UNIVERSITI TEKNIKAL MALAYSIA MELAKA
A Precision Assembly in Plastic Injection Mould
Thesis submitted in accordance with the requirements of the Universiti Teknikal
Malaysia Melaka for the Degree of Bachelor of Engineering (Honours)
Manufacturing (Process)
By
Husaini Bin Abdullah
Faculty of Manufacturing EngineeringApril 2008
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:
A Precision Assembly in Plastic Injection Mould
SESI PENGAJIAN: Semester 2 2007/2008
Saya Husaini Bin Abdullahmengaku membenarkan laporan PSM / tesis (Sarjana/Doktor Falsafah) ini disimpandi Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syaratkegunaan seperti berikut:
1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka danpenulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinanuntuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahanpertukaran antara institusi pengajian tinggi.
4. *Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan ataukepentingan Malaysia yang termaktub di dalam AKTA RAHSIARASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan olehorganisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)Alamat Tetap:4, Persiaran Mayang Pasir,11900 Bayan Lepas,Pulau Pinang.
Tarikh: 25 Mach 2008
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak organisasi berkenaandengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 15 Mei 2008Rujukan Tuan (Your Ref):
PustakawanPerpustakaan Universiti Teknikal Malaysia Melaka (UTeM)Taman Tasik Utama, Hang Tuah Jaya,Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD- LAPORAN PSM SARJANA MUDA KEJURUTERAAN PEMBUATAN (PROSES):Husaini Bin AbdullahTAJUK: A Precision Assembly in Plastic Injection Mould
Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk “APrecision Assembly in Plastic Injection Mould” mohon dikelaskan sebagaiterhad untuk tempoh lima (5) tahun dari tarikh surat ini memandangkan iamempunyai nilai dan potensi untuk dikomersialkan di masa hadapan.
Sekian dimaklumkan. Terima kasih.
“BERKHIDMAT UNTUK NEGARA KERANA ALLAH”
Yang benar,
……………………………………………………..MOHD AMRAN BIN ALIPensyarah,Fakulti Kejuruteraan Pembuatan
UNIVERSITI TEKNIKAL MALAYSIA MELAKAKarung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414 Email : [email protected]
DECLARATION
I hereby declare that this report entitled “A Precision Assembly in Plastic Injection
Mould” is the result of my own research except as cited in the references.
Signature :
Author’s Name : Husaini Bin Abdullah
Date : 25 Mach 2008
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Process). The members of the supervisory committee are as follow:
Mohd Amran Bin Ali(PSM Supervisor)
25 Mach 2008
ABSTRACT
This project describe the method that was used to assemble plastic injection moulding.
This project was done in the Manufacturing Workshop in Universiti Teknikal Malaysia
Melaka (UTeM) that located at Fasa B. The material that been used in this mould project
was Acrylic. This acrylic material was choose because of the characteristic that are
transparent. The purpose of this project is to assemble plates that been provided to be
one completed plastic injection moulding. The problem has been investigate such as
machining with wrong dimension, off set, over cut, not enough cut, standard part cannot
fit into plate and sharp edges. As a result, the plate must be remachining to get an actual
dimension according to the drawing that been provided. Type of machining that been
use in this project such as, milling machine, lathe machine, Computer Numerical Control
(CNC) machine and Electrical Discharge Machine (EDM) wirecut. This project started
from checking all plates to find out any defect or machining error or out of dimension in
plastic injection mould. Every plate will be using quality measurement tool. It will be
remachine if any defects found at mould plate. Various machines will be use such as
milling machine, EDM machine, CNC, chamfering machine, drilling machine and lathe
machine. During this project, all of learning outcome will be implement in every aspect
of work. In order to get accurate result in measurement, various equipment have been
used including vernier calliper, micrometer, high gauge, and Coordinate Measuring
Machine (CMM). In this project also use a quality measurement equipment to get an
accurate dimension. The equipment that involve in this project such as vernier caliper,
micrometer, height gauge and Coordinate Measuring Machine (CMM). As a result, the
measuring plate have been easier assembled with various mould component and finally
one completed mould set was produce.
ABSTRAK
Projek ini akan memperihalkan tentang cara untuk menggabungkan acuan suntikan.
Secara amnya, projek ini akan dijalankan di bengkel pembuatan Universtiti Teknikal
Malaysia Melaka (UTeM) yang terletak di kompleks Fasa B. Dalam projek ini, bahan
yang digunakan untuk membuat acuan ialah acrylic. Acrylic adalah bahan yang
diperbuat daripada plastik. Bahan ini dipilih kerana sifatnya yang lutsinar. Tujuan projek
ini dijalankan ialah untuk menyambung plat-plat yang dibekalkan menjadi satu acuan
yang lengkap. Ini kerana plat-plat yang dibekalkan mempunyai masalah seperti dimensi
yang salah, terpotong lebih, tidak cukup potong dan sebagainya. Maka plat-plat tersebut
perlu di mesin semula untuk mendapatkan ukuran sebenar mengikut lukisan yang
disediakan. Jenis mesin yang terlibat di dalam projek ini adalah mesin pengisar mesin
pengejat, mesin pengawalan berangka komputer dan mesin penyahcas elektrik Projek ini
dimulakan dengan menyemak kesemua plat untuk mengetahui kerosakan, kesilapan
memesin, dan terkeluar daripada dimensi yang ditetapkan. Setiap plate akan
menggunakan alat pengukuran yang berkualiti. Ianya akan dimesin semula jika terdapat
kerosakan. Pelbagai mesin digunakan seperti mesin pengisar mesin pengejat, mesin
pengawalan berangka komputer dan mesin penyahcas elektrik. Sepanjang projek ini,
segala hasil pembelajaran akan digunakan dalam setiap aspek kerja. Untuk mendapatkan
pengukuran yang tepat, pelbagai peralatan mengukur digunakan termasuk angkup
venier, tolok skru mikrometer, tolok tinggi dan mesin pengukur koordinasi. Hasilnya,
plat yang telah diukur, mudah untuk dicantumkan dengan pelbagai komponen acuan dan
akhirnya satu set acuan lengkap telah dihasilkan.
ACKNOWLEDGEMENTS
Assalamualaikum w.b.t. and warm greeting,
First of all, thank to ALLAH SWT for His blessings and for the strength given to me to
finish this Projek Sarjana Muda.
I would like to extend my heartfelt gratitude to all that have been contributed to the
success of this Projek Sarjana Muda. I wish to acknowledge and express my gratitude
and appreciation to my supervisor, Mr. Mohd Amran b. Md Ali for his supervision,
encouragement, suggestion and assistance through the research, technician and my
parent whose constant encouragement, faith and confidence besides continuously moral
support.
I also would like to convey my biggest thanks to Universiti Teknikal Malaysia Melaka
(UTeM) and Fakulti Kejuruteraan Pembuatan (FKP) especially Professor Dr. Mohd
Razali b. Muhamad, Dean of Faculty of Manufacturing Engineering, my PSM panel and
all the lectures in the faculty.
It is a pleasure for me to express huge gratitude to all technician especially Mohd
Farihan Bin Mohammad Sabtu and Muhammad Azwan bin Abdul Kadir who construct
and guide through completing this research while conducting the machining process in
manufacturing workshop as their kindness and willing really regards me with pleasure. I
could offer here only an inadequate gesture of my appreciation and all of your good
deeds will always be in my mind.
TABLE OF CONTENTS
Abstract…………………………………………………………………………...
Abstrak……………………………………………………………………………
Acknowledgement………………………………………………………………..
Table of Contents………………………………………………………………...
List of Tables……………………………………………………………………..
List of Figures…………………………………………………………………….
List of Abbreviations……………………………………………………………..
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1. INTRODUCTION……………………………………………………………
1.1 Background……..……………………….………………………………..
1.2 Objective of project……………………………………………………….
1.3 Problem Statement……….…..……………………………………………
1.4 Scope of the project……………………………………………………….
1.5 Project Overview….……….…..………………………………………….
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2. LITERATURE REVIEW………………………….………………………...
2.1 Mould……………………………………………………………………...
2.1.1 Two Plate Mould……………………………………………………..
2.1.2 Three Plate Mould……………………………………………………
2.2 Characteristic of Injection Moulding………………………………….…..
2.2.1 Impression…………………………..………………………………..
2.2.2 Runner.………………………...……………………………………..
2.2.3 Gate…………………………………………………………………..
2.2.4 Air Vent………………………………………………………………
2.3 Acrylic…………………………………………………………………….
2.3.1 Properties of Acrylic………………………………………………....
2.3.2 Advantages of Acrylic………………………………………………..
2.4 Conventional Machine…………………………………………………….
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2.4.1 Milling Machine………………………………………………...........
2.4.1.1 Type of Milling Machine……………………………………..
2.4.1.2 Vertical Milling Machine……………………………………..
2.4.2 Clasification of Milling.......................................................................
2.4.2.1 Peripheral Milling……………………………………………
2.4.2.2 Face Milling………………………………………………….
2.4.2.3 End Milling……………………………………………..........
2.5 Lathe Machine…………………………………………………………….
2.5.1 Component of Lathe Machine..........................................................
2.5.1.1 Bed and Ways..........................................................................
2.5.1.2 Head Stock...............................................................................
2.5.1.3 Tail Stock.................................................................................
2.5.1.4 Carriage....................................................................................
2.5.1.5 Feed Rod..................................................................................
2.5.1.6 Lead Screw...............................................................................
2.5.1.7 Crossfeed slide.........................................................................
2.5.1.8 Accessories and Attachments...................................................
2.5.1.9 Lathe Chuck.............................................................................
2.6 Advance Machining……………………………………………………….
2.6.1 Computer Numerical Control (CNC)………………………………..
2.6.1.1 Movements..............................................................................
2.6.1.2 Tool Changes...........................................................................
2.6.1.3 Drilling.....................................................................................
2.6.1.4 Drilling Cycle………………………………………………..
2.6.1.5 Parametric Programming…………………………………….
2.6.2 Electrical Discharge Machining (EDM)……………………………...
2.6.2.1 Wire EDM Cutting..................................................................
2.6.2.2 Possible Shapes.......................................................................
2.6.2.3 Advantages of Wire EDM cutting...........................................
2.7 Measuring Equipment....................................................................................
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2.7.1 Vernier caliper......................................................................................
2.7.2 Coordinate Measuring Machine (CMM)..............................................
2.7.2.1 Machine Body...........................................................................
2.7.2.2 Machine Probe………………………………………………..
2.7.2.3 Physical Principle………………………………………….....
2.7.3 Height Gauge………………………………………………………...
2.7.4 Micrometer…………………………………………………………..
2.7.4.1 Types…………………………………………………….......
2.7.4.2 Reading an Inch System Micrometer……………………......
2.7.4.3 Reading a Metric Micrometer……………………………......
3. METHODOLOGY……………………………………………………...……
3.1 Introduction………………………………………………………………...
3.2 Flow Chart of Mould Assembly……………………………………………
3.3 Selection of Component……………………………………………………
3.4 Assemble Moveable Half…………………………………………………..
3.5 Checking……………………………………………………………………
3.6 Machining……………………………………………………………..........
3.7 Assemble Stationary Half……………………………………………..........
3.8 Checking……………………………………………………………………
3.9 Assemble…………………………………………………………………...
4. PROBLEM ANALYSIS AND MOULD ASSEMBLY……………………..
4.1 Introduction…………………………………………………………………
4.2 Assembly drawing…………………………………………………………..
4.3 Problem Analysis …………………………………………………………...
4.3.1 Sprue Bush…………………………………………………………….
4.3.1. Measurement method…………………………………………
4.3.1.2 Machining Method………………………………………….
4.3.2 Shoulder Guide Bush Over Than Plate and Offset…………………..
4.3.2.1 Procedures…………………………………………………..
4.3.3 Core Plate…………………………………………………………….
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4.3.3.1 Method……………………………………………………...
4.3.4 Sprue Bush Loose…………………………………………………….
4.3.4.1 Measurement method……………………………………...
4.3.4.2 Machining Procedures…………………………………….
4.3.5. Cavity plate 2 ……………………………………………………….
4.3.5.1 Measurement Procedure…………………………………….
4.3.5.2 Machining Procedure………………………………………...
4.3.6 Socket Head Cap screw M6 x 25……………………………………
4.3.6.1 Procedure……………………………………………………
4.3.7 Socket Head Cap Screw M8 x 15…………………………………..
4.3.7.1 Procedure…………………………………………………...
4.3.8 Thread……………………………………………………………….
4.3.8.1 Procedure…………………………………………………..
4.3.9. Sharp Edge………………………………………………………….
4.3.9.1 Procedure…………………………………………………..
4.3.9.2 Result………………………………………………………
4.3.10 Oil, Scratch and Mark……………………………………………...
4.3.10.1 Procedure…………………………………………………
4.4 Mould Assembly……………………………………………………………
4.4.1 Moveable Half……………………………………………………….
4.4.1.1 Procedure…………………………………………………..
4.4.2 Fix Half……………………………………………………………..
4.4.2.1 Procedure…………………………………………………
4.4.3 Align Moveable Half and Stationary Half…………………………
5. DISCUSSION…………………………………………………………………
5.1 Introduction………………………………………………………………..
5.2 Machining Error…………………………………………………………...
5.3 Standard Part………………………………………………………………
5.4 Scratches …………………………………………………………………..
5.5 Overcut or not enough cut…………………………………………………
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5.6 Chamfering………………………………………………………………...
6. CONCLUSION & RECOMMENDATION………………………………...
6.1 Conclusion…………………………………………………………………
6.2 Recommendation…………………………………………………………..
References……………………………………………………………………….
Appendix A Garnt Chart of PSM 1..…………………………………………..
Appendix B Garnt Chart of PSM 2……………………………………………
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LIST OF TABLES
2.1.1.1 Acrylic Properties 15
LIST OF FIGURES
2.1.1.1 Clamping Unit
2.2.2.1 Two Plate Injection Moulding
2.3.2.1 Cooling System
2.4 Water Cooling Located Inside the Mould
2.5 Three Plate Mould
2.6 Concept of 3 Plate Mould
2.7 Impression
2.8 Sprue and Runner
2.9 Gate
2.10 Air Vent
2.11 Acrylic Material
2.12 Vertical Milling Machine
2.13 Face Milling
2.14 Lathe Machine Component
2.15 CNC machine
2.16 CNC spindle
2.17 CNC magazine
2.18 Drilling Process
2.19 EDM machine
2.20 EDM wire cut
2.21 Product from EDM Process
2.22 Vernier Caliper Parts
2.23 Coordinate Measurement Machine (CMM)
2.24 CMM probe
2.25 Height Gauge
2.26 Scriber
2.27 Micrometer
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3.1 Process Flow chart
3.2 Selected Acrylic Plate
3.3 Moveable Half Mould
3.4 CMM
3.5 EDM
3.6 Stationary Half Mould
3.7 Marking Mould
3.8 Complete Mould
4.1 Assembly Drawing
4.2 Bill of Material
4.3 Guide Piller and Shoulder Guide Bush
4.4 Ejector Pin, Locating Ring and Sprue Bush
4.5 Straight Guide Bush
4.6 Product Dimension
4.7 Sprue Bush Area
4.8 Sprue Bush
4.9 CMM Control Panel
4.10 Point to Measure
4.11 Initial Point
4.12 End Point
4.13 Result
4.14 Parting Tool
4.15 3 Jaw Lathe Machine
4.16 After Cutting Process
4.17 Shoulder Guide Bush Location
4.18 Guide Bush Shoulder
4.19 Guide Bush not enough cut hole
4.20 Parallel Bar
4.21 Workpiece on parallel bar
4.22 Edge finder
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4.23 Clamp in milling chuck
4.24 Display of DRO
4.25 X-axis button
4.26 zero button
4.27 Enter Button
4.28 Y-axis button
4.29 All X,Y, Z-axis set zero
4.30 X-axis 2mm
4.31 Y-axis 2mm
4.32 4 Fluid End Mill
4.33 Tool Position
4.34 Machining Process
4.35 Shoulder Guide Bush Fit into the Hole
4.36 Radius Area
4.37 File Area
4.38 core insert fit into core plate
4.39 Loose sprue bush
4.40 mild steel
4.41 Washer Area
4.42 Result
4.43 Facing Process
4.44 Parting process
4.45 washer
4.46 Cavity Insert Location
4.47 Measure Cavity Insert
4.48 Measure cavity plate 2
4.49 Result
4.50 Dial Gauge
4.51 Boring process
4.52 Cavity insert fix into cavity hole
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4.53 M6 x 25 locations
4.54 Socket Head Cap screw M6 x 25
4.55 Cutting Process
4.56 M6 screw that been cut
4.57 Cut off area
4.58 Ejector pin Socket Head cap screw M8 x 15 location
4.59 Cutting Process
4.60 Result
4.61 All M8 x 15 fit into hole
4.62 Damage Thread
4.63 Threading Tool
4.64 Tappering process
4.65 Result
4.66 Sharp edge
4.67 Chamfering machine
4.68 Chamfering Process
4.69 Repeating Process
4.70 Before chamfering
4.71 After Chamfering
4.72 Oil, scratch and mark
4.73 Denurated alcohol 95%
4.74 Workpiece
4.75 Cleaning Process
4.76 Clean Plate
4.77 Moveable Half Flow Chart
4.78 Ejector Base Plate
4.79 Socket head cap screw M6 x 25
4.80 Ejector Pin
4.81 Ejector Pin with Ejector Plate
4.82 Ejector Base Plate with Ejector Plate
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4.83 Core insert
4.84 Core plate
4.85 Core insert with core plate
4.86 Stripper plate
4.87 Stripper plate with core plate
4.88 Backup plate
4.89 Guide piller
4.90 Backup, Core Plate and Stripper Plate with Guide Piller
4.91 Ejector plate with backup, core plate, stripper plate
4.92 Spacer Block
4.93 Join spacer block
4.94 Bottom Clamping Plate
4.95 Socket head cap screw M10 x 100
4.96 Joint bottom clamping plate
4.97 Guide bush
4.98 Guide bush location
4.99 Set screw m6 x 10
4.100 Set screw M6 x 10 location
4.101 Socket head cap screw M6 x 25
4.102 Joint Socket head cap screw M6 x 25 with ejector pin
4.103 Complete movable half
4.104 Fix Half Flow Chart
4.105 Guide bush shoulder
4.106 Cavity plate
4.107 Guide bush shoulder with Cavity plate
4.108 Cavity inserts 1
4.109 Cavity insert 1 with cavity plate 2
4.110 Cavity inserts 2
4.111 Cavity Plate 1
4.112 Cavity Inserts 2 with Cavity Plate 1
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4.113 Cavity plate 1 with cavity plate 2
4.114 Top clamping plate
4.115 Socket head cap screw M6 x 25
4.116 Socket head cap screw M6 x 25 with top clamping plate
4.117 Sprue bush
4.118 Sprue bush in the locating ring
4.119 Locating ring
4.120 Counter sunk cap screw M4 x 8
4.121 Counter sunk cap screw M4 x 8 location
4.122 Complete fix half
4.123 Align fix half and stationary half
4.124 Complete set of mould
5.1 Datum and reference point
5.2 Digital Readout (DRO)
5.3 Clamping Area
5.4 Radius in core insert
5.5 Silicon area
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LIST OF ABBREVIATIONS
CMM - Coordinate Measurement Machine
EDM - Electric Discharge Machine
CAD - Computer Aided Design
CAM - Computer Aided Machining
CNC - Computer Numerical Control
NC - Numerical Control
DRO - Digital Read Out
CHAPTER 1
INTRODUCTION
1.1 Background
Injection moulding is a process in which a polymer is heated to a highly plastic state and
forced to flow under high pressure into a mold cavity, where it solidifies. The moulded
part, called a moulding, is then removed from the cavity. The process produces discrete
components that are almost always net shape. The production cycle time is typically in
the range 10 to 30 seconds, although cycles of one minute or longer are not uncommon.
Mould consists of various type of component. Such as locating ring, sprue bush, guide
bushes and guide pillar, ejector system, sprue puller, return pin and ejector rod. Mould is
devided into two parts. moveble half dan stationary half. Moveable half consist of
several component that which are core plate, support plate, space block, top ejector
plate, bottom ejector plate and bottom clamping plate, meanwhile stationary half is
consist of top clamping plate and cavity plate. There are two type of mould, firstly two
plate mould, and three plate mould.
In this project, the 2 plate mould was chosen in order to produce a cup mould. The
purpose is to assemble the cup mould and define any defect on the mould and proceed to
remachine the mould back if any defect is found. Mould are usually made from pre
hardener metal, but in this project, acrylic material was used as a mould. Acrylic is a
useful, clear plastic that resembles glass, but has properties that make it superior to glass
in many ways. Common brands of high-grade acrylic include Polycast, Lucite and
Plexiglass. There are two basic types of acrylic, extruded and cell cast. Extruded or
"continuous cast" acrylic is made by a less expensive process, is softer, can scratch
easier and may contain impurities. Cell cast acrylic is a higher quality acrylic and it has
been use for jet and airplane glass. The advantages using acrylic mould in this project,
the mould is transparent and clear. This mean every process in injection mould can be
see clearly.
Conventional machine has been used in this project. Variety machine such as milling
and lathe were use to remachine the defect area. The machining process that are learn at
the last semester such as drilling, boring, facing, surfacing and others are practiced in
this project.
Measurement equipment such as verniar caliper, high gauge, dial indicator and
Coordinate Measurement Machine (CMM) has been implemented in this project. This is
to ensure the accuracy of each plate. Accuracy is very important in injection moulding, it
is because it will influent the size of product.
1.2 Objectives
The main objective of this project is to assemble the plastic injection mould. To achieve
this project there are five objectives:
1. To find out any defect, machining error, out of dimension in plastic
injection mould.
2. To fix all mould plates at movable half and stationary half.
3. To align all the guide pin and guide bush between moveable half and
stationary half.
4. To fix all mould components and inserts to the reference follow the
assembly drawing.
5. To assemble all plates, component and insert for producing one set of
mould.
1.3 Problems Statement
After machining, all plates of injection mould need to be assemble into one mould.
However, there are some plates and components cannot assembly in one mould. Due to
that, procedure of mould assembly should be prepared for industrial guide.
There are many sources, why plastic injection mould cannot assembly. Firstly the
method to assemble between moveable half and stationary half is not documented. The
wrong method to assemble the mould was use. To solve this problem, procedure of
assembling mould should be documented.
Secondly, some plate may be machine with wrong dimension. For example offset, over
cut, not enough cut and etc. To ensure that all plate were machine accurately, all plate
should be checked using measurement tool such as vernier caliper, micrometer, and
CMM.
