduce material costs.
Advantages of Plastic Materials in General
Using plastic materials for manufacturing everyday items like spoons
offers several advantages:
1. **Lightweight**: Plastics are much lighter than metals or ceramics,
making them easy to handle and transport.
2. **Versatility**: Plastics can be molded into virtually any
shape, allowing for innovative and ergonomic designs.
3. **Corrosion Resistance**: Unlike metals, plastics do not rust or
corrode, which extends the lifespan of the product.
4. **Insulation Properties**: Plastics are good insulators of heat and
electricity, making them safe for use with hot foods and reducing the
risk of electrical hazards.
5. **Mass Production**: Plastics are ideal for mass production.
Injection molding, in particular, allows for the production of
large quantities of parts quickly and consistently.
6. **Cost Efficiency**: The production cost of plastic items is
generally lower compared to metal or ceramic counterparts, especially in
large volumes
PRODUCT DESIGN (3D)
PRODUCT DESIGN (2D)
PROCESS TYPE: INJECTION MOLDING
WHY INJECTION MOLDING IS USED FOR THE
MANUFACTURING OF THE PRODUCT?
Reasons for Using Injection Molding to Manufacture Plastic Spoons
Injection molding is the preferred method for manufacturing plastic
spoons due to several compelling reasons. The process offers numerous
advantages in terms of efficiency, precision, and cost-effectiveness,
which are essential for producing high-quality plastic products. Below
are the key reasons why injection molding is used for making plastic
spoons:
1. **High Efficiency and Productivity**
- **Rapid Production Cycles**: Injection molding allows for rapid
production cycles, enabling the manufacture of a large number of spoons
in a short period. This high-speed production is crucial for meeting
large-scale demands efficiently.
- **Automation Potential**: The process can be highly automated,
reducing the need for manual intervention and further speeding up
production while minimizing labor costs.
2. **Precision and Consistency**
- **Dimensional Accuracy**: Injection molding provides high
precision and accuracy in the production of complex shapes and intricate
details, ensuring that each spoon meets exact specifications.
- **Consistency in Output**: The process ensures uniformity across all
produced spoons, maintaining consistent quality and performance for
every item manufactured.
3. **Material Efficiency**
- **Minimal Waste**: The process uses precise amounts of material,
reducing waste and optimizing material usage. Any excess material can
often be recycled and reused within the production cycle.
- **Variety of Materials**: Injection molding supports a wide range of
thermoplastics, including Polypropylene (PP), which is ideal for making
durable and safe spoons.
4. **Design Flexibility**
- **Complex Geometries**: Injection molding can produce spoons
with complex geometries, including ergonomic handles and smooth,
rounded surfaces that are both functional and aesthetically pleasing.
- **Customization**: The mold design can be easily modified to create
different spoon sizes, shapes, and designs, providing flexibility to meet
varying customer requirements.
5. **Cost-Effectiveness**
- **Economies of Scale**: Injection molding is particularly cost-
effective for high-volume production runs, where the initial investment
in mold design and manufacturing is offset by the low per-unit cost of
production.
- **Reduced Labor Costs**: The high level of automation in injection
molding reduces the need for manual labor, contributing to lower
overall production costs.
6. **High-Quality Surface Finish**
- **Smooth Finishes**: Injection molding can produce spoons with
high-quality surface finishes, eliminating the need for extensive post-
processing. This results in visually appealing and easy-to-clean products.
- **Texture Options**: The mold surface can be textured to add grip
or other functional finishes to the spoons, enhancing their usability.
7. **Durability and Strength**
- **Enhanced Properties**: Injection-molded spoons exhibit excellent
mechanical properties, including high tensile strength and impact
resistance, which are critical for everyday use.
- **Thermal Stability**: The process allows for the production of
spoons that can withstand varying temperatures, ensuring they remain
stable and functional when used with hot or cold foods.
8. **Reproducibility**
- **High Repeatability**: Injection molding ensures that each spoon
produced is identical to the others, providing consistency in quality and
performance across large production batches.
- **Reliable Process**: The process parameters can be tightly
controlled, resulting in a highly reliable and repeatable manufacturing
method.
9. **Environmental Considerations**
- **Recyclable Materials**: Many of the materials used in injection
molding, including PP, are recyclable, contributing to sustainable
manufacturing practices.
- **Reduced Environmental Impact**: The efficient use of
materials and energy in the injection molding process helps to
minimize the environmental footprint of production.
Injection molding stands out as the optimal manufacturing process for
producing plastic spoons due to its efficiency, precision, and cost-
effectiveness. The ability to produce high volumes of consistent, high-
quality spoons with minimal waste and flexible design options makes
injection molding an indispensable method in the plastic manufacturing
industry.
MACHINE SELECTION
Considerations for Choosing the Appropriate Injection Molding
Machine for Manufacturing Plastic Spoons
Selecting the right injection molding machine is crucial for ensuring
efficient and cost-effective production of plastic spoons. Several factors
must be considered to match the machine's capabilities with the specific
requirements of the product and the production process. Here are the key
considerations:
1. **Clamping Force**
- **Product Size and Material**: The clamping force required is
determined by the size of the spoon and the type of material used
(Polypropylene in this case). The clamping force needs to be sufficient
to keep the mold closed during the injection process to prevent flash and
ensure proper filling of the mold.
- **Calculation**: For plastic spoons, a clamping force in the range of
50-150 tons is typically adequate, depending on the mold design and the
number of cavities.
2. **Shot Size**
- **Volume of Material**: The shot size, or the amount of molten
plastic injected into the mold, must be appropriate for the volume of the
spoon. It's important to choose a machine with a shot size that matches
the total volume of the cavities in the mold.
- **Capacity**: Ensure that the machine can deliver the precise amount
of PP required for each injection cycle. A machine with a shot size
capacity slightly higher than the actual requirement is recommended to
avoid short shots.
3. **Injection Pressure and Speed**
- **Filling and Packing**: The machine must provide adequate injection
pressure and speed to ensure the mold is filled properly and the material
is packed correctly to avoid defects such as voids, sink marks, and
incomplete filling.
- **Adjustability**: Machines with adjustable injection pressure and
speed settings are preferred to fine-tune the process parameters for
optimal product quality.
4. **Mold Size and Mounting**
- **Mold Dimensions**: The machine’s platens and tie-bar spacing
must accommodate the size of the mold. Ensure that the mold can be
mounted and fits within the machine’s dimensions.
- **Ejector System**: Check compatibility of the machine's ejector
system with the mold's ejection mechanism to ensure efficient part
removal.
5. **Number of Cavities**
- **Production Volume**: The number of cavities in the mold impacts
the machine choice. Higher cavity molds require machines with higher
clamping forces and shot sizes. Determine the appropriate machine size
based on the expected production volume and mold design.
- **Cycle Time**: Consider machines that can handle multi-cavity
molds efficiently to reduce cycle times and increase production rates.
6. **Material Compatibility**
- **Polypropylene Processing**: Ensure the machine is suitable for
processing Polypropylene, which has specific requirements for
temperature control, injection pressure, and screw design.
- **Screw and Barrel Design**: The machine should have a screw and
barrel designed for PP to ensure optimal melting and homogenization of
the material.
7. **Temperature Control**
- **Consistent Heating**: Precise temperature control is essential for
maintaining the quality of PP during the injection process. The machine
should have advanced temperature control systems for the barrel, nozzle,
and mold.
- **Cooling System**: Efficient mold cooling is crucial to reduce cycle
times and improve part quality. The machine should support effective
cooling systems compatible with the mold design.
8. **Automation and Control**
- **Process Monitoring**: Advanced machines offer real-time
monitoring and control systems to ensure consistent quality and reduce
the risk of defects. Features like closed-loop control, automatic part
ejection, and in-line quality inspection can improve productivity.
- **User Interface**: A user-friendly interface simplifies the setup and
operation of the machine, enabling quick adjustments and
troubleshooting.
9. **Energy Efficiency**
- **Operational Costs**: Energy-efficient machines reduce operational
costs and environmental impact. Consider machines with energy-saving
features such as servo motors and advanced insulation.
- **Sustainability**: Energy-efficient machines contribute to
sustainable manufacturing practices, aligning with industry standards for
reducing carbon footprint.
10. **Cost and Availability**
- **Budget Constraints**: Ensure the selected machine fits within the
project budget while meeting all technical requirements. Consider the
total cost of ownership, including maintenance and operational costs.
- **Supplier Support**: Choose machines from reputable manufacturers
with good after-sales support, training, and availability of spare parts.
Selecting the appropriate injection molding machine for manufacturing
plastic spoons involves evaluating various technical and economic
factors. By considering the clamping force, shot size, injection pressure,
mold size, material compatibility, temperature control, automation,
energy efficiency, and cost, you can ensure efficient and high-quality
production. Careful selection of the machine not only optimizes the
manufacturing process but also enhances the overall product quality and
production efficiency.
1. CLAMPING FORCE CALCULATION
The clamping force is calculated based on the projected area of the part and the injection
pressure.
Projected Area Calculation:
Assume the projected area of one spoon is approximately 15 cm215 \ \text{cm}^215 cm2.
For a four-impression mold, the total projected area is 4×15 cm2=60 cm24 \times 15 \
\text{cm}^2 = 60 \ \text{cm}^24×15 cm2=60 cm2.
Clamping Force Requirement:
Injection pressure for PP is approximately 500 bar500 \ \text{bar}500 bar (or 50 N/mm250
\ \text{N/mm}^250 N/mm2).
Total clamping force = Projected area×Injection pressure\text{Projected area} \times
\text{Injection pressure}Projected area×Injection pressure.
Convert the projected area to mm2\text{mm}^2mm2: 60 cm2=6000 mm260 \ \text{cm}^2
= 6000 \ \text{mm}^260 cm2=6000 mm2.
Clamping force = 6000 mm2×50 N/mm2=300,000 N=300 kN6000 \ \text{mm}^2 \
times 50 \ \text{N/mm}^2 = 300,000 \ \text{N} = 300 \
\text{kN}6000 mm2×50 N/mm2=300,000 N=300 kN.
Since it is recommended to have a safety factor of around 1.5, the required clamping force is
300 kN×1.5=450 kN300 \ \text{kN} \times 1.5 = 450 \ \text{kN}300 kN×1.5=450 kN.
2. Shot Size Calculation
The shot size is determined by the volume of plastic required to fill all four cavities, including
runners and sprue.
Volume of One Spoon:
Assume the volume of one spoon is approximately 10 cm310 \ \text{cm}^310
cm3. For four spoons, the volume is 4×10 cm3=40 cm34 \times 10 \ \text{cm}^3 =
40 \
\text{cm}^34×10 cm3=40 cm3.
Additional Volume for Runners and Sprue:
Assume an additional volume of 20 cm320 \ \text{cm}^320 cm3 for runners and sprue.
Total shot volume = 40 cm3+20 cm3=60 cm340 \ \text{cm}^3 + 20 \ \text{cm}^3 = 60 \
\text{cm}^340 cm3+20 cm3=60 cm3.
Convert this volume to grams, considering the density of PP is around 0.9 g/cm30.9 \
\text{g/cm}^30.9 g/cm3:
Total shot weight = 60 cm3×0.9 g/cm3=54 g60 \ \text{cm}^3 \times 0.9 \ \text{g/cm}^3 = 54 \
\text{g}60 cm3×0.9 g/cm3=54 g.
3. Machine Specifications
Based on the above calculations, the selected machine should have:
Clamping Force: At least 450 kN (preferably 500 kN to ensure adequate safety).
Shot Size: At least 54 g of PP.
Injection Pressure: Sufficient to handle PP injection (500 bar or more).
Tie Bar Distance: Sufficient to accommodate the mold dimensions.
Cooling System: Efficient cooling capacity to handle cycle times and ensure part quality.
MOLD DESIGN
mold with all the plates
2D designs of all the plates of the mold
MATERIAL SELECTION FOR MOLD
Mold Material Selection for Plastic Spoon Manufacturing
The selection of appropriate materials for each part of the injection mold
is crucial for ensuring the mold’s performance, durability, and cost-
effectiveness. Here are the primary parts of the mold and the
recommended materials for each, along with the reasons for their
selection:
1. **Cavity and Core**
**Material**: P20 Tool Steel (DIN 1.2311/1.2312)
**Reasons for Selection**:
- **Hardness and Strength**: P20 tool steel provides a good balance of
hardness and toughness, making it suitable for high-volume production
molds.
- **Machinability**: P20 is pre-hardened and can be easily machined,
allowing for precise and detailed mold features.
- **Polishability**: The material can be polished to achieve a high-
quality surface finish, which is essential for producing smooth plastic
spoons.
- **Durability**: P20 tool steel has good wear resistance, extending the
mold’s life even under continuous production conditions.
- **Cost-Effectiveness**: While providing excellent properties, P20 is
more cost-effective compared to other high-grade tool steels like H13.
2. **Mold Base**
**Material**: Mild Steel (DIN 1.1730 or equivalent)
**Reasons for Selection**:
- **Structural Support**: Mild steel offers sufficient strength and
rigidity to support the mold structure during the injection process.
- **Cost-Effective**: Mild steel is relatively inexpensive compared to
tool steels, reducing the overall cost of the mold base.
- **Machinability**: It is easy to machine and weld, facilitating the
manufacture and maintenance of the mold base.
- **Adequate Durability**: For the mold base, the primary requirement
is to hold the core and cavity inserts securely. Mild steel provides
adequate durability for this purpose.
3. **Ejector Pins**
**Material**: H13 Tool Steel
**Reasons for Selection**:
- **Hardness and Toughness**: H13 tool steel offers excellent
hardness and toughness, ensuring the ejector pins can withstand
repeated impacts and wear.
- **Heat Resistance**: H13 has superior heat resistance, which is
crucial since ejector pins operate in the heated environment of the mold.
- **Durability**: The material’s high wear resistance prolongs the
life of the ejector pins, reducing the need for frequent replacements.
4. **Sprue Bushing**
**Material**: Hardened Tool Steel (e.g., AISI D2)
**Reasons for Selection**:
- **Wear Resistance**: Hardened tool steel such as D2 is highly
resistant to abrasion, which is important for the sprue bushing as it
directs molten plastic into the mold.
- **Heat Resistance**: The material can withstand high temperatures
and repeated thermal cycling without degrading.
- **Durability**: Ensures a long service life even under the continuous
injection molding process.
5. **Guide Pins and Bushings**
**Material**: Hardened Steel (e.g., AISI 52100)
**Reasons for Selection**:
- **Precision and Alignment**: Hardened steel provides the necessary
hardness and wear resistance to maintain precise alignment of the mold
halves.
- **Longevity**: The material’s durability ensures that the guide
pins and bushings maintain their dimensions and functionality over
the mold’s lifespan.
Conclusion
The careful selection of materials for each part of the injection mold is
vital for optimizing performance, durability, and cost. The
combination of P20 tool steel, mild steel, H13 tool steel, hardened
steel, and copper alloys provides a balanced approach to achieving a
high-quality, efficient, and long-lasting mold for producing plastic
spoons. This selection ensures that each component of the mold can
perform its function effectively, contributing to the overall success of
the injection molding process.
MACHINING PROCESS OF THE MOLD
Machining Processes for Mold Parts
The production of injection mold components involves various
machining processes to ensure precision and quality. Below is an
overview of the machining processes for each of the specified parts:
1. **Core Plate and Cavity Plate**
**Material**: P20 Tool Steel
**Machining Processes**:
- **CNC Milling**: Used to rough out the basic shape of the core and
cavity, including any complex geometries and contours.
- **EDM (Electrical Discharge Machining)**: Applied for creating
intricate details, fine features, and tight tolerances that are difficult to
achieve with milling.
- **Grinding**: Used for achieving precise surface finishes and
dimensional accuracy.
- **Polishing**: Final surface finishing to achieve the required
smoothness for the cavity and core.
2. **Core Back Plate and Cavity Back Plate**
**Material**: Mild Steel or P20 Tool Steel
**Machining Processes**:
- **CNC Milling**: Used to rough and finish machine the back plates to
the required dimensions.
- **Drilling**: For creating holes for guide pins, screws, and cooling
channels.
- **Grinding**: To achieve flat and parallel surfaces with
high precision.
3. **Top Plate and Bottom Plate**
**Material**: Mild Steel
**Machining Processes**:
- **CNC Milling**: For shaping the top and bottom plates to the
required dimensions.
- **Drilling**: For creating holes for screws, guide pins, and cooling
channels.
- **Grinding**: To ensure flatness and parallelism.
4. **Ejector Plate**
**Material**: Mild Steel or Hardened Tool Steel
**Machining Processes**:
- **CNC Milling**: To machine the ejector plate to the
specified dimensions.
- **Drilling and Tapping**: For creating holes for ejector pins
and screws.
- **Grinding**: For achieving precise thickness and surface finish.
5. **Spacer Block**
**Material**: Mild Steel
**Machining Processes**:
- **CNC Milling**: To cut the spacer block to the desired dimensions.
- **Drilling**: For creating holes for mounting and alignment.
- **Grinding**: To achieve the required flatness and parallelism.
6. **Guide Pillar**
**Material**: Hardened Steel (AISI 52100)
**Machining Processes**:
- **Turning**: On a lathe to achieve the cylindrical shape and
precise diameter.
- **Grinding**: For achieving the required surface finish and
dimensional accuracy.
- **Hardening and Tempering**: Heat treatment to achieve the
desired hardness and toughness.
7. **Guide Bush**
**Material**: Hardened Steel (AISI 52100)
**Machining Processes**:
- **Turning**: To machine the outer and inner diameters.
- **Boring**: To achieve precise internal diameters.
- **Grinding**: For high precision and surface finish.
- **Hardening and Tempering**: Heat treatment to ensure
wear resistance and durability.
8. **Sprue Bush**
**Material**: Hardened Tool Steel (AISI D2)
**Machining Processes**:
- **Turning**: To machine the external and internal profiles.
- **Boring**: To achieve the precise internal diameter.
- **Grinding**: For surface finish and dimensional accuracy.
- **Heat Treatment**: Hardening to improve wear resistance.
9. **Ejector Pin**
**Material**: H13 Tool Steel
**Machining Processes**:
- **Turning**: To achieve the cylindrical shape and precise diameter.
- **Grinding**: For surface finish and dimensional accuracy.
- **Heat Treatment**: Hardening and tempering to ensure
durability and wear resistance.
Detailed Machining Steps for Each Part
1. **Core Plate and Cavity Plate**:
- **CNC Milling**:
- Rough Milling: Remove the bulk of the material.
- Finish Milling: Achieve close tolerances and detailed shapes.
- **EDM**:
- Wire EDM: For intricate cuts and fine details.
- Die-Sinking EDM: For deeper and more complex cavities.
- **Grinding**: Surface and cylindrical grinding for high precision.
- **Polishing**: Hand polishing or machine polishing for a smooth
surface.
2. **Core Back Plate and Cavity Back Plate**:
- **CNC Milling**:
- Rough Milling: Shape the plates.
- Finish Milling: Precision machining to final dimensions.
- **Drilling**: Create necessary holes for assembly and cooling
channels.
- **Grinding**: Final surface finishing.
3. **Top Plate and Bottom Plate**:
- **CNC Milling**:
- Rough and Finish Milling: To achieve required dimensions.
- **Drilling**: For assembly holes and other required features.
- **Grinding**: Ensure flatness and parallelism.
4. **Ejector Plate**:
- **CNC Milling**:
- Rough and Finish Milling: To specified dimensions.
- **Drilling and Tapping**: For ejector pin holes and screws.
- **Grinding**: Achieve precise thickness.
5. **Spacer Block**:
- **CNC Milling**:
- Cut to required size and shape.
- **Drilling**: For mounting holes.
- **Grinding**: Ensure flatness and precision.
6. **Guide Pillar**:
- **Turning**: On a lathe to shape and size.
- **Grinding**: For high precision and surface finish.
- **Heat Treatment**: Hardening and tempering.
7. **Guide Bush**:
- **Turning**: Shape the internal and external diameters.
- **Boring**: Precision internal diameter machining.
- **Grinding**: High precision and finish.
- **Heat Treatment**: Hardening process.
8. **Sprue Bush**:
- **Turning**: External and internal shaping.
- **Boring**: Precision internal diameter.
- **Grinding**: Surface finish.
- **Heat Treatment**: Hardening.
9. **Ejector Pin**:
- **Turning**: Shape and size.
- **Grinding**: Surface finish and precision.
- **Heat Treatment**: Hardening and tempering.
The detailed machining processes for each mold component ensure that
all parts meet the necessary specifications for high precision, durability,
and performance. By carefully selecting the appropriate materials and
machining methods, we can create a high-quality mold capable of
producing plastic spoons efficiently and reliably.
MOLD COST
ESTIMATION
[Link] COST
PART NAME MATERIAL TYPE MATERIAL WEIGHT(KG) TOTAL COST
COST(/KG)
CORE PLATE P20 TOOL STEEL 400 12 4800
CAVITY PLATE P20 TOOL STEEL 400 12 4800
CORE BACK MILD STEEL 70 8 560
PLATE
CAVITY BACK MILD STEEL 70 8 560
PLATE
TOP PLATE MILD STEEL 70 10 700
BOTTOM PLATE MILD STEEL 70 10 700
EJECTOR PLATE H13 TOOL STEEL 500 5 2500
SPACER BLOCK MILD STEEL 70 4 280
GUIDE PILLAR HARDENED 600 2 1200
STEEL
GUIDE BUSH HARDENED 600 1.5 900
STEEL
EJECTOR PIN H13 TOOL,STEEL 500 2 1000
TOTAL 18600
MATERIAL COST
2. MACHINING COST
MACHINING MACHINE TYPE HOURLY RATE HOURS TOTAL COST
OPERATION REQUIRED
CNC MILLING CNC MILLING 800 20 16000
MACHINE
TURNING LATHE MACHINE 500 10 5000
GRINDING GRINDING 400 15 6000
MACHINE
POLISHING MANUAL/AUTO 200 10 2000
MATIC
TOTAL 29000
MACHINING
COST
3. LABOUR COSTS
LABOUR ACTIVITY HOURLY RATE HOURS REQUIRED TOTAL COST
ASSEMBLY 500 5 2500
INSPECTION 300 1 300
TOTAL LABOUR COST 2800
4. ADDITIONAL COSTS
ITEM DESCRIPTION COST
DESIGN AND ENGINEERING CAD DESIGN AND 10000
ENGINEERING SERVICES
OVERHEAD COSTS UTILITIES,RENT,ETC 5000
CONTINGENCY UNEXPECTED COSTS(e.g. 5000
rework)
TOTAL ADDITIONAL COST 20000
5. TOTAL COST ESTIMATION
COST COMPONENT TOTAL COST
TOTAL MATERIAL COST 18600
TOTAL MACHINING COST 29000
TOTAL LABOUR COST 2800
TOTAL ADDITIONAL COST 20000
GRAND TOTAL COST 70400
MOLD ASSEMBLY AND FITTING PROCESS
Mold Assembly and Fitting Process
The assembly and fitting of an injection mold are critical stages in the
mold-making process, ensuring that all components fit together precisely
and function correctly. Here’s a detailed step-by-step guide to the mold
assembly and fitting process:
1. **Preparation**
- **Clean all components**: Ensure all mold components are clean and
free of debris or contaminants.
- **Inspection**: Check all parts for any defects or machining errors.
Verify dimensions and surface finishes against the design
specifications.
- **Organize parts**: Arrange all parts in a logical order for
assembly, starting with the base components.
2. **Assembling the Mold Base**
- **Place the bottom plate**: Secure the bottom plate on a flat, stable
surface.
- **Install the spacer blocks**: Attach the spacer blocks to the bottom
plate. These blocks create space for the ejector system.
- **Attach the core back plate**: Place the core back plate on top of the
spacer blocks and secure it.
3. **Installing the Core and Cavity Plates**
- **Position the core plate**: Carefully place the core plate on the core
back plate, ensuring proper alignment with any guide pins or bushings.
- **Position the cavity plate**: Place the cavity plate on the cavity back
plate. Ensure the alignment with guide pins to ensure proper mating with
the core plate.
- **Secure the plates**: Use screws or bolts to firmly attach the core
and cavity plates to their respective back plates.
4. **Guide System Installation**
- **Install guide pillars**: Insert the guide pillars into the holes in the
core plate. Ensure they are fully seated and aligned.
- **Install guide bushes**: Insert the guide bushes into the
corresponding holes in the cavity plate. Check for smooth movement
along the guide pillars.
5. **Ejector System Assembly**
- **Place the ejector plate**: Position the ejector plate on the core side
of the mold. Ensure it is properly aligned.
- **Insert ejector pins**: Place the ejector pins through the holes in the
ejector plate and into the corresponding holes in the core plate.
- **Secure the ejector plate**: Use screws or bolts to attach the ejector
plate to the spacer blocks. Make sure the ejector pins move freely.
- **Install return pins**: Attach the return pins (if used) to ensure the
ejector plate returns to its original position after each cycle.
6. **Cooling System Assembly**
- **Insert cooling channels**: Install the cooling channels into the core
and cavity plates as per the design specifications.
- **Attach water connectors**: Connect the water inlets and outlets to
the cooling channels. Ensure all connections are secure and leak-proof.
7. **Installing the Top Plate**
- **Position the top plate**: Place the top plate over the cavity plate.
Ensure alignment with the guide pillars and secure it with screws or
bolts.
- **Check for smooth operation**: Open and close the mold several
times to ensure all components move smoothly and align correctly.
8. **Sprue Bush Installation**
- **Insert the sprue bush**: Install the sprue bush into the cavity plate.
Ensure it is aligned with the injection nozzle.
- **Secure the sprue bush**: Tighten any retaining screws or bolts
to hold the sprue bush in place.
9. **Final Checks and Adjustments**
- **Alignment check**: Ensure the core and cavity plates align perfectly
and the guide pillars move smoothly within the guide bushes.
- **Ejector system check**: Verify that the ejector pins move freely
and return correctly after being pushed.
- **Cooling system check**: Run water through the cooling channels to
check for leaks and proper flow.
- **Surface finish check**: Inspect the cavity and core surfaces for any
scratches, dents, or imperfections.
10. **Polishing and Final Touches**
- **Polish surfaces**: Use appropriate polishing tools and compounds
to achieve the required surface finish on the mold cavities and cores.
- **Clean the mold**: Remove any polishing residues and clean the
mold thoroughly.
- **Apply anti-corrosion agents**: Coat the mold surfaces with a
suitable anti-corrosion agent to protect against rust and wear during
storage and use.
11. **Assembly Verification**
- **Trial assembly**: Assemble and disassemble the mold a few times
to ensure all parts fit together correctly and the mold functions
smoothly.
- **Document any issues**: Note any fitting problems or misalignments
and correct them before final assembly.
- **Final inspection**: Perform a detailed inspection of the entire mold
to ensure all components are properly assembled and meet the design
specifications
The assembly and fitting of an injection mold require meticulous
attention to detail and precision. Each step, from preparing the
components to the final inspection, is crucial for ensuring the mold
operates efficiently and produces high-quality parts. Proper assembly
and fitting not only enhance the mold’s performance but also extend
its lifespan and reliability.
MOLD TRIAL ON THE MACHINE
A suitable machine might be the ENGEL Victory 500/120 or a similar model from another reputable
manufacturer. This type of machine typically offers:
Clamping force of 500 kN.
Shot size of around 100 g.
Adequate tie bar distance and platen size.
Advanced control systems for precise injection and cooling.
Mold Trial Process on the Selected Machine
1. Preparation
Mold Inspection: Ensure the mold is clean and free of defects.
Machine Setup: Mount the mold on the machine and secure it properly. Connect the
cooling lines and ensure they are leak-free.
Material Preparation: Ensure PP granules are dried and ready for use.
2. Machine Setup
Clamping Force Adjustment: Set the clamping force according to the mold requirements
(e.g., 500 kN).
Injection Parameters:
Injection Pressure: Set to handle PP (around 500 bar).
Injection Speed: Adjust based on the part design and mold requirements.
Holding Pressure: Ensure proper packing of the material into the mold cavities.
Cooling Time: Adjust to ensure proper cooling and solidification of the spoons.
3. Initial Trial Runs
Dry Cycle: Run the machine without material to check for proper functioning and ensure
there are no mechanical issues.
Initial Injection: Start with a lower shot size and gradually increase until the mold is filled
properly.
Parameter Adjustment: Fine-tune the injection speed, pressure, and cooling time based on
the initial results.
4. Quality Check
Part Inspection: Inspect the first set of molded spoons for defects such as short shots,
warping, or flash.
Dimensional Check: Measure the spoons to ensure they meet the design specifications.
5. Optimization
Cycle Time Optimization: Adjust cooling times and other parameters to achieve the optimal
cycle time without compromising part quality.
Consistency Check: Ensure that the machine produces consistent parts with minimal
variation.
6. Production Run
Stability Check: Run the machine for an extended period to ensure stable production.
Continuous Monitoring: Regularly monitor the parts for quality and make necessary
adjustments.
Conclusion
Selecting the right injection molding machine involves considering the clamping force, shot size,
and other specifications based on the mold and material requirements. The mold trial process is
crucial for ensuring the mold functions correctly and produces high-quality parts. Proper
preparation, setup, and optimization are key steps to achieve successful mold trials and efficient
production runs.