PT 9213 PLASTICS MOULD & PRODUCT DESIGN SYLLABUS | ANNA UNIVERSITY MTECH PLASTIC TECHNOLOGY 1ST SEM SYLLABUS REGULATION 2009 2011 2012-2013 BELOW IS THE ANNA UNIVERSITY FIRST SEMESTER M.TECH PLASTIC TECHNOLOGY DEPARTMENT SYLLABUS, TEXTBOOKS, REFERENCE BOOKS,EXAM PORTIONS,QUESTION BANK,PREVIOUS YEAR QUESTION PAPERS,MODEL QUESTION PAPERS, CLASS NOTES, IMPORTANT 2 MARKS, 8 MARKS, 16 MARKS TOPICS. IT IS APPLICABLE FOR ALL STUDENTS ADMITTED IN THE YEAR 2011 2012-2013 (ANNA UNIVERSITY CHENNAI,TRICHY,MADURAI, TIRUNELVELI,COIMBATORE), 2009 REGULATION OF ANNA UNIVERSITY CHENNAI AND STUDENTS ADMITTED IN ANNA UNIVERSITY CHENNAI DURING 2009
PT 9213 PLASTICS MOULD & PRODUCT DESIGN L T P C
3 0 0 3 UNIT I INJECTION MOULD DESIGN 9
Introduction: Concept of design – mould design principles – layout of impression -
mould venting - mould alignment – mould location – mould clamping.
Selection of machines: Specifications of machines – types of machines - shot capacity
– shot weight - plasticizing capacity – nozzle details – minimum daylight – maximum
daylight – projected area – Injection pressure – Locking force – shut height - ejection
arrangement – dry cycle time – methodical approach to mould design - deciding
number of impressions – determination of economical no. of cavities.
Parting line/Parting surface: Types of parting surface - plain – stepped – irregular –
local stepped and profile parting surface – complex edge form.
Ejection system: Types of ejection – pin ejection – stepped pin - part pin –“D” pin –
blade ejection – sleeve ejection – stripper ejection – air ejection – double ejection –
delayed ejection - calculation of ejection force required.
Mould temperature control: Types of cooling – Bolster cooling – integral cooling
core/cavity – Insert cooling-core/cavity – Baffle cooling – Bubbler cooling – Deep
chamber design - spiral cooling – cooling through heat pipes – capillary tubes- heat
rods – mould temperature – melt temperature – heat removal rate – calculation of
cooling time.
UNIT II TYPES OF MOULDS 9
Feed system: Sprue, runner and gate – determination of runner-gate - size and cross
section-layout of runners – balancing of runners – types of gates – application of gates
to various products/materials – gate balancing.
Types of moulds: Two plate mould – single impression – multi impression – three plate
mould – multi day-light mould – stack mould – runnerless mould – hot runner and
insulated runner mould - split moulds – external undercut – internal undercut –finger
cam, dog leg cam and cam track actuation – spring - hydraulic actuation - split cavities
– split cores – threaded inserts – internal and external – standard mould bases –
Calculation of strength of cavities – strength of guide pillar and support pillar
requirements - Mould design check list.
Blow Mould Design & Extrusion Die Design
Types of blow moulds – extrusion – injection and stretch blow moulds – blow ratio –
parison design – pinch off design – parting line – clamping force – mould venting, mould
cooling – mould alignment – mould clamping. Extrusion Die Design: Basic concepts
5
UNIT III COMPRESSION & TRANSFER MOULD DESIGN 9
Types of compression mould - open flash - semi-positive type - positive - displacement
moulds - types of loading chambers - bulk factor - flash thickness - pot design – depth
of loading chamber calculation - projected area - compression pressure - clamping
force – deciding no. of impression by technological method - heating system - types of
heaters - heat losses - heat requirement & heater capacity- advantages and
disadvantages of compression mould.
Types of transfer moulds - integral pot transfer mould – Top & Bottom plunger design -
auxiliary ram transfer mould - transfer pot design - projected area - transfer pressure -
clamping force - pressure pad design - design of sprue runner and gate – calculations -
advantages and disadvantages of transfer mould.
UNIT IV PLASTICS PRODUCT DESIGN 9
Concepts – size, shape and function – form and function – Aesthetics, Ergonomics –
Shrinkage, Flash lines. Undercuts – External & Internal - Wall thickness – variances in
wall thickness – suggested wall thickness for thermoplastics and thermosetting
materials – steps in product design - emphasize on designing with engineering plastics
- Taper or draft - Fits & Tolerances – Designing with plastics for load bearing
applications like gears, bearing, etc.
Design of radii, fillets, ribs and bosses - Design for flow and shape -Moulded Holes –
through holes – blind holes – threaded holes – side holes – holes parallel to draw –
nearness of holes to each other and side wall – moulding holes not parallel to draw –
drilled and tapped holes – moulded threads – moulded lettering – surface treatment.
UNIT V TYPES OF INSERTS 9
Types of Inserts – Materials – selection of metal for inserts – minimum wall thickness of
material around inserts – anchorage – relieving moulding stresses around inserts –
location of inserts in the part – moulded in inserts – pressed in inserts -Design of
integral hinges, hinges and snap fits for boxes and assembly of moulded parts -
Designed mismatch for part assembly.
Quality and economy – tooling aspects on product design – process variables vs
product design – product design appraisal - Product design limitations – shrinkage vs
tolerance – end use requirements with case studies – product design tips - prototype
development – rapid prototyping techniques – stereo lithography.
TOTAL: 45 PERIODS
REFERENCES
1. R.G.W. PYE, Injection Mould Design for Thermoplastic, Affiliater East-West Press P.
Ltd., New Delhi, 1989.
2. Fischer (EG), Blow moulding of plastics, Newnus Butter Worths, London, 1976.
3. MV Soshi, Dies for Plastics Extrusion, S.G. Wasant for Macmillan India Ltd.,
Madras, 1992.
4. DYM, Injection Mould Design, Van Nostrand Reinhold Company, New York, 1987.
5. Neil L. Hancox, Design Data for Reinforced Plastics, Chapman & Hall, London,
1994.
6. Beck, Plastic Product Design, Yan Nostrand Reinhold Company, London, 1970.
7. Norman Lee, Blow Mould Design, Hanser Publishers, Munich, 1998.
PT 9213 PLASTICS MOULD & PRODUCT DESIGN L T P C
3 0 0 3 UNIT I INJECTION MOULD DESIGN 9
Introduction: Concept of design – mould design principles – layout of impression -
mould venting - mould alignment – mould location – mould clamping.
Selection of machines: Specifications of machines – types of machines - shot capacity
– shot weight - plasticizing capacity – nozzle details – minimum daylight – maximum
daylight – projected area – Injection pressure – Locking force – shut height - ejection
arrangement – dry cycle time – methodical approach to mould design - deciding
number of impressions – determination of economical no. of cavities.
Parting line/Parting surface: Types of parting surface - plain – stepped – irregular –
local stepped and profile parting surface – complex edge form.
Ejection system: Types of ejection – pin ejection – stepped pin - part pin –“D” pin –
blade ejection – sleeve ejection – stripper ejection – air ejection – double ejection –
delayed ejection - calculation of ejection force required.
Mould temperature control: Types of cooling – Bolster cooling – integral cooling
core/cavity – Insert cooling-core/cavity – Baffle cooling – Bubbler cooling – Deep
chamber design - spiral cooling – cooling through heat pipes – capillary tubes- heat
rods – mould temperature – melt temperature – heat removal rate – calculation of
cooling time.
UNIT II TYPES OF MOULDS 9
Feed system: Sprue, runner and gate – determination of runner-gate - size and cross
section-layout of runners – balancing of runners – types of gates – application of gates
to various products/materials – gate balancing.
Types of moulds: Two plate mould – single impression – multi impression – three plate
mould – multi day-light mould – stack mould – runnerless mould – hot runner and
insulated runner mould - split moulds – external undercut – internal undercut –finger
cam, dog leg cam and cam track actuation – spring - hydraulic actuation - split cavities
– split cores – threaded inserts – internal and external – standard mould bases –
Calculation of strength of cavities – strength of guide pillar and support pillar
requirements - Mould design check list.
Blow Mould Design & Extrusion Die Design
Types of blow moulds – extrusion – injection and stretch blow moulds – blow ratio –
parison design – pinch off design – parting line – clamping force – mould venting, mould
cooling – mould alignment – mould clamping. Extrusion Die Design: Basic concepts
5
UNIT III COMPRESSION & TRANSFER MOULD DESIGN 9
Types of compression mould - open flash - semi-positive type - positive - displacement
moulds - types of loading chambers - bulk factor - flash thickness - pot design – depth
of loading chamber calculation - projected area - compression pressure - clamping
force – deciding no. of impression by technological method - heating system - types of
heaters - heat losses - heat requirement & heater capacity- advantages and
disadvantages of compression mould.
Types of transfer moulds - integral pot transfer mould – Top & Bottom plunger design -
auxiliary ram transfer mould - transfer pot design - projected area - transfer pressure -
clamping force - pressure pad design - design of sprue runner and gate – calculations -
advantages and disadvantages of transfer mould.
UNIT IV PLASTICS PRODUCT DESIGN 9
Concepts – size, shape and function – form and function – Aesthetics, Ergonomics –
Shrinkage, Flash lines. Undercuts – External & Internal - Wall thickness – variances in
wall thickness – suggested wall thickness for thermoplastics and thermosetting
materials – steps in product design - emphasize on designing with engineering plastics
- Taper or draft - Fits & Tolerances – Designing with plastics for load bearing
applications like gears, bearing, etc.
Design of radii, fillets, ribs and bosses - Design for flow and shape -Moulded Holes –
through holes – blind holes – threaded holes – side holes – holes parallel to draw –
nearness of holes to each other and side wall – moulding holes not parallel to draw –
drilled and tapped holes – moulded threads – moulded lettering – surface treatment.
UNIT V TYPES OF INSERTS 9
Types of Inserts – Materials – selection of metal for inserts – minimum wall thickness of
material around inserts – anchorage – relieving moulding stresses around inserts –
location of inserts in the part – moulded in inserts – pressed in inserts -Design of
integral hinges, hinges and snap fits for boxes and assembly of moulded parts -
Designed mismatch for part assembly.
Quality and economy – tooling aspects on product design – process variables vs
product design – product design appraisal - Product design limitations – shrinkage vs
tolerance – end use requirements with case studies – product design tips - prototype
development – rapid prototyping techniques – stereo lithography.
TOTAL: 45 PERIODS
REFERENCES
1. R.G.W. PYE, Injection Mould Design for Thermoplastic, Affiliater East-West Press P.
Ltd., New Delhi, 1989.
2. Fischer (EG), Blow moulding of plastics, Newnus Butter Worths, London, 1976.
3. MV Soshi, Dies for Plastics Extrusion, S.G. Wasant for Macmillan India Ltd.,
Madras, 1992.
4. DYM, Injection Mould Design, Van Nostrand Reinhold Company, New York, 1987.
5. Neil L. Hancox, Design Data for Reinforced Plastics, Chapman & Hall, London,
1994.
6. Beck, Plastic Product Design, Yan Nostrand Reinhold Company, London, 1970.
7. Norman Lee, Blow Mould Design, Hanser Publishers, Munich, 1998.
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