SLC FT GG

Project Report
A PROJECT REPORT ON DESIGN &

MANUFACTURE OF SINGLE CAVITY
INJECTION MOULD FOR
“230B WHEEL CAP MOLD”
SUBMITTED BY: - VIGNESH S
REG: –1220556
BATCH: – 5TH “BATCH”
PROJECT GUIDEPRINCIPAL
Mr. KEMPARAJU C.S & PRAJWAL P.K
INSTRUCTORS
GT&TC, KOLAR
GOVT.TOOL ROOM AND TRAINING CENTRE

KAIGARIKA SANKIRNA, OLD DIC BUILDING, BANGLORE
KGF ROAD, KOLAR, KARANATAKA – 563101.
KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

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(AN
INDO-DANISH PROJECT)
KAIGARIKA SANKIRNA, OLD DIC BULDING
KOLAR-563101
This is to certify that the project titled “MANUFACTURE OF

SINGLE CAVITY INJECTION MOULD FOR 230B WHEEL CAP
MOULD” has been successfully carried out by Mr. VIGNESH
S Reg. No. 1220556 in partial fulfillment of the sectional
requirement for the award of “DIPLOMA IN TOOL & DIE
MAKING” at GOVT. TOOL ROOM & TRAINING CENTRE,
KOLAR during the year 2014-2018.
PROJECT GUIDE PRINCIPAL
Mr. PRAJWAL P.K Mr. KEMPARAJU C.S

INSTRUCTORS GT&TC, KOLAR
GT&TC, KOLAR

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EVALUATION SHEET
NAME: VIGNESH S BATCH: 5TH

REG.NO: 1220556 YEAR: IV
MARKS
SL. MARKS
DESCRIPTION OBTAINE
No. ALLOTTED
D
01. COMPONENT ANALYSIS 30
02. TOOL DESIGN ANALYSIS 50
03. ESTIMATION AND COSTING 40
TOOL MANUFACTURING
04.
PROCESS
50
05. TRAILS 10
06. DEFECTS & REMEDIES 10
07. PRESENTATION 10
TOTAL 200
SIGNATURE OF THE SIGNATURE OF THE

VIVA EXAMINER EVALUATOR
REMARKS:

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ACKNOWLEDEMENT (G.T & T.C)
During the course of this project work I was greatly

supported and guided by several colleagues of GT&TC. I will
take this opportunity to thank them all.
First of all, I will take great pleasure in expressing my deep

sense of gratitude to our Managing Director Sri RAGHU R who
has been guiding light to our organization.
I’m also grateful to our honorable General Manager Sri

RAMAPRASAD K.L for having given me opportunity to take
our in plant training.
I’m also indebted to our beloved principal Mr. KEMPARAJU

C.S for giving me the privilege of completing my training. At this
esteemed org. and also their assistance and support in course
of this project.
At the same time, I thank my Instructors Mr. PRAJWAL P.K all

staff of GT&TC for sharing their valuable experience. Their
influence has helped in molding ourselves to a productive &
confident toolmaker.

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During the course of this project I was greatly supported &
guided by several colleagues of GTTC I will take this
opportunity to thank them all.
I am also grateful to our honorable senior manager Mr.

SURESH SWAMITHAN TOYODA GOSEI KIRLOSKAR
AUTOMOTIVE PVT LTD. For having given me an opportunity
to take our implant training.
I am also grateful to Mr. SUGHAND KUMAR Senior

Engineering of Mold Maintenance TOYODA GOSEI
KIRLOSKAR AUTOMOTIVE PVT LTD. for providing me an
opportunity required to complete this project successfully.
I express my profound thanks with gratitude to

Engineering Mr. SURESH RAO. TOYODA GOSEI
KIRLOSKAR AUTOMOTIVE PVT LTD, assisted to complete
this project successfully.
My Sincere regards to all staff employees of TOYODA GOSEI

KIRLOSKAR AUTOMOTIVE PVT LTD, at Bangalore who
directly or indirectly helped me in carrying & completing my
project successfully

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GTTC (AT GLANCE)
Government Tool Room & Training Centre is one of the

excellent institution in our country imparting training &
enhancing technological excellence in the field of tool
Engineering.
GT & TC takes its pride in the industry by manufacturing

high Quality components & tools & also by training highly skilled
students.
It has most updated technology & training program to

meet the need of the present competitive world. It renders
training in Diploma in tool & Die making.
Diploma in tool & making in a job oriented course, in

which we become familiar with the latest technology. We are
trained in operating the most sophisticated m/c & design,
manufacturing of intricate moulds jigs fixture, Die casting dies.
We gain exposure in operation of milling, turning, grinding,
fitting, assembly
We are trained & directed towards all the requirements

& technological knowledge of present & future tooling
industry. Finally, I can testify that GTTC is one of the few
organizations of the 21st century.

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TOYODA GOSEI SOUTH INDIA Pvt. Ltd.
(TGSIN)
TG JAPAN GROUP
COMPANY PROFILE
 TGSIN was started in the year 1998 as a TG JAPAN GROUP of
Company. In collaboration with Kirloskar group.
 TGSIN was formed in the year from 1998 with 100% injection
molding parts manufacture. And from 2010 to till date safety system
related to automotive, like airbags assembly unit etc.
PLANT 1 PLANT 2 PLANT 3
1.INJECTION 1.ROBOT 1.INJECTION

MOULDING WELDING MOULDING
2.AIRBAG UNIT
UNIT 2.DIE SPOT
PUNCHING
2.PAINT M/C PRESS M/C
SHOP 3.SAFETY 3.INJECTION
SYSTEM PART
ASSEMBLY ASSEMBLY
WITH 4.DISPATCH
INJECTION
UNIT

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 The main activities include Plastic Injection Molding, Safety
products, Paint shop, Robot welding & Air bag punching.
 TGSIN Employee strength about 1000 people, Direct-600,
Indirect-400.
About the organization

 TGSIN has highly motivated human resources responsible
for the success of the concern.
 TGSIN has attracted mainly automotive customers like
Toyota, Nissan. World truck to name a few for its quality,
timely dispatches of supplies.
 TGSIN is committed to the terms of its global environment
protection. The certification of ISO/TS endorses our
corporate responsibility, coexistence with the environment
and coexistence with society.
 TGSIN reckons its human resources as its most treasured
asset and main source of strength for the organization

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SYNOPSIS
The process of Tool & Die Making involves a series of direct stages,
which completes in a proper planning and proper
thinking and co-ordination must result in a successive tool.
This report gives a vision to specialize in and provide

‘state-of-art’ in tool &die making and designing solutions like method
of design that is plotting the imaged idea (concept design) on the
paper as design, dividing the total processing into discrete module
like raw material selection, machining, job follow-up, assembly and
final tryout.
This project report gives a detailed knowledge of the tool making

techniques, the difficulties involved, and the skill of a tool maker. It
develops a theoretical knowledge and shows the expressing capacity
of a tool maker.
The project report is on single cavity mould for
“230B WHEEL CAP”.

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OBJECTIVES REPORT OF THE PROJECT
 To design a two plate mold for 230B WHEEL CAP.
 Knowledge in molding material, mainly automation

applications.
 Basic for all standard mold design and molding techniques.
 All methods of making molding tools, cavities etc. Both

conventional and Unconventional to determine the ideal way
to make the mould.
 All tool room machine, their functions and limitations to

design.
 The functions of piece part, estimating their factors upon

which it is based and how to estimate mould prices.
 The basic requirements of molded product design in order to

advice customers
 An appreciation of the economics of all facts of the custom

molding side of the plastic industry, i.e., design, tool making,
molding and secondary operations in Order to assist the initial
conception of a project.
 Drawing or drafting ability to convey clearly on a drawing

exactly what is required to the tool room.

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NATURE OF BUSINESS CARRIED
The business carried by the company is with a very focused objective of
selling up a modern plant to manufacture plastic interior and exterior
components for passenger’s vehicles comprising of ….…….
PRODUCT PROFILE: -
 Dash boards
 Bumpers
 Door panels
 Consoles
 Pillars
 Packages trays
 Door trims
 Radiator tanks
 Cockpit assembly
 Spoilers
 Grillers

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CONTENTS
SLNO DESCRIPTION PAGE NO
01 INTRODUCTION 13-25
02 COMPONENT ANALYSIS 26-32
03 TOOL DESIGN ANALYSIS 33-41
04 RAW MATERIAL SELECTION 42-47
05 ESTIMATION&COSTING 48-58
06 PROCESS PLANING 59-61
07 TOOL MANUFACTURING 62-72

PROCESS
08 HEAT TREATMENT 73-77
10 INSPECTION 78-86
11 POLISHING 87-90
12 ASSEMBELY 91-99
13 TRYOUT, DEFECTS&REMEDIES 100-105
14 CONCLUSION 106-107
15 BIBLIOGRAPHY 108

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INTRODUCTION OF PROJECT
REPORT
This project report gives a detailed knowledge of the
Tool Designing and Tool Making Techniques, the
difficulties involved and the skill of a Toolmaker.

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It develops the theoretical knowledge and shows the
expressing capacity of a Toolmaker.
The information presented in a project report on an

injection mould can be an asset not only to the toolmaker but
also to anyone concerned with tool making and production.
The aim of the project report is to explain each subject

from the foundation to the finish of the project in a simple and
clear manner.
BRIEF SPECIFICATION OF THE

PROJECT
TYPE OF MOULD INJECTION MOULD

Customer name Toyota kirloskar motor ltd.

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Type of molding Injection molding.
Number of cavities Single cavity.
Type of cooling Baffle &U circular cooling.
Type of ejection Hydraulic& Pin Ejection
Type of gate Valve gate
Feed system Valve gate& Hot runner
Component weight 406 Gms
Mould size 720X750X560 mm.
Mould weight 2350 kg’s. (approx.)
Material PC ABS IMC45(WH GRAY)
Shrinkage 0.8%
INTRODUCTION TO PLASTICS
Plastics offer themselves, as the most versatile of the
material for a very wide range of applications and being
synthetic, can be tailor made to meet even the most exact
individual application performance requirements of an end
product. Plastics offer not only versatility of application but in
respect of design and creative possibilities for newer

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applications, if one taken a look at the world scene one will
observe that there are hardly any fields, where the plastic
material are not being used in one or other form. Plastics are
applied in almost all industries like Agricultural, Automobile,
Construction, Defense, Medical Electronics Packaging and
Chemical industry.
Plastics have made and will continue to make an impact in

so many aspects of our lives because of the following
characteristics over the conventional material.
-Lightweight
-Low-cost
-Ease of processing
-Available as transparent, translucent or opaque
-Capable of being foamed and flexible form.
-Inertness to chemicals
-Available in wide range of colors
-Good thermal insulating properties

-Good electrical insulating properties
-Good strength to-mass production
-Low energy required for conversions
-Easy assembly of molded parts
-Property modification by blending, by adding additives
Plastics are broadly classified into two groups:

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 Thermoplastics.
 Thermosetting Plastics.
THERMO PLASTICS
Thermo plastics are used predominantly in our daily life.

Plastic bags, bowls and dishes in kitchen, mugs, buckets, and
water tanks in bathrooms are all made from thermo plastics.
These types of plastics soften when heated and

subsequently melt. But when cooled they become hard and
rigid once again. It is possible to melt old thermo plastic articles
and make new ones from them. This can be done again and
again a number of times.
THERMOSETTING PLASTICS
Thermoform setting plastics general have high thermal stability,

resistant to deformation under load, high dimensional stability,
excellent rigidity and hardness. Thermo set plastics softens only once

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under heat and harden material cannot be reheated as like
thermoplastic. However, the tightly cross-linked, high molecular
weight, thermosetting polymers are inherently weak and easily
fractured. They are not flame able with good heat resistance. Thermo
set plastic do not get soft on heating and never melt once set.
Electrical switches, cooker handle, telephone parts are

the examples of thermo set in general use. A completely
polymerized polymer can be shaped except by machining since
thermo set are all brittle.
The following major methods of transforming plastic

materials in to finished articles:
Thermoset plastic molding methods:
 Compression molding.
 Transfer molding.
 Transfer injection molding.
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Thermoplastic molding methods:
 Injection molding.
 Blow molding.
 Extrusion molding.
 Thermo forming.
 Rotational molding or centrifugal molding.
 Calendaring
INTRODUCTION TO MOULDS
MOULDING:
Mould is a tool, designed to form the component
with desired shape and size. The type of material to be molded
and the shape of the component are the major factor governing
the choice of the mould.

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Molding of plastic material comprises of
forming an article to the desired shape by the application of heat
and pressure in a hollow form or cavity.
Mould is a hollow form of cavity into which molten
plastic materials is forced to give the shape of the required
components. The terms generally refer to the assemble of parts
which go top make up the section of the injection molding
equipments in which plastics components are molded.
 TRANSFER MOULDING
 INJECTION MOULDING
COMMONLY USED MOULDING METHODS:
 COMPRESSION MOLDING
 EXTRUSION MOULDING
 BLOW MOULDING
 THERMO FORMING
INTRODUCTION TO INJECTION MOULDING

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The present time is considered to be the plastic age. Where an

unlimited number of plastic are being made available which in turn
broadens the avenues for a wide variety of application.
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Thermo plastics are generally processed by injection
molding which melts on heating and solidify on cooling. No
chemical change take place when the material is heated or cooled,
the change been entirely physical this cycle is repeated any
number of times.
Injection molding may be described as a batch process,

the granular molding material is loaded into the hopper and enters
the injection molding machine, passes into a heated cylinder and
into the mould by the means of convening plunger or reciprocating
screw.
The melt complete fills the mold cavity, solidifies and is

finally removed from the mold as finished article.
These are the following processes, which occur
during injection molding:
Plasticizing
Heating and melting of the granules of the plastics and

venting of the melt.
Injection

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The melt is injected into the relatively cold mold under high
pressure while closed. Solidification of the polymer begins
during the injection, first at the cavity walls.
Cooling
Molds are cooled in order to harden the material, which has

been injected into the mold, were the plastic material to
be solidified to facilitate ejection.
Mold release
The mold will be opened, ejects the component & gets

ready for the next cycle.
Platen size:
It is the area which is available between the tie bars,

which limit the dimensions of the mold which can be
mounted on the platen faces.
Minimum mold height (Tool shut height):
It limits the minimum height of the mold which can be

locked in position. Mold height can be increased by
inserting false plates between the mold and the moving
platen.
Maximum mold height:
It limits the maximum height of the mold that can be

mounted on the machine between the fixed and the moving
platen is in closed position.
Injection unit:

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Injection unit contains; Hopper, Barrel, Screw rod,
Heater bands, Hydro motor and nozzle. It contains hopper
and plasticizing unit, granular plastic material will be fed
through hopper to plasticizing unit, by rotation of screw rod
and barrel and it is injected through the nozzle to the
injection mold.
Clamping unit:
It consists of Fixed platen, Movable platen, and Tie bars.

Mold will be mounted and clamped between the two
platens with respect to working cycle. Register ringside of
the mold clamped at fixed platen side and ejection side of
the mold clamped at movable platen side. Plastic material
is injected from fixed platen side through sprue bush to
cavities. This unit clamps mold by toggle system or
hydraulic system.
Ejector unit:
This unit is fitted at moving platen side of the injection

molding machine. Ejector rod is clamped or connected with
ejector back plate and pushes the ejector unit by hydraulic
cylinder or mechanical.
Hydraulic controlling unit serves and pushes oil to all
moving parts of the machine, which works, on hydraulic
system and controlling unit controls it.
Controlling unit will control the setting of operating
parameters and machine settings, cooling circuit etc.
ADVANTAGES OF INJECTION MOULDING.

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 Parts can be produced at higher production rate
 Large volume of production is possible.
 Relatively low labor cost per unit.
 Parts with good surfaces or colors can be obtained.
 For many shapes this is the most economical method to

fabricate.
 Where manufacturing of parts in any other method is almost

impossible they can be easily produced by this method.
 Minimum scrap of the runners, gates and sprues can be

reduced.
 Close dimensional tolerance can be obtained.
 Parts can be molded with metallic and non-metallic inserts.
DISADVANTAGES:
 Comparatively costly process.

 Skilled workers are necessary for manufacturing and operating
these moulds.
 Assembly is not easy as there is more number of mating
Parts.
There is various type in injection mold, they are:

 1. Two plate mold.
 2. Three plate mold.
 3. Hot runner mold.

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2-PLATE MOULD:
A standard two plate mould is the simplest consisting

of one parting line opening or a single day light mould (exception
in case of stripper plate ejection). It consists of different parts
arranged and clamped in sequence, which make two main units of
the mould i.e., fixed half and movable half.
Advantages of two plate mold:

 Close dimensional tolerance can be maintained.
 Parts can be molded with metallic or non-metallic inserts.
 It offers simplicity of design, user friendliness, and utilization of
standard mold parts.
 For large production.
Limitation:
 Two-plate mold designs have limitations in component gate
positioning when conventionally fed.
 High material waste levels (sprue and runners).
 Lower production rates.
 Expensive in manufacturing.
 Skilled labor required.

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COMPONENT ANALYSIS
PHOTOGRAPH OF COMPONENT
230B wheel cap

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PART ASSEMBLY ON CAR

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Functional aspects of the component`
Before proceeding to the detailed tool design analysis,

component has to be analyzed for its material properties and
the applications of the components.
The 367A WHEEL CAP MOULD component is mainly used in

AUTO MOBILES. The components are fixed in wheel Rim
MATERIAL: PC ABS (IMC45WH GRAY)
SHRINKAGE: 0.6% - 0.8%
MOULD TEMPERATURE:
30 – 40o c (104 – 82.4 f) suggested 50 c (122 F). The mould
temperature determines the crystalline level.
MELT. TEMPERATURE:
230 – 300 c (410 – 374 F); higher range for low MFI resins and
vice-versa
INJECTION PRESSURE: 175 (bar)
COMPONENT WEIGHT: 406 gms

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USES OF 230B wheel cap
1.It is as an aesthetic part use in the car wheel. (Exterior part)
2.It is used to avoid rust in wheel rim & wheel clamping bolts
3.It gives a good look to the car
INJECTION SPEED:
Typically, fast injection speeds are used to minimize

internal stresses. It surfaces defects occur; slow speed
molding at higher temperature is preferred. Machines capable
of profiled speed are highly recommended.
CHEMICAL & PHYSICAL PROPERTIES
COMPONENT MATERIAL
PC ABS (poly carbonate)
• Excellent transparency
• High strength and toughness up to 140oC
• Very High Impact and break resistant
• Very good heat resistance
• High Weathering Resistance
• Good processing characteristics
• High capacity of wit stands capacity of wheel(RPM)

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INJECTION MOULDING PROCESS: -

Drying: Normally necessary if proper storage is used.
Melt Temperature: 230-300 ° C
PHYSICAL PROPERTIES:
 Tensile strength.
 Tensile elongation.
 Brittleness.
 Light resistance.
 Flexural modulus.
 Flexural strength.
 Good cushioning.
 Weather resistance.
PRE – MOLDING OPERTIONS
 PRE Heating (60 °c).
POST MOULDING OPERATION
 Painting
 Assembly of locking ring to wheel cap
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Painting process:
1. Antistatic air is applying to remove the dust at both side by
using a DE-IONIZER air gun.
2. IPA (iOS propylene alcohol) to remove the oil content in the
part.
3. After painting.
4. Baking (to make a paint dry by heating at °c)
5. Inspection by visual
Assembly of clamping ring:
After painting of the component clamping ring to be assemble.
Assembly process:
 Before assembly, to be inspect the part by visual.

 Assembly of clamping ring.
 After assembly inspection of clamping ring.
 Pack out.

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Before assembly:

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After assembly:

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Clamping ring
Functioning of clamping ring;
 Ring is provided for assembly of wheel cap

to wheel rim.

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TOOL DESIGN ANALYSIS
After analyzing the component thoroughly, the designer has

decided the manufacturing process of the component. The process
of manufacture should produce component with accurate
dimensions, good finish and higher rate of manufacture.
We have already discussed that a plastic, component can be

molded in four molding methods, i.e. injection molding,
compression molding, extrusion and transfer molding. Selection of
molding process largely depends on the molding material.
Features of tool design
 The tool designer should know the different manufacturing

process.
 Tool should be designed economically.
 Designer should provide a drawing to produce the work
piece.
 The designer should be able to suggest any rectification to
the problems arising out while assembly and manufacturing
process.
 The design may be turned as a complete plan for
manufacturing of the tool for given component, it includes
all the.

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Factors for designing
consideration: -
These factors to be considered before designing the tool

to make the successful design.
Primary consideration: -
 Part quality
 Economy of production.
Secondary considerations: -
 Parting surface
 Feed system
 Hot sprue
 Valve gate
 Hydraulic ejection
 Mirror finish cavity
 Cooling
 Type of cooling line.
1.PART QUALITY: -
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It mainly depends upon functional requirement and
customer satisfaction. The prime cost consideration is given to
the part quality requirement, which decides the method and
process of manufacturing.
1. ECONOMY OF PRODUCTION: -
The designer should design a mould in such a way that the

part will be produced at the most economical rate of production.
PARTING SURFACE:
This tool has a profile surface it is noted here that in cross
section, the molding form is constant with some profiles curves.
Component has profile parting surface.
FEED SYSTEM
The flow way, which connects the nozzle of the injection
molding machine to the cavity is referred as feed system. comprises
of, hot runner system
HOT SPURE:

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It is connecting member between the machine nozzle and
runner system. This is designed in such a way that is should minimize
the pressure drop and delivers material to the extreme end position.
Normally
VALVE GATE:
With its topless structure, the gate is machined directly into the
cavity, which is advantageous to cooling effectiveness and
transcription of pin diameter. In case of valve equipped with
separate tip heater located at its front-end, the tip heater can heat
synchronously with the molding cycle to employ intermittent heating.
This unique function facilitates the molding of the crystalline resins.
HYDRAULIC EJECTION:
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The type of ejection depends on the shape and type for component.
In This Mould it has special type of ejection it is (HYDRAULIC
EJECTION)
Ejector Pin - 42 Nos.
Push Back pins - 4 Nos.
MIRRORFINISH CAVITY:
It is a process made on either cavity surface or on core surface (if it

is considered in design). Mirror finish can be obtained by polishing.
Through different types of polishing equipments like (emery of all
types, polishing pastes, diamond pastes, polishing machines, oil
stones of all grades, ceramic stones etc.
 Mirror finish cavity is made for only aesthetic parts

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 Mirror finish parts can have painted and plated
COOLING:
Maintenance of the correct mould temperature

greatly influences the injection speed and the distortion of the mould
part. Water is common cooling medium. However, if temperature
exceeding 900C are required oil cooling is preferred.
Main Functions of Cooling

 To decrease the cycle time.
 To remove the component easily.
In This Mold Channel with Baffle and U Circular Cooling Is Given

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Purpose of Cooling:
 The temperature has to be controlled for two purpose.

 To keep the temperature of the mould at a constant level during
the operation.
 To heat the mould to working temperature before the start of
production.
 Cooling takes a maximum portion to reduce the over ‘all mold
cycles.

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HYDRAULIC CYLINDER PROCESS:
 Hydraulic system is use to operate the core ejection

system
 The working pressure of operating the cylinder is set
to (70bar)
 The main parts of the hydraulic cylinder are
 Piston
 Cylinder body
 Piston rod
 Piston seal
 Rod seal
 Wiper/dust seal

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 The hydraulic cylinder is having two ports for Forward
& reverse movements, direction is control by solenoid
valve & is pressure is controlled by proportional
pressure relief valve.
 In machine separate hydraulic power pack to operate
mold core ejection cylinders, which is interfaced with
machine functioning.

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SELECTION OF RAW MATERIAL
The steel used in the manufacture of a mold base various
depending upon the requirements of the application proper material

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selection & proper combination of alloys in varying percentage is
require for finished tools.
CRITERIA FOR SELECTION OF

MATERIAL
The primary factors influencing the selection of material for plastic
molds are: -
 Type of plastic to be molded

 Method of molding.
 Design of the part to be molded. (Size & complexity)
 No of the component produced.
Other factors inter related with the primary factor are physical
and chemical properties of mould materials
 Palatability is essentially important for transparent for

transparent plastics.
 Where a smooth surface on final product is mandatory
 Structural soundness and uniformly.
 Toughness
 Resistance to corrosion.
The material selected for our tool should have very good
dimension stability under extreme mold temperature (i.e. above
125c) for a long period.
Tool steel distinguish by method and care in manufacturing a quality

of steel suitable for use in the making of tools, as opposed to
structural steel. Each part of the tool has its own function to perform,
which effects raw material for the particular part. The basic material
is selected for this tool is STEEL.
MILD STEEL

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Mild steel is also known as ST-42 is a material which is
easy to machine and also very economic. The most of the
mould base is manufactured out of this material.
CASE HARDENING STEEL
The is codification for case hardened steel is 17MnCr95. Case

hardening steel is selected for the parts, which should be hard and
wear resistance on the surface only and core of the part should be
soft. Casehardening steel contains 17% of carbon, 1% of
manganese and 0.9% of chromium. This steel has to be carburized
and then hardened. It can be hardened up to depth of 0.86 to 1mm.
Usually guide pillar and guide bush are case hardened.
P20
The is codification of P20 is T35Cr2Mn80M045. It is pre-hardened

mould steel that has very good polish ability and good machinability
P20 steel contains 0.85%of manganese, 0.5%of silicon, 1.78%of
chromium, 0.35%of carbon and others.
SL NO DESCRIPTION MATERIAL REMARKS
01 TOP PLATE ST-42 -

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02 CAVITY HOUSING PLATE ST-42 -
03 CORE HOUSING PLATE ST-42 -
04 SPACER ST-42 -
05 EJECTOR PLATE ST-42 -
06 EJECTOR BACK PLATE ST-42 -
07 BOTTOM PLATE ST-42 -
08 LOCATING RING ST-42 -
09 SUPORT PILLER ST-42 -
10 CORE P20 52-54HRC
11 CAVITY P20 52-54HRC
12 MAIN GUIDE PILLER OHNS 58-60CHD
13 MAIN GUIDE BUSH OHNS 58-60CHD
14 EJECTOR GUIDE PILLER OHNS 58-60CHD
15 EJECTOR GUIDE BUSH OHNS 58-60CHD
16 SPURE BUSH OHNS 52-54HRC
17 REST-BUTTON OHNS 52-54HRC

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ESTIMATION
Estimation is an art of finding the cost, which is likely to be
incurred on the manufacture of an article before it is actually
manufactured. It requires high technical knowledge about
manufacturing methods and operations etc. Be sure whether ten

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manufacture of a particular article is profitable or not. In case the tool
cost is estimated from the design.
Functions of Estimation:
 Determine material cost.

 Determine labor cost.
 Cost of material to be produced.
 Determine cost of tools and equipments.
 Overhead charges including selling, packing and transport.
 Selling price after adding due profit.
Advantages of Estimation:
 To help the owners in deciding the selling price.

 To help in filling up of tenders.
 To decide about the amount of overheads this helps in
comparing and checking the actual overheads of the factory.
 To decide about the wage rate of the workers.
 It helps to decide whether a particular item should be produced
from market or to manufacture.
Total Cost = Prime Cost + Overhead Cost + Design Charges +

Risk Factors.
Prime Cost = R.M. Cost + Machining Cost + Std items Cost + Heat
Treatment Cost + Assembly Charges + Tryout.
Profit + 20% of total cost.

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Present market price list of raw materials: -
 St-42 :- Rs 100/kg
 OHNS :- Rs 220/kg
 HDS :- Rs 230/kg
 P20 :- Rs 380/kg
Estimated Machine Operation Cost: -
 Surface Grinding :- Rs. 100/Hr

 Cylindrical Grinding :- Rs. 150/Hr
 CNC Milling :- Rs. 1000/Hr
 Sparking :- Rs. 500/Hr
 Wire Cutting :- Rs. 450/Hr
 Drilling :- Rs. 100/Hr
 Turning :- Rs. 150/Hr
 Bench Work :- Rs. 60/Hr.
DESCRIPTION COST IN RUPEES (Rs)

Raw Material Cost Rs. 658000/-
Standard Items Cost Rs. 600000/-
Machining Cost Rs. 10,00000/-
Heat treatment Charges Rs. 40000/-
Assembly Charges Rs. 30000/-

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Tryout Rs. 10000/-
Prime Cost Rs. 24,46,000/-
 Standard items [HOT RUNNER SYSTEM< Screws, Ejector

pins, Push back pins, etc, = Rs. 6,00,000/-
TOTAL ESTIMATED COST: -

Prime cost Rs. 24,46,000/-
Design Cost Rs. 60,000/-
Over Head Cost Rs. 60,000/-
Risk Factor Rs. 60,000/-
Total Estimated Cost Rs. 28,26,000/-
 Design Cost = 15% of Prime Cost.

 Over Head Cost = 15% of Prime Cost.
 Risk Factor = 15% of Prime Cost.
COSTING
Costing may be defined as a system of accounts in which

expenditure analyzed to find the total cost of each particular unit if
production is more accuracy. The project of preparing cost accounts
is knowing the exact cost incurred during each operation involved in

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you the manufacture of the article and the cost of other activities of
the business.
Cost accounting is done by a person qualified for account

& not by qualified technician.
Aims of costing: -
 Detecting the wastages.

 Helping in reduction of the total cost of manufacturing.
 To help in formulating the policies for changing the price pf the
product.
 To suggest changes in design if the cost is high.
 Determining the cost of each article.
 To provide information to a certain the selling price of the
products.
 To determine the cost incurred during each operation to keep
control over worker’s wage.
Advantages of costing: -
 Its keeps control over selling price.

 It is useful in tracing wastage, leakage & spoiled material.
 Profitable & unprofitable activities are traced properly.
 Actual causes of reduction in profit can be easily found.

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THE VARIOUS COMPONENT OF COST OF ANY PRODUCT
MANUFACTURED IN ANY PRODUCTION CONSIDERED ARE AS
FOLLOWS: -
 Prime cost = Direct material + Direct labor + Direct expenses.

 Factory cost = Prime cost + Factory overheads.
 Cost of production = Factory cost + Administrative overheads +
Miscellaneous overheads.
 Total cost = cost of production + selling & distribution
overheads.
 Profit = 15% of Total cost.
 Selling cost = Total cost + profit.
MISCELLANEUOS OVERHEADS: -
 Design charges = 10% of prime cost.

 Inspection charges = 10% of prime cost.
 Profile margin = 15% of prime cost.
THE ELEMENTS OF COST CAN BE CLASSIFIED IN TO

FOLLOWING: -
 MATERIAL
 Direct material.
 In direct material.
 LABOUR

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 Direct labor.
 Indirect labor.
 EXPENSES
 Direct expenses.
 Overhead expenses.
 Factory expenses.
 Administration expenses.
 Selling & distribution.
STANDARD ITEMS COST: -
HOT RUNNER HEATER = 3,00,000/-
Company – YUDO, JAPAN, Co…., LTD.
ESTIMATED MACHINE OPERATION COST: -
 Surface Grinding :- Rs. 100/Hr.

 Cylindrical Grinding :- Rs. 150/Hr.
 CNC Milling :- Rs. 1000/Hr.
 Sparking :- Rs. 500/Hr.
 Wire Cutting :- Rs. 450/Hr.
 Drilling :- Rs. 100/Hr.
 Turning :- Rs. 150/Hr.
PRESENT HEAT TREATMENT CHARGES: -
 Case hardening = Rs. 100/kg.

 Through hardening = Rs. 150/kg. (Total cost = Rs. 40,000)
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ACTUAL RAW MATERIAL COST: -
MATERIAL QUANTITY IN RATE/KG COST IN RS

KGS
P20 380 1500 5,70,000
ST-42 40 1000 40,000
OHNS 120 1206 1,44,720
HDS 300 750 2,25,000
TOTAL MATERIAL COST 9,79,720
ACTUAL MACHINING COST: -
OPERATION RS/HR HOURS COST IN RS

MILLING 350 190 66,500
GRINDING 300 250 75,000
DRILLING 150 75 11,250
TURNING 200 60 12,000
SPARKING 700 250 1,75,000
CNC MILLING 1100 750 8,25,000
WIRE CUT 350 150 52,500
BENCH WORK 100 50 5000
TOTAL MACHINING COST 12,22,250

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TOTAL MACHINING HOURS: -
TOTAL MACHINING COST: -

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ACTUAL PRIME COST: -
Raw Material Cost Rs. 9,79,720/-
Standard Items Cost Rs.7,10,000/-
Machining Cost Rs. 12,22,250/-
Heat treatment Charges Rs. 40000/-
Assembly Charges Rs. 30000/-
Tryout Rs. 10000/-
TOTAL PRIME COST Rs. 29,91,970/-
TOTAL TOOL COST:

Prime cost Rs. 24,12,000/-
Design Cost Rs. 60,000/-
Over Head Cost Rs. 60,000/-
Risk Factor Rs. 60,000/-
Total Estimated Cost Rs. 25,92,000/-

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DESIGN COST = 15% OF PRIME COST.
OVER HEAD COST =15% OF PRIME COST.
PROFIT = 15% OF TOTAL COST
= 4,51,000/-.
TOTAL SELLING PRICE = TOTAL COST+PROFIT

= RS. 25,92,000 + 4,51,000
= RS 30,43,000/-.
ACTUAL TOOL COST = 30,43,000/-.
TOTAL TOOL COST

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Process planning
Before actual manufacturing of the tool parts, the tool maker

has to be decide the process of manufacturing of each part from the
raw material stage to finished product. the procedure is called as
process planning.
Process planning includes developing the method of
manufacture the tool, so that it can be provide d economically at a
competitive price .it establishes the correct sequence of operations
The process planning directly effects the tool cost i.e. an
incorrectly planned manufacturing process increases machining time
there by increases the tool cost.
For the manufacturing of hardened parts extra care should be
taken while deciding the manufacturing process, because machining
of the hardened parts is relatively costly and tedious
Requirement in process planning

 A brief description of the job to be manufactured.
 Specification and standers to be adopted by the job.
 Drawing should facilate all the specification of the job.
 Equipment data should include capacity of machines

availability of equipment in the job.
 Condition and location of existing plant.
 Existing man power and staff

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PROCESS PLANING INVOLVES FOLLOWING

STEPS:
 Planning
 Routing
 Scheduling
 Dispatching
 Follow up
 Inspection
Steps in process planning:
1. Design review to make quality requirements and

manufacturability simpler.
2. Study and critically analyze the manufacturing specification
available.
3. Determine what parts are to be manufactured.
4. Continuous follow up each part from the raw material to the
finished part.
5. Prepare a list of raw material of right quality and quantity.
6. Determine the most economical process for manufacturing.
7. Select the proper machine and best sequence of operation.
8. Provide clear documentation of each operation.
9. Determine the stages of inspection.
10. Assemble all the parts of mold with proper care.
11. Tryout of fabricated tool.
12. Trouble shooting of the component.
13. Determine the actual cost of the tool and component.

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MANUFACTURING PROCESS
FLOW CHART FOR TOOL MAKING
Design

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Planning
R.M. store
General machining
Pre tooling Turning Milling Grinding
Stage inspection
Special purpose machining
Bench work
Stage inspection
Heat treatment
Stage inspection
Grinding
Machining operation
EDM CNC Milling WEDM
Stage inspection
Polishing
Final inspection
Assembly
Try out
Rework Component inspection Accepted
MANUFACTURING OF TOOL ELEMENTS &

TOOL TERMINILOGY

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1. LOCATING RING
Material ST - 42
It is a circular member fitted on the front of the mould. Its

purpose is to locate mould in its correct position; it has sliding
fit with the hole in fixed platen.
1. Raw material is pre-machined with 0.5mm grinding

allowance.
2. Dia. 180 for fit is maintained on lathe.
3. Drilling of the clearance hole and counter bore for screws.
4. Thickness grinding to required size with parallelity.
5. Inspection of all details as per drawing.
2. TOP PLATE
Material ST - 42
It is the top most member of the mould, it has threaded

holes to fit in register ring. It has cooling hole connection to
cavity insert.
1. Raw material is premachined with 0.4mm grinding

Allowance
2. Grinding thickness to parallelism and all sides to a extract
Right angle.
3. Boring for locating ring and sprue bush to be seated.
4. Drilling and Tapping of threaded holes for fitting of register

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ring in the top plate.
6. Drilling of clearance holes and counter bores for screws.
8. Final inspection with all assembly
3. CAVITY PLATE
Material ST - 42
In this plate the cavity profile is machined as per design.

Cavity profile gives a outside profile of a component.
1. Raw material is pre machined with 0.8mm

grinding allowance.
Right angle.
3 Drilling the screw holes as per drawing.
4 Guide bush holes were drilled and bored.
5 CNC milling of Cavity Profile as per design.
6 Drilling of cooling hole as per drawing.
7 Assemble the guide pillar in cavity plate
8 Inspection of all details as per drawing final inspection
With all assembly.
4. CORE PLATE

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Material ST - 42
In this plate core profile is machined as per design. The

core profile gives an inside profile of the component.

allowance
Right angle.
3. Drilling the screw holes as per drawing
4. Drilling and boring of guide pillar holes.
5. CNC milling of Core Profile as per design.
6 Drilling of cooling hole as per drawing
7 Assembly the guide bush in the core plate
8 Inspection of all details as per design
9 Final inspection with all assembly
5. SPACERS
Material – ST - 42
These are the rectangular blocks. These are used to give gap for
ejector mechanism to actuate. These have relief hole for clamping
screws.
1. Pre tooling with 0.5 mm allowance for grinding.
2. Grinding of thickness all sides to exact right angles and
Maintaining the dimension
3. Drilling hole clearance for screws.

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4. Inspection all details as per design.
6. EJECTOR ASSEMBLY
Material – ST- 42
Ejector assembly consists of ejector plate, ejector back

plate and ejector guide pillar and ejector guide bush. Ejector
plate houses ejector pins, push back pins and ejector guide
bush.
The purpose of ejector back plate is to transmit the force
from actuating system of the injection-molding machine to the
mould ejector assembly. The ejector plate is securely attached
to the back plate with the help of screws.
1. Pre tooling with 0.5 mm allowance for grinding
2. Grinding of thickness all sides to exact right angles and
Maintaining the dimension
3. Drilling of fitting holes for ejector and ejector back plate by
Assembling together.
4. Drilling hole clearance and counter bore hole for return pin.
5. Drilling and reaming for return pin holes in ejector back
Plate.
6. Inspection all details as per design.
7. GUIDE PILLAR AND BUSHES

Material – OHNS

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 It is necessary that the core & cavity are in perfect alignment
with each other.
 This is done by incorporating guide pillars on the mould plate,
which enter into corresponding guide bushes of the other plate
as the mould closes.
 Guide bushes provide a wear resisting surface on the guide
pillar which results in replacement of the event of wear or
damage.
 The internal bore of the bushes is designed as a precision
sliding fit. H7/H6 on the adjacent pillars.
 The external different diameter of bush impresses a fit into the
mould plate H7/H6. The pillar is given a 15 angle for distance
of 50mm.
 Generally, four guide pillar are provided in an injection mould.
Three pillars are of equal size while the fourth one is made
slightly smaller or bigger for the purpose of fool proofing.
 It is made of case hardened steel. Pillars are hardened to
57/59 HRC, while the bushes to 59/61HRC.
8. RETURN PINS
Material – Std.
These are large diameter pins fitted closely to the

comers of the ejector plate assembly. These pins end at
the parting surface and protrude when ejector system is
actuated. It pushed back to its position when tool is closed.

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9. EJECTOR PINS
This is the simplest and common type of ejection.

The purpose of ejector pins is to take out the component
from the core when the mould is opened. These are
circular steel rods called ejector pins fitted in
Ejector assembly. The ejector pin must have good slide
fit on its mating hole.
Material – Std.
Ejector Pin - 12 (11Nos.)
10. SPRUE BUSH
Material – OHNS
It is the part in which the sprue is formed. It connects the machine
nozzle to the start of runner system. It has an internal taper of 2.50
– 40 degree.
1. Material was turn as per drawing by keeping grinding

Allowance.
2. Heat treatment was done according to requirement.
3. Cylindrical grinding of respective parts which has fit

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Diameter
4. Wire cutting of the sprue bush with respect angle.
5. Sparking the sprue in sprue bush, by using a copper
Electrode.
11. BOTTOM PLATE
Material – ST - 42
It is the last member of the mould to which the core
plate, core back plate and spacers are clamped. It is
machined. It has a hole in center in to which the ejector grid,
which enter in plate while ejecting.

Allowance
2. Grinding thickness with parallelity and size is maintained.
3. Boring for ejector rod according to drawing.
4. Clearance holes for screws are drilled.
12. CORE INSERTS (P20)
It gives the internal profile of the component

allowance
3. Drilling of clamping hole and dowels.
4. CNC milling according to the drawing.
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7. Then maintain right angle and sizing.
8. CNC milling according to model.
9. EDM machining according to drawing.
10. Wire cut of the ejector holes.
13. CAVITY INSERTS(P20)
It gives the external profile of the component.

allowance
3. Drilling of clamping hole and cooling holes.
4. CNC milling according to the drawing with 0.3 stocks.
7. Right angle grinding and sizing.
8. Then CNC milling as per model.
9. EDM machining according to drawing.
10. Wire cut of the cavity inserts pocket.
MANUFACTURING OF ELECTRODES
A. Electrode for CORE and CAVITY.

1. Pre machining of electrode with a grinding allowance

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2. Grinding to parallelism and mark reference.
3. Tapping hole for electrode to be held in a fixture
4. CNC milling as per drawing keeping spark gap.
B. Electrode for SPRUE.

1. Turning of sprue taper with 0.075mm inside spark gap.

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HEAT TREATMENT
Heat treatment is a process of heating and cooling the

metals under definite conditions change their properties
according to the process used, steel can be hardened to resist
cutting action, scratching, indentation or penetration by other
materials. In some cases, steel is softened to permit further
machining.
In this process internal stresses can be removed from

the metals and grain structure may be altered.
The metals are made more resistant to wear, heat and

corrosion.
Hardening:
Hardening is a process that includes hardness and
wear resistance to the steel the hardening process is carried
out in the following procedure.
Pre – heating:
It is very important part of treatment. The work piece is held in
the muffle furnace to a temperature of 800c and held at that
temperature for 30 minutes and then it is transfers to neutral salt
bath.
If the work piece is not pre heated the work tend to crack
during quenching when it is heated from room temperature to the
hardening temperature. The life of the work piece is also reduced

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Heating to hardening temperature:
After heat treatment the work piece is transfer to the neatly
salt bath which is maintained at hardening temperature. The job is
soaked to ensure uniform heating of the work piece from case to the
core of the work piece.
Quenching:
Quenching is done to cool the part rapidly and to transfer to
the austenite to marten site structure without allowing the
formation of pearlite. Agitating the work piece in quenching media
ensures uniform quenching of the core and surface.
Tempering:
Tempering is a process whereby parts are heated between
150c-300c following hardening of case hardening,
 To relive stress from the hardening operation.
 To soften the part to deserved hardness.
 To develop dimensional stability.
Stress relieving:
 Stress relieving is a process whereby cooling are heated
to 650c followed by cooling.

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 To reduce stress due to welding or cooling working.
 To develop dimensional stability.
Vacuum hardening:
A major benefit of vacuum hardening is that it produces an
end product will minimum distortion of scaling. The controlled
environment of precise temperature controls the dimension and also
enables the achievement of higher standard for the metal as alloy
part. The vacuum process delivers a bright and clear finish.

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INSPECTION
Inspection plays an important role in tool making of

manufacturing of any part. It seems that the manufacturing of
component or part will have its own importance in a particular field in
order to determine the fitness of anything made. Man has always
used inspection.
Types of inspection:
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 Tool inspection
 First piece inspection
 Working inspection
 Sample inspection
 Operation inspection
 Final inspection
 Functional inspection
 Visual inspection
 Floor or patrol inspection
Functional inspection:
It involves testing, the function of a product practically by
assembling it with the mating part in order to clarify whether the
guiding or locking areas are molded properly for its efficient function.
Visual inspection:
This method involves the use of the human eye to judge the quality
and aestheticism of a product.
FINAL INSPECTION
After assembly the final inspection is carried out to confirm the
alignment, parallelity of the tool, pitches and sizes of the tool etc. at
last inspection of component after tryout is done to verify whether the
component.

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TYPES OF FIT ASSOCIATED WITH VARIOUS
PARTS OF INJECTION MOULDING TOOL:
DESCRIPTION TYPE OF FIT FIT
Locating ring to top Slack running fit H7/m6

Plate
Guide pillar and guide Sliding fit H7/h6
Bush
Guide bush with floating Light force fit H7/g6
Cavity plate and core
Plate
Push back pin in core Running fit H7/r6
plate
Guide bush with floating Light force fit H7/g6
cavity plate and core
plate
Sprue bush in the top Push fit H7/i6
plate
Ejector pin with core Close running fit H7/k6
insert
Ejector guide bush and Slack running fit H7/m6
guide pillar
Ejector bush with ejector Running fit H7/r6
plate
Ejector pillar with bottom Press fit H7/f6
plate
Purpose of Inspection:
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 It helps in detecting defects arising in production due to
defective machinery process.
 It traces defects in raw material, which may be unsuitable to be
used in a tool.
 Inspection reduces further work on semi-finished parts thereby
avoiding further wastage of time and money.
 It ensures whether the quantity of the goods
 It ensures whether the quantity of the goods supplied to the
customer is according to the standards.
Final tool assembly is the stage where the mould is aligned
between core and cavity with respect to each other.
Measuring instruments used:

In this tool, Vermeer caliper, Micrometer, Depth micrometer, Dial
indicator, Slip gauges, Radius gauge etc., are used for the inspection
of parts in the shop floor
polishing
The expansion & development of plastics industry has
been attended by many problems, including those associated
with the cutting, shaping polishing and maintenance of the
moulds. Almost all the machines operations leave cutter
marks on the machined surface, which must be removed
before a mould can be put in to production. Polishing is the
last finishing operation done on core & cavity as well as side
cores for converting the rough surface into a smooth surface.

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Need of Polishing:
 Badly finished areas in the mold, causing the molding to stick
or adhere to the mould often cause ejection difficulties.
 If a molding is to transparent or translucent or to have a high
brilliance and reflect ability as required.
 To protect from acid formation and prevent from rusting
surface.
Factors which affect polish ability:

Tool steel quality
Heat treatment
Polishing technique
Advantage of polishing:
 Good surface finish
 Easy ejection.
 Easy flow.
 Stress free component.
 To reduce risk of local corrosion.
 To reduce risk of facture due to fatigue.
 To remove week top layer in the mold.
TOOL STEEL QUALITY:

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Particles or areas in the steel surface, which deviate
from the matrix in terms of hardness and other properties, can
cause problems during polishing. Slag in conclusions of
various types and porosities by improving homogeneity of
steel can improve polishing properties.
POLISHING TECHNIQUE:
In general, it can be stated that polishing technique is
the most important factor. If a suitable polishing technique is
used, it is always possible to achieve acceptable results.
Providing correctly heat treated good quality tool steel is used.
If, however, an unsuitable technique is used, even the best
steels can be ruined.
POLISHABILITY:
Polishing is a time consuming, and consequently
expensive process sometimes accounting for up to 30% of the
tool cost of the mould. The results obtained depend to a large
extent on the polishing techniques used and the following
points:
 The cleanliness of the steel (Type of steel, distribution
and size of non-metallic inclusions it contains)
 The homogeneity of the steel
 The hardness of the steel (How the heat treatment has
been carried out.)
.

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INGREDIENTS USED:
 Polishing stone (medium).
 Emery paper (180, 220, 400).
 Lapping paste.
 Diamond paste
MIRRORFINISH CAVITY:
It is a process made on either cavity surface or on core surface (if its
considered in design).it can obtain by sand blasting if the grain
structure is larger. Texturing has many different types of producing
different texture surface. To produce different texture, they have
different surface templates to make in unique style.
Firstly, a template in given design placed thoroughly on cavity
surface, (before undergoing the process cavity surface should be
exactly polished) because a uniform surface in a cavity gives a
uniform texture surface and after a liquid chemical base poured on
the template which is contact with cavity surface. They dry it for some
time; due a chemical reaction an impression in a template transforms
impression to cavity surface.
TEXTURING is normally called a CHEMICAL ETCHING

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We have now come to the final stage of manufacturing of this
tool. Assembly is a high skilled operation, which is done by the tool
maker. The skill of the tool maker is requiring in fitting in each part
into the right place as per design to produce successful tool. The
two important things to be kept in mind while assembling are care
and cleanliness. If the care is not taken while handling the parts it
leads to damages which in turns leads to loss of time and increase
the cost.
FINAL ASSEMBLY PROCESS
Assembly is the final and foremost important stage in the

manufacturing of the mould. In this process even a slight in
accuracy may cause distortion or incorrect functioning of the tool.
To overcome this problem, a systematic assembly procedure
has to be followed.
The procedures involved are as follows

1. Preparation and checking the alignment of mould box.
2. Assembly of top half
3. Assembly of bottom half
Mold alignment:
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Before going for assembly of all the parts the mould box (mould base)
should be checked for perfect alignment.
All the parts are clamped together as per design with pillars and
bushes in their respective places. The other parts are not assembled. The
bottom half is placed on flat surface. A thin film of oil is applied to the
sliding surface until the halves but on to each other. Then the halves are
opened.
Ejector assembly:
After checking the mold box alignment, ejector assembly should be

checked for alignment. For this, the ejector plate is clamped together along
with the ejector guide bush. The ejector guide pillars are assembled in the
respective holes in core housing. A thin film or oil is applied on the sliding
surface of pillars and bushes. If the ejector assembly is not sliding
smoothly, then polish in pillars on the lathe until the ejector assembly
slides smoothly.
Blue matching: (bedding)

Blue matching is a procedure where a paste known as Prussian
blue is applied on any one of the parting surface. The two halves
are assembled with some pressure for mating of the parting surface.
After opening the two halves the blue will highlight the high
points on the parting surface. The high points are removed by
polishing or by grinding. this process is followed until an even film of
blue is transformed from one to the other.
In this tool blue matching was done to check the matching
surfaces. steps taken during final assembly.
ASSEMBLY MACHINING OPERATIONS.

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1. All screw holes are transferred from screw hole of core &
cavity plates to their respective back plates.
2. All relief holes are drilled.
3. All pillar holes, puller bolt holes, are too transferred to
respective plate.
4. Height of all core pins, ejector pins push back pins matched to
the respective surface.
5. All guides for respective side cores were matched and
clamped in the housing.

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PROCEDURE INVOLVED IN FIXED HALF ASSEMBLY

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PROCEDURE
1. All the parts to be cleaned oil stoned & lubricated.
2. Clean the guide bush hole and fit the guide bush into the
cavity plate. And locked.
3. Fit the cavity insert into the cavity plate and clamped by
screws.
4. Mount the cavity plate to top plate.
5. Fit the locating ring into the top plate.
6. Fit the sprue bush & lock it to cavity plate.
7. Fit the finger cam pin assembly into the cavity plate.
8. Identify all the fixed half parts with numbers and letters for
easy Reassembly.
9. Fit the couplers to cavity cooling holes.

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Project Report
ASSEMBLY MOVING HALF

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Project Report
PROCEDURE
1. Clean all the screw holes, Pin holes, pillar holes.

2. Grounded surface of all parts to be cleaned, oil stoned &
lubricated.
3. Fit the guide pillars into the core housing plate.
4. Fit the spring into the core housing plate.
5. Place the ejector plate and align the return pin through
the ejector plate spring and core housing plate.
6. Fit the ejector guide bush and guide pillar into the ejector
plate and mount guide pillar to core plate.
7. Align the all ejector pins throw the ejector plate core
housing plate and core insert. Lock the ejector pins.
8. Clamp the ejector plate and ejector back plate.
9. Place the parallel blocks.
10. Fit rest buttons into the bottom plate.
11. Place the bottom plate upon the parallel blocks and
mount the moving side to core housing plate’
12. Fit the guide rails into the core housing plate.
13. Align the side core and fit the stoppers.
14. Fit the couplers to cooling holes.
16. Identify all the moving half parts with numbers and letters
for easy Reassembly.

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Project Report
PIN AND HYDRALUIC CORE
EJECTION

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Project Report
MOULD ASSEMBLY:
1. The core half or bottom half in kept stationary.

2. The cavity half is chained and lifted up with help of an over
head crane.
3. Reference surface is confirmed between guide pillars and
guide bushes.
4. The top half is slowly brought down.
5. At this stage the core insert surface but with cavity insert
surface.
6. Heights of the core insert are maintained until the core
matches with the cavity.

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Project Report

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Project Report
TRYOUT
Trying out of tool is procedure it is done after the final

assembly, if every detail has been looked off carefully during
manufacturing of too. This will part of during the try out where the
tool is subjected to actual looking conditions and check the
working performance of tool and type of molding defects are noted
and then re-worked in tool.
The 230B wheel cap was loaded on 550tones

molding machine which full fills all necessary required
functions. The molding machine that is shut height, locking
pressure & injection pressure etc.
The tool was mounted on the machine using overhead

crane, the locating was located in the bore of the platen and the
tool was clamped to the platen using clamping devices.
After clamping the guiding parts of the tool were

lubricated and the tool was opened and closed 2-3 times to
check the proper alignment of both halves. Prior to try-out, the
movement of moving half is set so that the component ejected
without any restriction.

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Project Report
The tool was pre-heated and then the tool was kept ready
for trial. The injection machine barrel was cleaned because the
previously used material was different.
The PC ABS material was put into the machine hopper.

The temperature at the different stages in cylinder was
adjusted. The actuator (screw rod) is made to move towards
the mold
and injection pressure is adjusted. The material is injected into

the mold and the mold is kept closed for a specified time (cure
time). The mold is opened and the component is ejected.
In the first shot the component was unfilled because of

less injection pressure. Then the injection pressure was
increased and in second shot the cavities were filling and the
component was obtained.
The component is inspected for various defects and if

necessary the tool is re-worked.
In this tool the component was inspected and the

dimensions were as per the drawing. Thus the first trial was
successful.

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Project Report
TIME IN
SL.NO DESCRIPTION SEC
Mould closing
1 time 2
2 Injection time 6
3 Holding time 3
4 Cooling time 9
Mould opening
5 time 3
6 Ejection time 3
TOTAL TIME 26
COMPONENT PARAMETERS
01. MATERIAL PC ABS IMC WH 45
(GRAY)
02. SCREW SPEED 60 RPM
03. SHOT WEIGHT 408.5gms.
04. COMPONENT WEIGHT 406gms.
WITHOUT RUNNER
05. MOULD HEIGHT 720 h

06. LOCKING PRESSURE 550 tons
07. PREHEATING 60oc (2-3 hrs)
08. TYPE OF MACHINE EC 550Nii-36A
(TOSHIBA)

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Project Report
CYCLE TIME OF THE MACHINE

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Project Report
TRY OUT PROCEDURE
1. The tool is loaded on the injection molding machine.

2. The locating ring is located in the bore of the platen.
3. The ejector rod of proper size is fixed to the machine.
4. The moving platen is made to butt to the three bottom place and
clamping pressure is exerted.
5. The tool is opened and closed two to three times to check
the proper alignment of the both halves.
6. Prior to the try-out the movement of the moving half is set so
that the component and the sprue get ejected without any
reason.
7. The preheated material is put in the machine hopper.
8. The temperatures at the different stages in cylinder are adjusted.
9. the actuator is made to move (screw or plunger)
10. Injection pressure is adjusted.
When everything is set material is injected, the mould is
injected, and mould is kept closed for a specific period (core
time)
11. During which period the fluid material becomes solid and
rigid.
12. The coolant (water is made to circulate) through the water
ways of the mould. So that heat from the fluid plastic is
transferred to the mould and from to their circulating fluid.
13. The mould is opened and the component is ejected out.

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Project Report
14. The component is inspected for various defects if necessary,
the tool is reworked.
DEFECTS AND REMEDIES
In first trail the component had some defects partial

filling of the mould. Some more defects were also find out.
Defects & Remedies of try out
1.Sink Mark Fast filling is used.

2.waviness Mould temperature monitoring.
3.Flash on parting Over packing
line
Some defects and remedies are given below which can
be used if necessary.
DEFECTS REMEDIES
2. Variations in Dimensions to be corrected.

components dimension
3. Dull surface finishing Diamond polishing done
4. Flash is absorbed at pl Adjust the dimension or decrease the
surface part thickness ratio.

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Project Report
TROUBLE SHOOTING
Trying out of tool is procedure it is done after the final

assembly, if every detail has been looked off carefully during
manufacturing of too. This will part of during the try out where the
tool is subjected to actual looking conditions and check the
working performance of tool and type of molding defects are noted
and then reworked in tool.
The 328A wheel cap MOULD was loaded on 550 tone

molding machine which full fills all necessary required
functions. The molding machine that is shut height, locking
pressure & injection pressure etc.

106
Project Report

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Project Report
Conclusion:
This project report on “Two plate mold” gives the general
idea of tool making by explaining the various aspects, from
designing process to matching.
This project is an idea and acts as a reference guide in

field of tool making. It explains the methodical way of
manufacturing a tool and how to overcome some
problems in molding process.
As a whole this project has helped in improving our overall

skill as a tool maker and also helped us in presenting our
views, regarding this particular trade and project.
TOYODA GOSIE SOUTH INDIA Pvt.Ltd..
(TGSIN)TG JAPAN GROUP Where I had an opportunity to

108
Project Report
come across this project tool was of very much
importance to build my career and also it gives exposure
to modern industrial working atmosphere
Bibliography:
Theory of molds by R.S Nagesh

R.G.W. Pye
Plastic technology
Westerman tables

109

SLC FT GG

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Project Report

A PROJECT REPORT ON DESIGN &

GOVT.TOOL ROOM AND TRAINING CENTRE

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

This is to certify that the project titled “MANUFACTURE OF

PROJECT GUIDE PRINCIPAL

Mr. PRAJWAL P.K Mr. KEMPARAJU C.S

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

NAME: VIGNESH S BATCH: 5TH

SIGNATURE OF THE SIGNATURE OF THE

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

During the course of this project work I was greatly

First of all, I will take great pleasure in expressing my deep

I’m also grateful to our honorable General Manager Sri

I’m also indebted to our beloved principal Mr. KEMPARAJU

At the same time, I thank my Instructors Mr. PRAJWAL P.K all

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

I am also grateful to our honorable senior manager Mr.

I am also grateful to Mr. SUGHAND KUMAR Senior

I express my profound thanks with gratitude to

My Sincere regards to all staff employees of TOYODA GOSEI

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

Government Tool Room & Training Centre is one of the

GT & TC takes its pride in the industry by manufacturing

It has most updated technology & training program to

Diploma in tool & making in a job oriented course, in

We are trained & directed towards all the requirements

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

PLANT 1 PLANT 2 PLANT 3

1.INJECTION 1.ROBOT 1.INJECTION

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

About the organization

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

thinking and co-ordination must result in a successive tool.

This report gives a vision to specialize in and provide

This project report gives a detailed knowledge of the tool making

The project report is on single cavity mould for

“230B WHEEL CAP”.

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

 To design a two plate mold for 230B WHEEL CAP.

 Knowledge in molding material, mainly automation

 Basic for all standard mold design and molding techniques.

 All methods of making molding tools, cavities etc. Both

 All tool room machine, their functions and limitations to

 The functions of piece part, estimating their factors upon

 The basic requirements of molded product design in order to

 An appreciation of the economics of all facts of the custom

 Drawing or drafting ability to convey clearly on a drawing

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

02 COMPONENT ANALYSIS 26-32

03 TOOL DESIGN ANALYSIS 33-41

04 RAW MATERIAL SELECTION 42-47

06 PROCESS PLANING 59-61

07 TOOL MANUFACTURING 62-72

08 HEAT TREATMENT 73-77

13 TRYOUT, DEFECTS&REMEDIES 100-105

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

KAIGARIKA SANKIRNA, OLD DIC BUILDING KOLAR 563101.

The information presented in a project report on an

The aim of the project report is to explain each subject