project work

 CENTRAL INSTITUTE OF PETROCHEMICAL  ENGINEERING &. TECHNOLOGY CIPET (CSTS) IMPHAL  

                                                                   A                                                                                                                                              PROJECT REPORT

                                                  ON                                                                                                                                                                                                    

“ PRODUCTION OF 20 Ltr. JAR. CAP BY INJECTION MOULDING MACHINE”

                                                          

 

    sir. I.  Ranjit Singh                                 Sir. I.  Ranjit Singh   

   (PROJECT GUIDE)                                 (COURSE-IN-CHARGE)                                  

                                                            

                                            Sir Imo Thiyam   

                                       (CENTRE IN-CHARGE)                                                                                                                        

                                                      Submitted by

                                   DPT VI^th Sem. Batch No. – 14th

(Academic Year 2020-23)

 

       STUDENT NAME Hall Ticket No.

 

1.  BORUAH- **********

2. Dutta-         **********

 

 

CENTRAL INSTITUTE OF PETROCHEMICAL ENGINEERING & TECHNOLOGY (CIPET)

Department of Chemicals & Petrochemicals Ministry of Chemical & Fertilizers, Govt. of India

C-12, Industrial Estate, Takyelpat,

Imphal – 795 001

Email: imphal@cipet.gov.in 

Website: www.cipet.gov.in

  ROJECT WORK 2020-2023

  CENTRAL INSTITUTE OF PETROCHEMICAL  ENGINEERING  &                                TECHNOLOGY (CIPET)

 

BONAFIDE CERTIFICATE

 

This is to certify that this project report entitled Study on “PROJECTION, PRODUCTION OF 20 Ltr. JAR. CAP BY INJECTION MOULDING MACHINE” is the bonafide work done by “ 1. Mainee Boruah, 2.Lajmi Saikia & 3.Dipshika Dutta ”  of the final year Diploma in Plastics Engineering & Technology course in Central Institute of Plastics Engineering & Technology, Imphal, Manipur during the academic year of 2020-2023 as partial fulfillment of the course.

 

 

 

      Signature                                           Signature

Mr. S.Sanjoy Salam                                  Mr. I. Ranjit Singh(Project Guide)           Course In-Charge)

  Signature                                                                Signature

Mr. I. Ranjit Singh                                                                    Mr. Imo Thiyam

 (Training In-Charge)    (Centre In-Charge)

 

                                                              Signature

External Examiner with Seal

 

  

 ACKNOWLEDGEMENT

 

Most Humbly, We the project fellows, 1.  Boruah 2.  Saikia & 3.  Dutta (DPT-VI^th Semester of 2020-23 batches) would like to express our profound and sincere gratitude to our most reverend Centre In-charge, Shri Imo Thiyam for allowing us to carry out a project work as partial fulfillment of our course. We are also indebted to our Training In-charge/ course In-charge, Shri I. Ranjit Singh for giving us an opportunity to complete the project work.

We nevertheless, extend our utmost and sincere gratitude to our project guide Sir. Sanjoy and owe his relentless whole hearted guidance and co-operation, intellectual contribution & generous suggestion which help and facilitate us to complete our project work successfully and properly.

We once again would prefer to say our heartiest intimacy and thanks to specially our Project Guide Sir Sanjoy to aware us time to time about project & provide every extreme help from processing to acquire the required data regarding completion of project work who assisted us with perpetual generosity and providing us the facilities of library during preparation of our project work.

Lastly but not least, we are indeed indebted to our fraternity for their sincere co-operation, valuable suggestions and encouragement in completing the project in time.

 

Project Fellow

 

     Name :

1. BORUAH              ( ******** )

2. SAIKIA                  ( ********)

3. DUTTA                       ( *******   )

 

                        DPT-VI^th Semester (14^th Batch) CIPET, Imphal, Manipur.

Content

S. No.	Description	Page No.
1.	Introduction	5 to 6
2.	a. PLASTICS  MATERIAL	7 to 8
3.	INJECTION MOULDING TECHNIQUE · PRINCIPLE · PART AND FUNCTION · PROCESS PARAMETER · CYCLE TIME ANALAYSIS	9 to 21
4.	CAUSE AND REMEDIES	22 to 25
5.	CONCLUSION	26
6.	BIBLIOGRAPHY	27

INTRODUCTION

 

Water Storage Container’s JAR CAP is an indispensable component without it the water contained inside would quickly become contaminated with debris & bacteria in addition to a host of other undesirable creatures. To keep the water fresh, cool & clean you are going to want to invest in water Storage Container JAR CAP that can with stand the elements & ensure as tight seal with your Water Storage Container (jar).

Features:

· Elegant design

· Dimensionally accurate

· Easy to fit

PLASTICS: -

Plastics are any synthetic or semi-synthetic organic polymer. Most industrial plastic is made from petrochemical. The name “plastic” re jifers to property of plastic city which is the ability to deform without breaking.

1.  PLASTIC WATER STORAGE CONTAINER : -

FIGURE: - WATER STORAGE CONTAINERS

             2. WHAT DEFINES A SUCCESSFUL WATER CONTAINERS CAP?

Ø Durability & compliance with established safety regulations.

Ø The presence of a breather to ensure consistent freshness & purity of the water contained inside the Containers.

Well-insulted & capable of keeping the temperature of the water consistent & with in a define range no matter the climate or weather. Most

 

TYPES OF RAW MATERIAL

MATERIALS: -

These materials are used to make water storage Containers as well as CAP

 

Polymer                          Condition                         Crystallinity [%]

LDPE                               All                                        40-50

LLDPE                             All                                         60

HDPE                              All                                         60-80

Polypropylene (PP)        Rapidly cooled                       45-50

Polyethylene                      Slowly cooled                      20-30

Terephthalate (PET)

Polyethylene                Quenched                                   0-10

Terephthalate (PET)

 

Polymer Percent of       Molders %

LDPE                               86

LLDPE                             69

HDPE                               33

Polypropylene                   22

Nylon (All Types)              21

Polycarbonate                   20

PVC (All Types)                 25

LLDPE: -

Linear low density polyethylene normally called as LLDPE is used as a raw material. Following are the grade number of same.

Injection moulding grade of LLDPE is LL36IA045.

Where, 

LL - stands of linear low density.

36 -  Stands for density 0.936 gms per cubic centimeter.

I -  stands for injection moulding grade.    

A - Stands for prime grade material.

045 - Stands for melt flow index (4.5 gms/10 min).

In the same way any company’s raw material grade can be interpreted. Raw material is in the form of plane natural colorless granules. It is to be compound and granulated with master batch as additives to convert in black and milky white or blue Colour or any other colour.

ADDITIVES: -

Some additives are to be added to resin for making its suitable for particular application, for example carbon black is to be compounded with base resin for UV protection, some color UV grade master batch are also available to make color product which are exposed to sunlight.

Titanium based master batch are used to make the resin white (milky white) anti-static agent are also available which keep product away from dust.

Following are the details of the mater batch normally required: -

 

Master batch white: Colour: Milky White

Base:  LDPE

Titanium loading: High

Master batch blue: Colour: Dark Blue

STRUCTURE OF LLDPE MATERIAL: -

Polyethylene (PE) is a chemically simple molecule:5

 

CH₃-CH₂-(-CH₂ –CH₂-) _x-CH₂-CH₂

 NJECTION MOULDING TECHNIQUE TO MAKE THE CAP 

The CAP Manufacturing technique they are given below: -

A. Introduction

B. Part and function

C. Process parameters

D. Cycle time analysis

A. INJECTION MOULDING:

INTRODUCTION: -

The injection machine is machines that melt plasticized the plastic material inside the heating cylinder and inject this in to the mould tool to create the molded product by solidifying inside it. The injection machine is constructed of a mould clamping device that opens and closes the mould tool and devices that plasticized and inject the molding martial inside the closed mould

fig. - injection mould

fig - injection mould cap

PROCESS OF CAP MAKING BY INJECTION MOULDING MACHINE: -

· Feed of row material in to the hopper

· Plasticized material in to the barrel

· Mould close

· Injection moulding (mould filling)

· Holding time and Pressure

· Cooling and Refill

· Screw Back

· Mould Open

· Ejection

FEED OF ROW MATERIAL IN TO THE HOPPER: - 

In this process first we feed the raw material in to hopper with the help of hopper loader. The row material for injection molding is most commonly supplied in pellet or granular form resin pellets are powered in to the feed hopper.

PLASTICIZED MATERIAL IN TO THE BARREL: -

In this process material is feeding in to the barrel and feeding by screw help screw is rotated and material is come in first in feed zone to the beginning of the metering zone screw have flights and these flights compress the material against the inside diameter of the barrel which create s viscous heat this heat is mainly responsible for Melton the material the heater bands outside the barrel help to maintain the material in the molten state and lastly melt material is injected in to the closed mould.

MOULD CLOSE: -

The mould should be closed as quickly as possible without putting undue strain on the mould or the machine.

INJECTION MOULDING (MOULD FILLING): -

  In general, mould filling takes place rapidly however consideration should be given not to generate excessive shear stress. An ideal fill time should prevent large reduction in melt temperature (less than 20) and avoid the generation of high injection pressure (less than 100 MPa).

In injection speed should be adjust to produce the require filling time the injection pressure should be set to enable the injection speed to be achieved.

HOLDING TIME AND PRESSURE:-

During this stage a little more material is forced in to the mould before the gate freezes off the pressure prevents the material in the mould from flowing back in to the injection cylinder

The length of time required for holding depends upon the material being molded, gate, and size, melt and mold temperature. The setting of the hold on stage is critical to the size and dimensional stability of component. There are two aspects of this phase pressurization, when the cavity pressure increases compensation, when cavity pressure decreases.

COOLING AND REFILL: -

The effectively starts after hold no time, should be components become cool enough to be ejected immediately after the screw back phase than no further cooling time is necessary, the total time needed is largely depended on the wall thickness of the component and can be calculated accordingly.

SCREW BACK: -

During the cooling time the screw rotates and is the place backwards along the injection cylinder. The backward displacement takes place during the cooling time of the component. For efficient operations this should never

Cause the cooling time to be extended beyond the necessary time for the cooling of the component.

MOLD OPEN: -

The same principles as apply to mould open as to mould close abrupt opening should be avoided so as to prevent damage to the machine and mould. The distance of opening should be just enough to Allow for the moulding to be ejected clearly. This will keep cycle time to a minimum.

EJECTION: -

Adequate time must be allowed for the ejection of the component from the mould. Ejection can be employed in a semi-auto or automatic mode. Automatic ejection can be mechanical or hydraulic means, or by pneumatic, depending on the ejection system supplied with the tool. Air ejector blows the component clear and can be set on a pulsating or continuously blow sequences. Timers can be use on both hydraulic and air ejection.

fig-injection moulding machine

B. PART AND FUNTION OF INJECTION MOULDING

HOPPER:-

It is a reservoir of the material the material will feed in to the hopper and feed to the main mill by passing through the vibro feeder.

FIG:-HOPPER

MOTOR: -

 It is an electro mechanical device which is convert the electrical energy in to mechanical energy. It helps to rotate the blades to each other by rotating the blades and its cut the granule material in to powder form

FIG:-MOTOR

THERMOCOUPLE:-

It is a electrical device which main function is to sense the temperature of electrical                 heter

FIGURE: - THERMOCOUPLE

BARREL:-

Barrel is a major part that melts resins transmitted from hopper through screws and structured in a way that can heat up resins to the proper temperature. A band heater, which can control temperatures in five sections, is attached outside the barrel. Melted resins are supplied to the mold passing through barrel head, shot-off nozzle, and one-touch nozzle.

FIG:-BARREL

SCREW:-

The 3-stage type screw of the single flight is usually used. The screw design consists of the basic design based on the premises of smooth conveyance of pellet, plasticization for melting, duration and compression, and measurement with a little unevenness. Supply (feed section): Stroke is designed long for conveying and melting the pellet, and increasing plasticization quantity. Compression (compression section): Return the air and water involved in the feed section to the hopper side and deaerate. In addition, a sufficiently melting mechanism is required. Because PC is a high viscosity material, the rapid compression type is unsuitable and moderating compression type with gradually increasing outside diameter is recommended. Measurement (metering section): In order to suppress the measurement unevenness, the measurement stroke is designed long.

                                                                     FIG:-SCREW

NON RETURN VALVE:-

The screw head is equipped with the non return valve to maintain the effective injection pressure by preventing a part of measured resin from backflow through the ditch of the screw at the time of injection.

 

   FIGURE: - NON RETURN VALVE`

NOZZLE:-

A nozzle with the structure without PC stagnation is desirable as possible. Therefore, it is necessary to avoid using the needle shut off nozzle and torpedo nozzle due to resin stagnation. The open nozzle is the best for use. The open nozzle is easy to cause drooling, stringiness, and it is difficult to prevent them but using a long-extended nozzle and adjusting independently the temperature at two separate places of the tip and the bottom, are effective.

HEATER:-

Since PC is molded at high temperature, the heater with heat capacity can be heated to about 370℃ is used, and a band heater is usually used. When disassembling to clean the nozzle and cylinder head and when the heater is stuck with drooling resin, the heater is disconnected. It is necessary to note that it is easy to cause the burn when continuing molding without being aware of heater disconnection.                       

 FIG :- BAND HEATER

INJECTION CYLINDER :-

.The injection cylinder in injection machine is a hydraulic cylinder that pushes the molten plastic into the mold cavity. The injection cylinder has to be able to withstand high temperatures and pressures, and provide smooth and precise movement. The injection cylinder is one of the main components of the injection unit, along with the screw, barrel, nozzle, and valve.

     TIE BAR:-

•  Tie bars support clamping power, and 4 tie bars are located between the fixing  platen and the support platen.      

FIG :-TIE BAR 

PROCESS PROCEDURE/PARAMETERS:-

PROCESS PROCEDURE OF INJECTION MOULDING MACHINE:-

In this process technique high automation of manufacturing and precision and accuracy of paramount importance. Thermoplastics and thermoset is plasticized controlled temperature inside the screw pump (a combination of screw and barrel), then forced under pressure through a nozzle in to into sprue, runners, gates, and cavities of mould. The master polymer undergoes solidification rapidly. The mould is opened, and the part is ejected from the mould. High production runs, low labor costs, high reproducibility of complex details, and excellent finish are the merits. 

Typical Products:- Spools, Bobbing, Packaging, Bottles cap, Automotive Dash board, Gem Clips, Gears, Crates, Buckets, Film, Boxes, Flower pots etc.

A host of injection molding machinery is available today – hand operated machine (oldest) and the state of the 

art microprocessor controller machinery to full fill the spectrum of end product requirements and cost/performance balance.

PARAMETERS FOR INJECTION MOULDING MACHINE:-

         Parameter that helps to select the right options are –

•   setting  up specific performance requirements;
•   Evaluating materials requirements and their processing                capabilities;
•   Designing parts on the basis of material and processing              characteristics, considering  part complexity and size as well         as  a product and process cost compression.
•   Designing and manufacturing tools (mould, dies, etc.) to permit    ease of processing;
•   Setting up the complete line, including auxiliary equipment;
•  Testing and proving quality control, from delivery of the plastics,    through production, to the end product finally.
•   Interfacing all these parameters by using logic and experience    and /or obtaining a required update on technology.

         PROCESSING CHARACTERISTICS:-

There are many processes for plastics. Selection of a process               depends on many factors including:

           - Quantity and production rate

          - Dimensional accuracy and surface finish

          - Form and detail of the product

          - Nature of material

          - Size of final product

IN GENERAL, PLASTICS PROCESSES HAVE THREE PHASES:-

1. Heating - To soften or melt the plastic

2. Shaping / Forming - Under constraint of some kind

3. Cooling - So that it retains its shape

 

INJECTION MOLDING PROCESSING CHARACTERISTICS:-

Injection molding is accomplished by forcing molten plastic under  pressure into a cavity formed between two matched metal mold valves. Once the plastic cools, the molds are opened and the part is removed

-Part cost - low

-Tooling cost - high

-Production Rate - high

-Can produce intricate

PARTS:-

-Large variety of polymers gives wide range of properties.

-Can produce a wide range of part sizes with different press sizes.

FUNCTIONS:-

1. Allow rapid freezing of polymer: isolate the cavity and permits withdrawal of the screw

2. Narrow and thin solid section: be sheared off easily after demolding

3. Increase shear rates as melt flows through: lower viscosity to ease rapid and complete filling of complex shapes.

TROUBLESHOOTING:-

	PROBLEM CAUSE	POSSIBLE REMEDIES
Machine	-Melt/barrel Temperature too high. -Back pressure high. -More melt resistance time.   -Screw speed too high. -Dirty plasticizing unit. - Dirty Hopper.	-Reduce the melt/temperature   -Reduce the back pressure. -Check the resistance time of                                the material inside the barrel. -Reduce the screw speed -Purging the plasticizing unit -Check the hopper thoroughly for any contamination.
Material	Dust in regrind material.	-Reduce the regrind %, if possible or eliminate.                       -Check the dye / Master Batch for compatibility.
Mould	Hot runner temperature high.	-Correct the hot sprue/ Manifold temperature. - Check for impurities, wear and dead edges in flow paths.

  COMMON FAULTS AND REMEDIES

Following are some of the common defects in Injection Molding. The solutions mentioned are possible solutions and must be tried out with safety in mind. Please always follow the material manufacturer and machine manufacturer's guidelines for safety   

No	Defect	Image	Possible Reason	Possible Solution
1	Short Shot		Molten Plastic is not reaching the mold cavity section	Increase melt temperature Increase mold temperature Increase injection speed Increase injection pressure if process is pressure limited Check if the mold is vented in the area of short shots Increase gate and runner sizes
2	Flash		Molten Plastic is flowing into unwanted sections of the mold cavity	Check for Mold shut-off and mold damage Decrease melt temperature Decrease mold temperature Decrease injection speed
3	Sink		Plastic is shrinking as it cools but additional plastic cannot be for further compensation of the shrinkage	Increase pack and hold pressures Increase pack and hold times Decrease mold temperatures Decrease melt temperatures
4	Splay		A layer/ streak of a unwanted gaseous byproduct from the melt or moisture in the material comes in between the melt flow and the cavity walls preventing the texture from being picked up and in addition eventually leaving a residue	Dry plastic to suggested moisture levels Decrease injection speeds Decrease melt temperature Decrease screw rotation speeds Decrease back pressure Increase mold temperatures Increase venting Increase gate sizes
5	Warpage		A differential cooling rate of the melt in two sections of the molded product	Decrease melt temperature Experiment with differential mold temperatures on the fixed and movable sides Increase pack and hold pressures Increase pack and hold times Increase cooling time
6	Burn Marks		When air and gasses get trapped inside the mold cavity during plastic injection, the high pressure results in the dieseling of the plastic resulting in the burning of the plastic.	Increase venting in the mold Decrease injection speed Decrease melt temperature Decrease Screw Rotation Speeds
7	Voids		Usually occur with the parts are thick. The walls solidify and the plastic melt shrinks towards the wall and therefore sucks a vacuum void on the inside of the part	Reduce melt temperature Reduce mold temperature Reduce injection speed Increase pack and hold pressures Increase pack and hold times
8	Bubbles		When moisture and/or a gaseous byproduct gets mixed with the melt and is injected in the mold cavity this moisture or gas if embedded inside the melt can show up as bubbles	Dry material to suggested moisture levels Increase back pressure Reduce melt temperature
9	Gate Blush		Shows up at the gate when the material is sheared differently compared to the rest of the part	Slow down the injection speeds in the gate area Profile the injection speeds if necessary Experiment with increasing and decreasing melt temperatures or hot tip temperatures in case of hot runner molds
10	Jetting		Usually seen with the part is thick causing the injected plastic to ‘snake fall’ on to the cold mold surface and start freezing immediately. When the fresh plastic come in it does not blend well with the first material causing the jetting marks	Reduce injection speed Increase melt temperature Change gate location
11	Weld Lines		The melt flow front is usually cold due to the exposure to the cold cavity. When two flow fronts meet as in a flow around a mold pin they do not fuse uniformly causing a weld line. Sometimes air can also get trapped in to form the defect	Increase melt temperature Increase mold temperatures Increase injection speeds Increase venting

           

Conclusion

As we are not familiar with the production Injection Moulding Machine, we could not say and clear some aspects. But we have tried our best to get understand about the machine and its process .In continuation of above, we study about the JAR CAP and came to know about the material, Master-batch, different additives as well material form which is used to manufacture JAR CAP through Injection Moulding Machine. We study about the benefits of the material and the reason for which it is used to manufacture JAR CAP. By using this CAP, we can keep our water in the Containers free from any contaminants like dust, dirt, insects, etc. which protects us from many kinds of disease.