Design and Fabrication of Injection Mold of a
Thermoplastic Component
Final Year Project Report
Group: 49
Batch: 2012-2013
Daniyal Najam
ME-12179
Umer Iftikhar
ME-12330
Talha Rajput
ME-12331
Rafiullah
ME-12332
Internal Advisor:
Ms. Erum Khan
Assistant Professor
Department of Mechanical Engineering
External Advisor:
Mr. Sami ud din
Manager Business Development
Tooling Technologies and Services.
Reference#: 06/2005
DEPARTMENT OF MECHANICAL ENGINEERING
NED UNIVERSITY OF ENGINEERING AND
TECHNOLOGY
i
CERTIFICATE
It is to certify that the following students have completed their project Design and
Fabrication of Injection Mold of a Thermoplastic Component satisfactorily.
Group: 49
Name
Batch: 2012-2013
Seat No.
Daniyal Najam
ME-12179
Umer Iftikhar
ME-12330
Talha Rajput
ME-12331
Rafiullah
ME-12332
Internal Advisor
External Advisor
Ms. Erum Khan
Mr. Sami ud din
Assistant Professor
Manager Business Development
Department of Mechanical Engineering
Tooling Technologies and Services.
NEDUniversity of Engg. & Tech.
Project Coordinator
Mr. Masood Ahmad Khan
Department of Mechanical Engineering
NEDUniversity of Engg. & Tech.
DEPARTMENT OF MECHANICAL ENGINEERINGNED
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
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ACKNOWLEDGEMENTS
First of all, we would like to thank Almighty Allah for giving us the ability and
strength to pursue this project and to complete it successfully.
Secondly, we would like to thank our external advisor Mr. Sami ud din, Manager
Business Development at Tooling Technologies and Services for providing complete
guidance throughout this project and never stepping back whenever we needed him
the most. He has always been available to us despite his busy schedule to answer our
queries and guiding us how to approach towards our project step by step.
Last but not the least, we would like to thank and acknowledge the efforts of our
internal advisor Ms. Erum Khan for providing us with all the guidance we needed
throughout our evaluations and the initiation of our project
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ABSTRACT
This project was meant to provide us some flavor of this huge molding industry.
Injection Moldings considered being one of the most prominent processes for mass
production of plastic products. One of the biggest challenges, facing injection molders
today, is to determine the proper settings for the IM process variables. Selecting the
proper settings for an injection molding process is crucial because the behavior of the
polymeric material during shaping is highly influenced by the process variables.
Consequently, the process variables govern the quality of the parts produced. The
difficulty of optimizing an injection molding process is that the performance measures
usually show conflicting behavior. Therefore, a compromise must be found between
all of the performance measures of interest. Our concern and objective was mainly the
mechanical design and fabrication of injection mold but we have covered other
aspects in this report as well.
In the first half of this report we give an overview of Dies and mold technology.
In the second half, we discuss the different aspects of mechanical design i.e. clamping
force, pressure force, heat transfer and shrinkage produced.
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TABLES OF CONTENTS
1.1Polymer
1.2 Classification of Polymers
1.2.1Thermoplastic
1.2.1.1 Crystalline Thermoplastic
1.2.1.2 Amorphous Thermoplastic
1.2.1(A) Advantages of Thermoplastics
1.2.1(B) Disadvantages Of Thermoplastics
1.2.2 Thermosets
1.2.2(A) Advantages of Thermosets
1.2.2(B) Disadvantages Of Thermosets
2. Plastic Processing
2.1 Extrusion
2.1.1 Direct Extrusion
2.1.2 Indirect Extrusion
2.1.3 Hydrostatic Extrusion
2.1.4 Impact Extrusion
2.2 Blow Molding
2.2.1 Extrusion Blow Molding
2.2.2 Rotational Molding
10
2.3 Thermoforming
10
2.4 Compression Molding
11
2.5 Transfer Molding
12
2.6 Castings
13
3. Material for Injection Mold
14
3.1 Steels
15
3.2 Non-Ferrous Metallic Materials
15
3.1 Steels
15
3.1.1 Case Hardening Steels
16
3.1.2 Nitriding Steels
16
3.1.3 Through Hardening Steels
16
3.1.4 Tempered Steel
16
3.1.5 Martensitic Hardness Steel
17
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3.1.6 Refined Steel
17
3.2 Non-Ferrous Metallic Materials
17
3.2.1 Copper Allows
17
3.2.2 Zinc Alloys
17
3.2.3 Aluminum Alloys
18
3.2.4 Bismuth Tin Alloys
18
4. Mold Making
19
4.1 Cavity Producing
20
4.1.1 Casting
20
4.1.2 Sand Casting
20
4.1.3 Precision Cast-Ceramic Casting
21
4.1.4 Die Casting
22
4.1.5 Metal Spraying
23
4.1.6 Electrolytic Deposition
25
4.1.7 Hobbing
26
4.1.8 Machining and Other Material Removing Operations
27
4.2 Surface Treatment (Finishing)
28
4.2.1
Grinding and Polishing (Manual or Assisted)
29
4.2.2
Sand Blasting [Jet Lapping]
29
4.2.3
Pressure Lapping
29
4.2.4
Cutting by Spark Erosion with Traveling Wire
30
4.2.5
Chemical Material Removing-Etching
30
4.2.6
Spark Erosion or Chemical Dissolution
32
4.2.7
Electrical Discharge Machining
33
4.2.7.1 EDM Parameter Trade Off
33
4.2.7.2 Typical EDM Parameters
33
4.2.7.3 Wear Ratio
34
4.2.7.4 Electrode Material and Properties
34
4.2.7.5 Dielectric Properties
34
4.2.7.6 EDM Surface Characteristics
34
4.2.7.7 Typical Micro EDM Characteristics
35
5. Injection Molding Machine
36
5.1 Machine Components
36
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5.1.1 Injection System
36
5.1.2 The Hopper
37
5.1.3 The Barrel
37
5.1.4 The Reciprocating Screw
37
5.1.5 The Nozzle
38
5.2 Injection Molding Process
38
5.2.1 Clamping
38
5.2.2 Injection
39
5.2.3 Cooling
39
5.2.4 Ejection
39
5.3 Flow Chart
40
5.4 Types of Injection Molding Machine
41
5.4.1 The Ram Machine
41
5.4.2 Reciprocating Screw
41
6. Injection Mold
42
6.1 Types of Injection Mold
42
6.1.1 Cold Runner Mold
42
6.1.1.1 Types of Cold Runner Mold
42
A) Two Plate Mold
42
B) Three Plate Mold
43
6.1.1(A) Disadvantages
43
6.1.1(B) Advantages
43
6.1.2 Hot Runner Mold
44
6.1.2.1 Types of Hot Runner Mold
44
1) Two Plate Mold
44
6.1.2.1.1 Externally Heated Hot Runner Mold
44
6.1.2.1.2 Internally Heated Hot Runner Mold
44
6.1.2.1.3 Insulated Hot Runner Mold
45
6.1.2.1.4 The Hot Manifold Mold
45
6.1.2.1.5 The Stacked Mold
45
6.2 Components of Injection Mold
46
6.2.1 Function of Injection Mold Components
6.3 Types of Runner System
47
48
6.3.1 Standard Runner System
48
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6.3.2 Hot Runner System
48
6.3.3 Cold Runner System
49
6.4 Design of Runner
50
6.5 Design of Sprue
51
6.6 Design of Gates
51
6.6.1 Position of the Gate at the Part
6.7 Cavity Layout
52
53
6.7.1 Circular Layout
53
6.7.2 Layout in Series
54
6.7.3 Symmetrical Layouts
54
6.8 Heat Exchange System
55
6.8.1 Design Parameters for Heat Exchange System
56
1. Cooling Time
56
2. Balance of Heat Flows
57
6.9 Ejection Systems
59
6.10 Venting Of Mold
61
7. Design of an Injection Mold
63
7.1 Part Modeling
63
7.2 No of Cavities
63
7.3 Calculations
63
7.3.1 Area of Runner
63
7.3.2 Volume of Runner
63
7.3.3 Clamping Force
63
7.3.4 Clamp Area
64
7.3.5 Cooling Time
64
7.3.6 Balance of Heat Flow
65
7.3.7 Heat Flux from Molding
65
7.3.8 Heat Flux Balance
66
7.3.9 Heat Flow by Convection
66
7.3.10 Heat Flow from Radiation at The Side Of The Mold
66
8. Defects in Injection Molding and Their Solution
68
8.1 Short Shot Defect
68
8.2 Flash Defect
68
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8.3 Sink Defect
69
8.4 Splay Defect
70
8.5 Warpage Defect
70
8.6 Burn Marks Defect
71
8.7 Voids Defect
72
8.8 Bubbles Defect
72
8.9 Weld Lines Defect
73
9. Mold Designing Using Pro-Engineer Wild Fire 5.0 &
Autodesk Moldflow Advisor 2017
74
9.1 Terminologies Used In Pro-Engineer
74
9.2 Process Flow of Mold Design
75
10. Plastic Advisor Report
76-101
11. Gant Chart
102
12. Minutes of Meeting
103-112
13. Appendix
114-118
14. References
119
15. Drawings
120-131
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