DYNAMIC INDUSTRIES

Report on Manufacturing of an injection mould component as per customers requirement and comparison of conventional milling and CNC milling methods. By Nitish Kumar Roll no. 322, GR no. 71122100019 Submitted for Technical internship programme Training Supervisor and Guide

Prof. Ravi Terkar Associate Professor, MPSTME Mr. Anup Parikh Chairman, Dynamic Industries Ltd.

MUKESH PATEL SCHOOL OF TECHNOLOGY MANAGEMENT & ENGINEERING SVKM's NARSEE MONJEE INSTITUTE OF MANAGEMENT STUDIES (Declared as Deemed-to-be University Under Section 3 of the UGC Act. 1956) Vile Parle (w), Mumbai-400 056.

DYNAMIC INDUSTRIES

ACKNOWLEDGMENT
It gives me immense pleasure to present this training report at DYNAMIC INDUSTRIES LTD. This training provided me a golden opportunity to expose myself to the industrial environment. I am very grateful to my training Guides, Mr Anup Parikh & Prof. Ravi Terker for their motivation and continuous support as well as guidance to pursue and complete this report. Their wide knowledge and logical way of thinking have been of great value for me. They were always there to meet and talk about research ideas, to proof read and mark-up my papers, and to ask me good questions to help me to think through my research. Without their encouragement and constant guidance, I could not have finished this synopsis. I would like to thank to Mr Chandrakant Vichrolia, Mr Chetan Majithia & Mr. Amol Deshmukh for their valuable support and encouragement during the research work. Further I believe that the list of people would remain incomplete if I fail to mention my supervisors & department colleagues; they were constant source of encouragement and timely help.

Thanks Nitish Kumar

DYNAMIC INDUSTRIES

Contents
1 ABSTRACT ................................................................................................................................................... 1 2 Company profile ......................................................................................................................................... 2 2.1 One-Stop Service .............................................................................................................................. 2 2.2 Quality Policy of Dynamic Industries ................................................................................................... 2 2.3 List of Esteemed Customers ........................................................................................................... 3 2.4 Facilities Available at Dynamic Industries ........................................................................................... 4 2.5 Some of the products of Dynamic Industries are ................................................................................ 5 3 INTRODUCTION .......................................................................................................................................... 9 4 Product Design ......................................................................................................................................... 10 4.1 Milling14 4.2 Shaping ............................................................................................................................................. 15 4.3 Grinding...16 5 Understanding the Basics of the Injection Mould ................................................................................... 17 5.1 Number of Cavities ............................................................................................................................ 18 5.2 Runners and Gates ............................................................................................................................ 20 5.3 Venting: ............................................................................................................................................. 21 5.4 Cooling: ............................................................................................................................................. 22 5.5 Ejection:............................................................................................................................................. 23 6 Machining and Finishing processes of mould .......................................................................................... 24 6.1 CNC machining..24 6.2 CNC Control Systems 25 6.3 Open Loop Systems ........................................................................................................................... 25 6.4 Close Loop Systems ............................................................................................................................ 25 6.4 Features of CNC................................................................................................................................. 26 6.5 Basic CNC Principles .......................................................................................................................... 28 6.6 Motion Control .................................................................................................................................. 29 6.7 Types of CNC machines...................................................................................................................... 31

DYNAMIC INDUSTRIES 6.8 Importance of higher axes machining ............................................................................................... 31 6.9 Applications Of Cnc Machines ......................................................................................................... 32 6.10 OTHER FUNCTIONS OF CNC.. .......................................................................................................... 33 7 Electrical discharge machine ................................................................................................................ 35 7.1 Characteristics of EDM.. ................................................................................................................ 36 7.2 DIELECTRIC .................................................................................................................................... 37 8 MAIN PROJECT.. ................................................................................................................................ 41 8.1 Observations ................................................................................................................................. 44 8.2 Results..44 9 Conclusion.44 10 References...45

DYNAMIC INDUSTRIES

ABSTRACT
Dynamic Industries is an upcoming mould making and moulding company specialized in Automobile, Air-conditioners, Water Purifier System, Bio-medical, Television and House Hold Industries. My project is related to the production, design & manufacturing of an injection mould component known as Shroud in this case. In my training here, Ill be monitoring and studying the mould making process starting from the product design to the final trial & correction, alongside with the use of CNC milling machines and its comparison with conventional milling so as to know which is better and what are their advantages and disadvantages.

DYNAMIC INDUSTRIES

Company profile

Dynamic Industries is an upcoming mould making and moulding company specialized in Automobile, Air-conditioners, Water Purifier System, Bio-medical, Television and House Hold Industries.

Industries Serviced:
Automobiles Water Treatment Consumer Appliances Electrical and Electronics Thermoforming Bio-Medicals

One-Stop Service:
We have integrated product development, mould design and manufacturing facilities along with injection moulding facilities to provide one-step service.

Quality Policy of Dynamic Industries:

Quality policy is to achieve sustained, profitable growth by providing services which consistently satisfy the needs and expectation of our customers. To achieve and maintain a level of quality which enhances the company's reputation with customers. To provide a quality product that satisfies our customer's requirement, deliver on time. We are committed to continuously improve our processes to provide goods and services at a better value to our customers.
2

DYNAMIC INDUSTRIES

List of Esteemed Customers: Mutual Industries Ltd. Ronch Polymers Ltd. TVS Motor Company Ltd. Sundaram Auto-Components Ltd. Tata Auto-Components Pvt. Ltd. Banco Products (India) Ltd. Alkraft Thermo technologies Pvt. Ltd. Kabra Extrusiontechnik Pvt. Ltd. Jyoti Plastic Works Pvt. Ltd. Polysmart Technologies Pvt. Ltd. Auro Plastic Injection Moulders Pvt. Ltd Hitachi Home & Life Solution Ltd Rajoo Engineers Ltd. Tata InfoTech Ltd. Sui Generics Transpo International Polyset Plastics Transasia Bio Medicals Kirti Industries Ltd. Rita International Harita Infoserve Ltd. Lear Corporation Supreme Treaves Pvt. Ltd. Vipul Plastocrafts

DYNAMIC INDUSTRIES

Facilities Available at Dynamic Industries:

DYNAMIC INDUSTRIES

Some of the products of Dynamic Industries are:

DYNAMIC INDUSTRIES

DYNAMIC INDUSTRIES

DYNAMIC INDUSTRIES

Mould Process Chart of the Company:

DYNAMIC INDUSTRIES

INTRODUCTION:
The whole process of manufacturing of moulds comprises of following stages:

General Mould Manufacturing Chart

DYNAMIC INDUSTRIES

Product Design:
The product design is given by the customer to the manufacturer. Product design is made on the 3D designing softwares like Unigraphics, PRO-E etc. by the customer and then it is sent to the manufacturer and the manufacturer improves it further if there is any problem in the design so as to get the required mould.

Pre machining:
Pre machining of raw material is done to get the uniform surface for machining before it is sent for further machining like in CNC and EDM.

The three basic steps involved in Pre machining are: Milling:

A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges. One or more number of cutters can be mounted simultaneously on the arbor of milling machine. This is the reason that a milling machine finds wide application in production work. Milling machine is used for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads, and helical surfaces of various cross-sections. In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters.

10

DYNAMIC INDUSTRIES

Milling Machine

PRINCIPLE OF MILLING:
In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For cutting operation, the workpiece is fed against the rotary cutter. As the workpiece moves against the cutting edges of milling cutter, metal is removed in form chips. Machined surface is formed in one or more passes of the work. The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, between centers, in a special fixture or bolted to machine table. The rotatory speed of the cutting tool and the feed rate of the workpiece depend upon the type of material being machined.

11

DYNAMIC INDUSTRIES

Principle of Milling

The rotational axis of the milling cutter may be horizontal. This is called plain milling. Plain milling is usually carried out on a horizontal milling machine. When the rotational axis of the milling cutter is perpendicular to the machined surface, the process is called face milling or end milling. Vertical milling machines are the machines mostly used for this type of milling.

12

DYNAMIC INDUSTRIES

Milling Methods:
Up-milling:
In the up-milling, the metal is removed in form of small chips by a cutter rotating against the direction of travel of the workpiece. In this type of milling, the chip thickness is minimum at the start of the cut and maximum at the end of cut. As a result the cutting force also varies from zero to the maximum value per tooth movement of the milling cutter. The major disadvantages of up-milling process are the tendency of cutting force to lift the work from the fixture and poor surface finish obtained. But being a safer process, it is commonly used method of milling.

Up Milling

13

DYNAMIC INDUSTRIES

Down-milling:
In this method, the metal is removed by a cutter rotating in the same direction of feed of the workpiece. The effect of this that the teeth cut downward instead of upwards. Chip thickness is maximum at the start of the cut and minimum in the end. In this method, it is claimed that there is less friction involved and consequently less heat is generated on the contact surface of the cutter and workpiece. Down milling can be used advantageously on many kinds of work to increase the number of pieces per sharpening and to produce a better finish. With down milling, saws cut long thin slots more satisfactorily than with standard milling. Another advantage is that slightly lower power consumption is obtainable by climb milling, since there is no need to drive the table against the cutter.

Down milling

14

DYNAMIC INDUSTRIES

Shaping:
Process of removing metal from surface by the use of a single point cutting tool held in ram that reciprocates the tool in a linear direction across the work piece held on the table of the machine.

Shaper

The main motion shown is performed either by the tool. It consists of two strokes, the working (cutting) stroke and the return (idle) stroke. The speed of the return stroke is greater than that of the cutting one for saving the time. The feed is performed by the workpiece.

Shaping Process:
A shaper operates by moving a hardened cutting tool backwards and forwards across the workpiece. On the return stroke of the ram the tool is lifted clear of the workpiece, reducing the cutting action to one direction only. The workpiece mounts on a rigid, box shaped table in front of the machine. The height of the table can be adjusted to suit this workpiece, and the table can traverse sideways underneath the reciprocating tool which is mounted on the ram, the table motion is usually under the control of an automatic feed mechanism which acts on the feedscrew. The ram slides back and forth above the work, at the front end of the ram is a vertical tool-slide that may be
15

DYNAMIC INDUSTRIES

adjusted to either side of the vertical plane. This tool-slide holds the clapper box and toolpost from where the tool can be positioned to cut the straight, flat surface on the top of the workpiece. The tool-slide permits feeding the tool downwards to put on a cut it or may be set away from the vertical plane, as required. The ram is adjustable for stroke and, due to the geometry of the linkage, it moves faster on the return (noncutting) stroke than on the forward, cutting stroke.

Grinding:
Grinding is a metal cutting operation performed by means of a rotating abrasive wheel that acts as a cutting tool. It is used to finish work pieces which must show a high surface quality, accuracy of shape and dimensions. It is considered as a finishing operation because it removes comparatively little metal, usually 0.25 to 0.50 mm and the accuracy in dimensions is in the order of 0.000025 mm.

Grinding Machine

16

DYNAMIC INDUSTRIES

Understanding the Basics of the Injection Mould:

Mould Cavity Space:
The mould cavity space is a shape inside the mould, ``excavated'' in such a manner that when the moulding material is forced into this space it will take on the shape of the cavity space and, therefore, the desired product. The principle of a mould is almost as old as human civilization. Moulds have been used to make tools, weapons, bells, statues, and household articles, by pouring liquid metals (iron, bronze) into sand forms. Such moulds, which are still used today in foundries, can be used only once because the mould is destroyed to release the product after it has solidified. Today, we are looking for permanent moulds that can be used over and over. Now moulds are made from strong, durable materials, such as steel, or from softer aluminum or metal alloys and even from certain plastics where a long mould life is not required because the planned production is small. In injection moulding the (hot) plastic is injected into the cavity space with high pressure, so the mould must be strong enough to resist the injection pressure without deforming.

Mould Cavity Space and Parting Line

17

DYNAMIC INDUSTRIES

Number of Cavities:
Many moulds, particularly moulds for larger products, are built for only one cavity space but many moulds, especially large production moulds, are built with 2 or more cavities. The reason for this is purely economical. It takes only little more time to inject several cavities than to inject one. For example, a 4-cavity mould requires only (approximately) one-fourth of the machine time of a single-cavity mould. Conversely, the production increases in proportion to the number of cavities. Today, most multicavity moulds are built with a preferred number of cavities: 2, 4, 6, 8, 12, 16, 24, 32, 48, 64, 96, and 128. These numbers are selected because the cavities can be easily arranged in a rectangular pattern, which is easier for designing and dimensioning, for manufacturing, and for symmetry around the center of the machine, which is highly desirable to ensure equal clamping force for each cavity. A smaller number of cavities can also be laid out in a circular pattern, even with odd numbers of cavities, such as 3, 5, 7, and 9.

Cavity Shape:
The shape of the cavity is essentially the ``negative'' of the shape of the desired product, with dimensional allowances added to allow for shrinking of the plastic. The shape of the cavity is usually created with chip-removing machine tools, or with electric discharge machining (EDM), with chemical etching, or by any new method that may be available to remove metal or build it up, such as galvanic processes.

Cavity and Core:

By convention, the hollow (concave) portion of the cavity space is called the cavity. The matching, often raised (or convex) portion of the cavity space is called the core. Most plastic products are cup-shaped. This does not mean that they look like a cup, but they do have an inside and an outside. The outside of the product is formed by the cavity, the inside by the core. Usually, the cavities are placed in the mould half that is mounted on the injection side, while the cores are placed in the moving half of the mould. The reason for this is that all injection moulding machines provide an ejection mechanism on the moving platen and the products tend to shrink onto and cling to the core, from where they are then ejected.
18

DYNAMIC INDUSTRIES

The Parting Line:

To be able to produce a mould (and to remove the moulded pieces), we must have at least two separate mould halves, with the cavity in one side and the core in the other. The parting line can have any shape, but for ease of mould manufacturing, it is preferable to have it in one plane. The parting line is always at the widest circumference of the product, to make ejection of the product from the mould possible. With some shapes it may be necessary to offset the parting line, or to have it at an angle, but in any event it is best to have is so that it can be easily machined, and often ground, to ensure that it shuts off tightly when the mould is clamped during injection. If the parting line is poorly finished the plastic will escape, which shows up on the product as an unsightly sharp projection, or ``flash,'' which must then be removed; otherwise, the product could be unusable. There is even a danger that the plastic could squirt out of the mould and do personal damage.

Parting Line

19

DYNAMIC INDUSTRIES

Runners and Gates:

We must add provisions for bringing the plastic into the cavity spaces. This must be done with enough pressure so that the cavity spaces are filled completely before the plastic ``freezes,'' that is, cools so much that the plastic cannot flow anymore. The flow passages are the sprue, from where the machine nozzle contacts the mould, the runners, which distribute the plastic to the individual cavities, and the gates, which are (usually) small openings leading from the runner into the cavity space.

Runners, Gates and Sprue

20

DYNAMIC INDUSTRIES

Venting:
As the plastic flows from the gate into the cavity space, the air trapped in it as the mould closed must be permitted to escape. Typically, the trapped air is being pushed ahead by the rapidly advancing plastic front, toward all points farthest away from the gate. The faster the plastic enters which is usually desirable the more the trapped air is compressed if it is not permitted to escape, or vented. This rapidly compressed air heats up to such an extent that the plastic in contact with the air will overheat and possibly be burnt. Even if the air is not hot enough to burn the plastic, it may prevent the filling of any small corners where air is trapped and cause incomplete filling of the cavity. Most cavity spaces can be vented successfully at the parting line, but often additional vents, especially in deep recesses or in ribs, are necessary. Another venting problem arises when plastic fronts flowing from two or more directions collide and trap air between them. Unless vents are placed there the plastic will not ``knit'' and may even leave a hole in the wall of the product. This can be the case when more than one gate feeds one cavity space, or when the plastic flow splits in two after leaving the gate, due to the shape of the product or the location of the gate. Within the cavity space, plastic always flows along the path of least resistance, and if there are thinner areas, they will fill only after the thicker sections are full.

Venting in an Injection Mould

21

DYNAMIC INDUSTRIES

Cooling:
Cooling and productivity are closely tied. In injection moulding, the plastic is heated in the moulding machine to its processing (melt) temperature by adding energy in the form of heat, which is mostly generated by the rotation (work) of the extruder screw. After injection, the plastic must be cooled; in other words, the heat energy in the plastic must be removed by cooling, so that the moulded piece becomes rigid enough for ejection. Cooling may proceed slowly, by just letting the heat dissipate into the mould and from there into the environment. This is not suitable for large production, but for very short runs ``artificial'' cooling of a mould is not always required. However, for a production mould, good cooling to remove the heat efficiently is very important. Moulds are usually built with cooling channels. These channels are usually connected in series with one inlet and one outlet for water flow.

Cooling of an Injection Mould

22

DYNAMIC INDUSTRIES

Ejection:
After the plastic in the cavity spaces has cooled sufficiently and is rigid enough and ready for removal, the mould halves move apart, allowing sufficient space between the mould halves for removal of the product. As with cooling, the complexity of any provision for ejection from the mould is a question of the desired productivity. Some products don't need any provision within the mould for ejection. For example, a quick blast from an air jet applied manually by an operator and directed at the parting line can lift a (simple) product off the core or out of the cavity, but this would not be practical in most moulds, and is rarely used for real production. Locating ejectors is important. Balanced pressure on the part by all ejectors is important. Accurate location of ejectors on part walls, ribs, and bosses is highly desirable. Part appearance and function must be taken into consideration when designing the ejection system. Stripper Plate ejection is highly preferred due to the even pressure and minimal witness marks on the part.

Usually, the products are ejected by one of the following methods:

(1) (2) (3) (4) (5) (6) Pin (and sleeve) Stripper plate or stripper ring Air alone Air assist Combination of any of the above (1), (2), (3), and (4) Unscrewing, in case of screw caps, etc.

Use of Ejector Pin and Ejector Plate in a Mould 23

DYNAMIC INDUSTRIES

Machining and Finishing processes of mould

CNC Machining:
It is a process used in the manufacturing sector that involves the use of computers to control machine tools. Tools that can be controlled in this manner include lathes, mills, routers and grinders. The CNC in CNC Machining stands for Computer Numerical Control. On the surface, it may look like a normal PC controlling the machines, but the computer's unique software and control console are what really sets the system apart for use in CNC machining. Under CNC Machining, machine tools function through numerical control. A computer program is customized for an object and the machines are programmed with CNC machining language (called G-code) that essentially controls all features like feed rate, coordination, location and speeds. With CNC machining, the computer can control exact positioning and velocity. CNC machining is used in manufacturing both metal and plastic parts. First a CAD drawing is created (either 2D or 3D), and then a code is created that the CNC machine will understand. The program is loaded and finally an operator runs a test of the program to ensure there are no problems. This trial run is referred to as "cutting air" and it is an important step because any mistake with speed and tool position could result in a scraped part or a damaged machine. Computer Numerical Control (CNC) is a specialized and versatile form of soft Automation and its applications cover many kinds, although it was initially developed to control the motion and operation of machine tools. Computer Numerical Control may be considered to be a means of operating a machine through the use of discrete numerical values fed into the machine, where the required input technical information is stored on a kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine follows a predetermined sequence of machining operations at the predetermined speeds necessary to produce a work piece of the right shape and size and thus according to

24

DYNAMIC INDUSTRIES

completely predictable results. A different product can be produced through reprogramming and a low-quantity production run of different products is justified.

CNC Control Systems:

Open Loop Systems:
Open loop systems have no access to the real time data about the performance of the system and therefore no immediate corrective action can be taken in case of system disturbance. This system is normally applied only to the case where the output is almost constant and predictable. Therefore, an open loop system is unlikely to be used to control machine tools since the cutting force and loading of a machine tool is never a constant. The only exception is the wire cut machine for which some machine tool builders still prefer to use an open loop system because there is virtually no cutting force in wire cut machining.

Block diagram of an open loop system

Close Loop Systems:

In a close loop system, feedback devices closely monitor the output and any disturbance will be corrected in the first instance. Therefore high system accuracy is achievable. This system is more powerful than the open loop system and can be applied to the case where the output is subjected to frequent change. Nowadays, almost all CNC machines use this control system.

Block diagram of a close loop system 25

DYNAMIC INDUSTRIES

Features of CNC:
Computer NC systems include additional features beyond what is feasible with conventional hard-wired NC. These features, many of which are standard on most CNC Machine Control units (MCU), include the following:

Storage of more than one part program:

With improvements in computer storage technology, newer CNC controllers have sufficient capacity to store multiple programs. Controller manufacturers generally offer one or more memory expansions as options to the MCU

Various forms of program input:

Whereas conventional (hard-wired) MCUs are limited to punched tape as the input medium for entering part programs, CNC controllers generally possess multiple data entry capabilities, such as punched tape, magnetic tape, floppy diskettes, RS-232 communications with external computers, and manual data input (operator entry of program).

Program editing at the machine tool:

CNC permits a part program to be edited while it resides in the MCU computer memory. Hence, a part program can be tested and corrected entirely at the machine site, rather than being returned to the programming office for corrections. In addition to part program corrections, editing also permits cutting conditions in the machining cycle to be optimized. After the program has been corrected and optimized, the revised version can be stored on punched tape or other media for future use.

Fixed cycles and programming subroutines:

The increased memory capacity and the ability to program the control computer provide the opportunity to store frequently used machining cycles as macros, which can be called by the part program. Instead of writing the full instructions for
26

DYNAMIC INDUSTRIES

the particular cycle into every program, a programmer includes a call statement in the part program to indicate that the macro cycle should be executed. These cycl es often require that certain parameters be defined, for example, a bolt hole circle, in which the diameter of the bolt circle, the spacing of the bolt holes, and other parameters must be specified.

Interpolation:

Some of the interpolation schemes are normally executed only on a CNC system because of computational requirements. Linear and circular interpolation are sometimes hard-wired into the control unit, but helical, parabolic, and cubic interpolations are usually executed by a stored program algorithm.

Positioning features for setup:

Setting up the machine tool for a given work part involves installing and aligning a fixture on the machine tool table. This must be accomplished so that the machine axes are established with respect to the work part. The alignment task can be facilitated using certain features made possible by software options in the CNC system. Position set is one of the features. With position set, the operator is not required to locate the fixture on the machine table with extreme accuracy. Instead, the machine tool axes are referenced to the location of the fixture using a target point or set of target points on the work or fixture.

Cutter length and size compensation: In older

style controls, cutter dimensions hade to be set precisely to agree with the tool path defined in the part program. Alternative methods for ensuring accurate tool path definition have been incorporated into the CNC controls. One method involves manually entering the actual tool dimensions into the MCU. These actual dimensions may differ from those originally programmed. Compensations are then automatically made in the computed tool path. Another method involves use of a tool length sensor built into the machine. In this technique, the cutter is mounted in the spindle and the sensor measures its length. This measured value is then used to correct the programmed tool path. This feature is applicable when the cutter moves at high feed rates. It is designed to avoid tool marks on the work surface that would be generated due to machine tool dynamics when the cutter path changes abruptly. Instead, the feed rate is smoothly
27

Acceleration and deceleration calculation:

DYNAMIC INDUSTRIES

decelerated in anticipation of a tool path change and then accelerated back up to the programmed feed rate after the direction change.

Communications interface:
With the trend toward interfacing and networking in plants today, most modern CNC controllers are equipped with a standard RS-232 or other communications interface to link the machine to other computers and computer- driven devices. This is useful for various applications, such as (1)downloading part programs from a central data file; (2)collecting operational data such as workpiece counts, cycle times, and machine utilization; and (3)interfacing with peripheral equipment, such as robots that unload and load parts.

Basic CNC Principles:

All computer controlled machines are able to accurately and repeatedly control motion in various directions. Each of these directions of motion is called an axis. Depending on the machine type there are commonly two to five axes. Additionally, a CNC axis may be either a linear axis in which movement is in a straight line, or a rotary axis with motion following a circular path.

Linear Axis and Rotary Axis of CNC

28

DYNAMIC INDUSTRIES

Motion Control:
The most basic function of any CNC machine is automatic, precise, and consistent motion control. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path).

29

DYNAMIC INDUSTRIES

TYPES OF CNC MACHINES BASED ON AXES:

2 & 3 axes CNC machines:
CNC lathes will be coming under 2 axes machines. There will be two axes along which motion takes place. The saddle will be moving longitudinally on the bed (Z-axis) and the cross slide moves transversely on the saddle (along X-axis). In 3-axes machines, there will be one more axis, perpendicular to the above two axes. By the simultaneous control of all the 3 axes, complex surfaces can be machined.

3 Axes CNC Machine

30

DYNAMIC INDUSTRIES

4 & 5 axes CNC machines:

4 and 5 axes CNC machines provide multi-axis machining capabilities beyond the standard 3- axis CNC tool path movements. A 5-axis milling centre includes the three X, Y, Z axes, the A axis which is rotary tilting of the spindle and the B-axis, which can be a rotary index table.

5 Axes CNC Machine

Importance of higher axes machining:

Reduced cycle time by machining complex components using a single setup. In addition to time savings, improved accuracy can also be achieved as positioning errors between setups are eliminated. Improved surface finish and tool life by tilting the tool to maintain optimum tool to part contact all the times. Improved access to under cuts and deep pockets. By tilting the tool, the tool can be made normal to the work surface and the errors may be reduced as the major component of cutting force will be along the tool axis. Higher axes machining has been widely used for machining sculptures surfaces in aerospace and automobile industry.
31

DYNAMIC INDUSTRIES

APPLICATIONS OF CNC MACHINES: CNC machines are widely used in the metal cutting industry and are best used to produce the following types of product:
Parts with complicated contours. Parts requiring close tolerance and/or good repeatability. Parts requiring expensive jigs and fixtures if produced on conventional machines. Parts that may have several engineering changes, such as during the development stage of a prototype. In cases where human errors could be extremely costly. Parts that are needed in a hurry. Small batch lots or short production runs.

Some common types of CNC machines and instruments used in industry are as following:
Drilling Machine. Lathe/ Turning Centre. Milling/ Machining Centre. Turret Press and Punching Machine. Wire cut Electro Discharge Machine (EDM). Grinding Machine. Laser Cutting Machine. Water Jet Cutting Machine. Electro Discharge Machine. Coordinate Measuring Machine Industrial Robot.

32

DYNAMIC INDUSTRIES

OTHER FUNCTIONS OF CNC:

Modern CNC systems have some specially designed functions to simplify the manual programming. Some of the functions are: a. Mirror Image:
This is the function that converts the programmed path to its mirror image, which is identical in dimensions but geometrically opposite about one or two axes.

b. Programme Repetition and Looping:

In actual machining, it is not always possible to machine to the final dimension in one go. This function enables the looping of a portion of the programme so that portion can be executed repeatedly.

c. Pocketing Cycle:
Pocketing is a common process in machining. This is to excavate the material within a boundary normally in zigzag path and layer by layer. In a pocketing cycle, the pattern of cutting is pre-determined. The user is required to input parameters including the length, width and depth of the pocket, tool path spacing, and layer depth. The CNC system will then automatically work out the tool path.

d. Drilling, Boring, Reaming and Tapping Cycle:

This is similar to pocketing cycle. In this function, the drilling pattern is predetermined by the CNC system. What the user has to do is to input the required parameters such as the total depth of the hole, the down feed depth, the relief height and the dwell time at the bottom of the hole.

33

DYNAMIC INDUSTRIES

Uses of CNC milling in plastic injection mould making Some of the main operations done by CNC milling are:

Mould base work. The insert pockets, the core and cavity pockets, interlock pockets, slide openings, many water-lines, in fact, just about everything you find in a mould base. Roughing and semi-finishing of cores and cavity blocks. Now, with hard-milling a common operation, many cores and cavities are finished in the CNC. As much of the detail as possible is milled because it is so much faster than EDM or grinding. Electrodes are made in the CNC. Both copper and graphite electrodes are made here. Once the program is made, you can make as many duplicates as you want, even for replacement parts far in the future. All kinds of inserts, slide components, lifter details, and other features used in injection moulds. Another close relative is the 5 axis CNC milling machine. These are highly sophisticated machines that are becoming increasingly common. They are very versatile and able to machine 5 sides of a workpiece in one setup, plus the infinite number of angles sometimes required.

34

DYNAMIC INDUSTRIES

ELECTRICAL DISCHARGE MACHINE

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion. In this process an electric spark is used as the cutting tool to cut (erode) the workpiece to produce the finished part to the desired shape. The metal-removal process is performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current through the electrode to the workpiece. This removes (erodes) very tiny pieces of metal from the workpiece at a controlled rate. In EDM, a potential difference is applied between the tool and workpiece. Both the tool and the work material are to be conductors of electricity. The tool and the work material are immersed in a dielectric medium. Generally kerosene or deionized water is used as the dielectric medium. A gap is maintained between the tool and the workpiece. Depending upon the applied potential difference and the gap between the tool and workpiece, an electric field would be established. Generally the tool is connected to the negative terminal of the generator and the workpiece is connected to positive terminal. When the power is supplied a large number of electrons will flow from the tool to the job and ions from the job to the tool. This is called avalanche motion of electrons. Such movement of electrons and ions can be visually seen as a spark. Thus the electrical energy is dissipated as the thermal energy of the spark. The high speed electrons then impinge on the job and ions on the tool. The kinetic energy of the electrons and ions on impact with the surface of the job and tool respectively would be converted into thermal energy or heat flux. Such intense localised heat flux leads to extreme instantaneous confined rise in temperature which would be in excess of 10,000oC. Such localised extreme rise in temperature leads to material removal. Material removal occurs due to instant vapourisation of the material as well as due to melting. The molten metal is not removed completely but only partially. Generally the workpiece is made positive and the tool negative. Hence, the electrons strike the job leading to crater formation due to high temperature and melting and material removal. Similarly, the positive ions impinge on the tool leading to tool wear. In EDM, the generator is used to apply voltage pulses between the tool and the job. A constant voltage is not applied. The sparks get distributed all over the tool surface leading to uniformly distributed material removal under the tool.

35

DYNAMIC INDUSTRIES

EDM

Characteristics of EDM:
(a) The process can be used to machine any work material if it is electrically conductive (b) Material removal depends on mainly thermal properties of the work material rather than its strength, hardness etc. (c) In EDM there is a physical tool and geometry of the tool is the positive impression of the hole or geometric feature machined (d) The tool has to be electrically conductive as well. The tool wear once again depends on the thermal properties of the tool material (e) Though the local temperature rise is rather high, still due to very small pulse on time, there is not enough time for the heat to diffuse and thus almost no increase in bulk temperature takes place. Thus the heat affected zone is limited to 2 4 m of the spark crater (f) However rapid heating and cooling and local high temperature leads to surface hardening which may be desirable in some applications
36

DYNAMIC INDUSTRIES

(g) Though there is a possibility of taper cut and overcut in EDM, but they can be controlled and avoided by using Insulation over the EDM tool.

Prevention of Overcut

DIELECTRIC
In EDM, material removal mainly occurs due to thermal evaporation and melting. As thermal processing is required to be carried out in absence of oxygen so that the process can be controlled and oxidation avoided. Oxidation often leads to poor surface conductivity (electrical) of the workpiece hindering further machining. Hence, dielectric fluid should provide an oxygen free machining environment. Further it should have enough strong dielectric resistance so that it does not breakdown electrically too easily but at the same time ionise when electrons collide with its molecule. Moreover, during sparking it should be thermally resistant as well. Generally kerosene and deionised water is used as dielectric fluid in EDM. Tap water cannot be used as it ionises too early and thus breakdown due to presence of salts as impurities occur. Dielectric medium is generally flushed around the spark zone. It is also applied through the tool to achieve efficient removal of molten material.

ELECTRODE MATERIAL
Electrode material should be such that it would not undergo much tool wear when it is impinged by positive ions. Thus the localised temperature rise has to be less by tailoring or properly choosing its properties or even when temperature increases, there would be less melting. Further, the tool should be easi.ly workable as intricate shaped geometric features are machined in EDM.
37

DYNAMIC INDUSTRIES

The basic characteristics of electrode materials are:

High electrical conductivity electrons are cold emitted more easily and there is less bulk electrical heating High thermal conductivity for the same heat load, the local temperature rise would be less due to faster heat conducted to the bulk of the tool and thus less tool wear Higher density for the same heat load and same tool wear by weight there would be less volume removal or tool wear and thus less dimensional loss or inaccuracy High melting point high melting point leads to less tool wear due to less tool material melting for the same heat load Easy manufacturability Cost cheap

The followings are the different electrode materials which are used commonly in the industry:
Graphite Electrolytic oxygen free copper Tellurium copper 99% Cu + 0.5% tellurium Brass

Tools of EDM 38

DYNAMIC INDUSTRIES

EDM Operation on a Mould

With a combination of EDM and CNC machining, you can obtain injection moulds made of aluminium with sharp, clear features.

The best time to use EDM during the mould building process:

Table to Show when and Why to Use EDM 39

DYNAMIC INDUSTRIES

Mould of fan shroud of TATA Motors EURO V standard based car:

The Final Product:

40

DYNAMIC INDUSTRIES

MAIN PROJECT: Comparison of CNC milling and Conventional Milling and to know which is better:
Main advantages of CNC over Conventional:
Computer numerical control (CNC) machinery has improved woodworking by automating critical functions that once required manual input. In doing so, it has made high production milling, routing and other practices more feasible in terms of manpower, and narrowed the gap between proficient and expert machine operators.

Better Production Capacity:

Due to their automatic operation and excellent cutting ability, CNC machines can produce multiple pieces in remarkably less time than standard machines. The production capacity of a CNC machine depends on its table size and number of cutter heads. Opting for an oversized table and five cutter heads can create a dramatic surge in production.

Increased Cutting Accuracy:

CNC milling cuts with more accuracy than standard machinery for an obvious reason: software programs control it. In addition to increasing design options, these programs refine cutting accuracy, creating consistent precision. CNC millers cut with greater accuracy than standard ones, producing intricate designs that would be impossible otherwise.

Faster workpiece machining:

Since current model CNC machine tools are guarded (splash guards, windows, etc.) in a much better manner than most conventional milling tools, users can apply the most efficient cutting conditions to attain the best cycle times. Conventional Milling machinists tend to nurse-along their machining operations to minimize the chips and coolant are constantly thrown from the work area.

Complexity of work pieces to be machined:

CNC machines can generate very complex motions, making it possible to machine shapes that cannot be generated on conventional machine tools.
41

DYNAMIC INDUSTRIES

Reduced Rework:
As a consequence of increased cutting accuracy, CNC milling machine reduce rework, helping the production process to maintain fluidity and economy. As with increased cutting accuracy, the reason for reduced rework is computer control that eliminates human error.

Reduced Waste:
Reduced rework and reduced waste go hand-in-hand. If your company has a high production rate, reducing waste pieces can be a valuable cost saving measure. Trash cans full of discarded work pieces are not a sign of booming business; they are a sign business is conducted ineffectively from a machining standpoint. CNC machining can help to change this.

Easier to Operate:
CNC milling machines require training and practice to operate correctly. But once you learn the ropes, their operation becomes second nature. Unlike older machines that required constant dexterity from their operators, CNC machines allow operators to oversee the production process as they manipulate a computer as needed.

Feedback to production control:

Since CNC milling machines have a built-in computer, they can relay information about how they're running to other parts of the company using the same network that other computers in the company are using.

Automatic working:
When it comes to actually running production (after programming and setup are completed), just about every major problem faced by a conventional milling machinist's workload has been solved by CNC machine tools. While a conventional milling machinist must be involved with everything happening on a conventional machine, once a CNC operator loads a workpiece and activates the cycle, the CNC machine takes over, completing all tasks a manual machinist normally does. Specific examples include tool changing, speed, feed, and coolant selection, generating the motion needed to machine work pieces (a conventional machinist turns hand-wheels to cause motion), and in some cases, even chip removal.

42

DYNAMIC INDUSTRIES

Use of designing software:

Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money.

Experimental Calculation to check whether CNC milling is better or conventional milling: 1. CNC:
Running cost per hour: Rs. 600/Labour cost: Rs. 30/- per hour Tool set up time: 10 mins. Machining Time: 4 Hours. The total cost of running the CNC for 4 hours is Rs. 2400/Here, in this case the labour cost will be considered for only one hour because the CNC is run by a computer program automatically so there is no need of any labour after setting up of CNC.

2. Conventional Milling:
Running cost per hour: Rs. 100/Labour cost: Rs. 25/- per hour Tool set up time: 20 mins. Machining Time: 8 Hours. The total cost of running the Conventional milling for 8 hours is Rs. 800/In Conventional milling a person is required to run the machine to get the desired output. So, the labour cost after 8 hours will be Rs. 800/-.

43

DYNAMIC INDUSTRIES

Observations:
We can observe that the tool set-up time and machining time on CNC is half of that of Conventional milling and the total running time of CNC is also half of Conventional milling. This shows that a lot of time is saved on CNC than Conventional Milling. The machining time of CNC is also half of Conventional Milling machine i.e. in CNC two jobs can be machined in 8 hours whereas in Conventional Milling machine only one can be completed. One of the main thing observed was the surface finishing on CNC milling was much better than Conventional milling machine. Another main thing observed is that the total cost of CNC milling is much higher than Conventional milling machine.

Result:
Profit earned by the manufacturer is more on CNC and the customers expense is more but at the same time the surface finish on CNC is also of high quality and as per customers requirement they want to have a good high quality product. So, CNC milling is a much better choice than using conventional milling because it will benefit both the manufacturer and the customer. CNC machining can be a cost efficient process, particularly for high volume production runs.

Conclusion:
After doing my Technical Internship at Dynamic Industries, I have understood how the moulds are manufactured and the various machines which are used in manufacturing of moulds like CNC, EDM etc. By comparing CNC and Conventional milling method, I found that the cost of machining of CNC is more than the Conventional milling so the manufacturer will earn more by using CNC milling machines instead of Conventional milling methods. But the customer wants that the product should be accurate and of a very high quality and this is achieved only in CNC milling so the CNC milling will benefit both the customer and manufacturer. So, the CNC milling method is much better than Conventional milling method.

44

DYNAMIC INDUSTRIES

References:
http://www.global-plastic-injection-molding.com
http://cncmachinetools.org

http://www.automationsol.com http://www.ehow.com Malloy, Robert A. (1994). Plastic Part Design for Injection Moulding. Munich Vienna New York. Hanser.Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994). Manufacturing Processes Reference Guide. Industrial Press, Inc.

45

DYNAMIC INDUSTRIES

46