MINIATURE ROTOMOULDING MACHINE 1

Chapter-1
Introduction

1.1 Introduction about Rotomoulding Machine :-

 This project develops Rocking Oven Type Rotational Moulding

Machine. Moulding refers to a manufacturing process that involves the
shaping of raw material via a rigid frame. Rotational moulding uses this
process to create hollow shapes and products.
 Rotational Moulding - also referred as Rotomoulding or Rotational
Casting is one of the fastest growing plastic processing methods today.
Rotational moulding is a unique plastic moulding process used
primarily to create seamless, stress-free, hollow one-piece items.
 The technique allows obtaining small parts as well as containers of
huge capacity. Formed parts, multi -layer mouldings or soft mouldings
without joining lines can be produced, what gives an idea of the
versatility of this technique. In comparison to other plastic processing
techniques, rotational moulding has particular advantage in terms of
relatively low level of residual stresses and inexpensive moulds.
 In many cases, pieces virtually impossible to fabricate by any other
processes can be produced by rotomoulding. Rotational Moulding also
has few competitors for the production of large hollow objects in one
piece. It is best known for the manufacture of tanks but it can also be
used to make complex medical products, toys,etc.

1.2 History :-

In 1855 R. Peters of Britain documented the first use of biaxial rotation and
heat. This rotational moulding process was used to create metal shells and
other hollow vessels. The main purpose of using rotational moulding was to
create consistency in wall thickness and density. In 1905 in the United States
F.A. Voelke used this method for the hollowing of wax objects. This led to
G.S. Baker's and G.W. Perks's process of making hollow chocolate eggs in
1910. Rotational moulding developed further and R.J. Powell used this

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process for moulding plaster of paris in the 1920s. These early methods using
different materials directed the advancements in the way rotational moulding
is used today with plastics.

Plastics were introduced to the rotational moulding process in the early 1950s.
One of the first applications was to manufacture doll heads. The machinery
was made of an E Blue box-oven machine, inspired by a General Motors rear
axle, powered by an external electric motor and heated by floor-mounted gas
burners. The mould was made out of electroformed nickel-copper, and the
plastic was a liquid PVC PLASTISOLS. The cooling method consisted of
placing the mould into cold water. This process of rotational moulding led to
the creation of other plastic toys. As demand and popularity of this process
increased, it was used to create other products such as road cones, marine
buoys, and car armrests. This popularity led to the development of larger
machinery. A new system of heating was also created, going from the original
direct gas jets to the current indirect high velocity air system. In Europe during
the 1960s the Engel process was developed. This allowed the creation of
large hollow containers to be created in low density polyethylene. The cooling
method consisted of turning off the burners and allowing the plastic to harden
while still rocking in the mould.

In 1976, the Association of Rotational Moulders (ARM) was started in Chicago

as a worldwide trade association. The main objective of this association is to
increase awareness of the rotational moulding technology and process.

In the 1980s, new plastics, such as poly carbonate, polyester, and nylon,
were introduced to rotational moulding. This has led to new uses for this
process, such as the creation of fuel tanks and industrial mouldings.

1.3 Moulds use for rotomoulding :-

The possibility of immediately obtaining hollow bodied articles without the

need for subsequent welding or assembly has guaranteed an ever-increasing
success for rotational moulding. The traditional applications in classic form
(square and cylindrical tanks, balls, dust bins and banks) have now been left

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behind and we now have articles with complex geometry (shaped air filters,
pallets, lamp posts) and refined aesthetic products too (garden furniture,
flower pots and etc.). In this highly dynamic context, and thanks to the
extremely up to date tools that it has available, ROTOMACHINERY GROUP
is in the forefront in the design and construction of all types of moulds.

On specific request from the customer, we proceed through the preparation of

a virtual preview of the article, which can be modified and adapted. When
approval is obtained for the design, the overall dimensions of the rotation are
checked and then the construction design is drafted and manufacture begins.
Thanks to ROTOMACHINERY GROUP’s 35 years of experience the firm
provides valuable assistance in the choice of suitable solutions (bracing of
containers, opening points of the mould, deciding the quantity and quality of
the most suitable materials). Once construction is completed, each mould
undergoes testing on the plant that is in function in the testing department, in
order to verify that the article has the required characteristics.

1.4 Method of manufacturing mould :-

A model of the product is made (with casting contraction and

molding shrinkage added)
pattern is then transferred to a foundry where aluminium castings, similar in
shape to the pattern, are produced. These castings are subject to machining
and other engineering process, to create the finished tool.
There are a number of variations on this theme, such as the direct CNC
machining of the patterns, the use of flexible patterns to allow undercuts in the
tool, and the use of plaster instead of the usual foundry sand.
Where the quantity of the required rotomouldings suggests that multiple
cavities or moulds are required, the cost of second and subsequent moulds is
significantly lower than the original mould.

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1.5 Reasons to use :-

Fig. 1.5: Rotomoulding mould making

 Still the most cost-effective method for complex mouldings

 Suitable for small- to large-sized mouldings
 Ideal for higher volume applications as multiple cavities can be produced at
lower cost
 Can provide a range of surface finishes produced by shot peening, photo-
etching, or
 Tools can be modified to accommodate design changes.

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1.6 Process:-

Broadly the process is classified in to following sub

processes:

1. Compounding to produce colored of Granules

2. Pulverizing to convert material in to Resin form
3. Rotational Moulding to produce the final product

First Process: Compounding by means of Extrusion

The LLDPE raw material with suitable master batch is being fed in to the
barrel cylinder through storage hopper. The barrel is preheated by heating
zones and suitable temperature control system to process the input material.
The rotating screw pushes the material towards die end with uniform and
homogenized plastics melt. The screw is rotated by suitable AC motor
coupled with heavy duty gearbox. The plastics strands extruded from die are
fed in to high speed Pelletiser unit after they get cooled and traveled through
SS water cooling tank. Pelletiser cuts the strands in to desired size of pellets
which can be collected in to storage silo.

Second Process: Pulverizing

The compounded or colored granules are being fed in to Pulverizing machine

as Input material. The granules are fed in to Disc Mill via vibratory feeder
which feeds the material as per rate of vibration of the device. The fed
material is being crushed in to Mill at very high speed by one Rotating blade
and one stationery blade. The crushed material is conveyed in to cyclone
hopper at height via efficient suction system.

The Rotary Air lock devise separates the blown air and pulverized resin and
allows the powder passes in to Screen Vibro unit. Vibro screen unit screens
the powder as per mesh used and discharge the final product in to the storage
silo. The course particles are fed again in to the Mill to repulverise the same.

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Compounding by means of High speed Mixer (Incase the Extrusion process is

not used to produce the colored Granules)

The pulverized resin is being mixed with other ingredients to prepare a ready
formulation. This process is also being adopted by many processors instead
of producing granules from Extrusion Plant.

In the process the polymers mixed with other ingredients is being loaded in to
Mixer vessel. The mixer vessel is made from special double wall construction
of SS and MS Plates. In which the material is being mixed by means of
specially designed two nos blades running at very high speed. The mixing
cycle is decided by the certain set temperature. Normally batch time is 10- 15
minutes depending upon grade, quantity and formulation of material to be
mixed. After cycle time is over, the the material is being discharged and
collected in to silo. The final material is uniformly and homogenized mixed
which is ideal to use as for Rotomoulding process.

Third Process: Rotational moulding

In the other Plastics processes like Injection Moulding, Blow Moulding &
Extrusion Process, the plastics material is being melt at certain higher
temperature and conveyed forward in to die or mould by special designed
Screw. Unlike such processes ,Rotational Moulding is a very simple process.
In which it is easy to produce hollow and seamless products of all the sizes
and profiles. Since Rotational Moulding is a very simple and economical
process along with low cost Moulds , it is very popular in India especially to
produce the water storage tanks.

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1.6.1 Process step of rotomoulding :-

Fig. 1.6.1: Process step of rotomoulding

It comprises of mainly four steps as per following:

1. Mould Charging:A predetermined amount of plastic (either in

powdered or liquid form) is poured into a hollow metal mould which is made
from either Cast iron or Aluminium. The amount of plastic used in the metal
mould will be equivalent to the weight of the finished product. Rotational
moulding has one big advantage of no waste. All the plastic poured into the
mould is used. When the powder is loaded into the mould it is closed, locked,
and loaded into the oven.

2. Heating:The mould is then moved into the heat source where the rotation
starts. The rotation speed is slow, less than 20 rotations/minute; the process
is not centrifugal. This is so all the plastic is dispersed equally. Heating the
mould in an oven while it rotates, until all the polymer has melted and adhered
to the mould wall. The hollow part should be rotated through two or more
axes, rotating at different speeds, in order to avoid the accumulation of

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polymer powder. The length of time the mould spends in the oven is critical:
too long and the polymer will degrade, reducing impact strength. If the mould
spends too little time in the oven, the polymer melt may be incomplete.

3. Cooling:After the heating cycling is complete, the mould is removed from

the oven and the cooling cycle begins. Cooling of the mould is usually done
by fan. This stage of the cycle can be quite lengthy. The polymer must be
cooled so that it solidifies and can be handled safely by the operator. This
typically takes tens of minutes. The part will shrink on cooling, coming away
from the mould, and facilitating easy removal of the part. The cooling rate
must be kept within a certain range.

4. De-moulding:When it has cooled sufficiently to be handled and the

polymer can retain its shape, the mould is opened and the part is removed.
The moulding process can then be repeated by adding the polymer powder to
the mould.

1.7 Types of rotomoulding machine :-

(1) Rock N Roll Machine

(2) Bi Axial Rotomoulding Machine (Two Arm & Three Arm)

(3) Fix Oven Type Rotomoulding Machine

(4) Shuttle Machine

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(1) Rock N Roll Machine :-

Fig.1.7.1: Rock N Roll Machine

Unique Features:

 Various thicknesses in the product are possible

 Flexibility of different models to produce from 200 ltr to 25000 Ltr

vertical tanks
 Special article like Drainage Pipes, Boats, up to 6.5 Mtr. Can be
produced in Rock n Roll comfortably
 Sturdy Machine suitable for manufacturing large size hollow products.
Up to 40000 Itrs / 10000 USG. Capacity
 Speed variable drive for Rocking & Rolling for better control of the
product
 Low pressure Burners which are very simple & can be adjusted from
outside
 Microprocessor based machine control panel with digital display
 Most economical with less investment
 Faster return of investment due to lesser production cost even for wide
range of products to be produced

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(2) Bi Axial Rotomoulding Machine (Two Arm & Three Arm):-

Fig. 1.7.2: Bi Axial Rotomoulding Machine (Two Arm & Three Arm)[2]

Unique Features:

• Most efficient in Fuel, Energy consumption and State of The Art

Technology compared to other types of machines

 Specially designed for the energy saving environmental friendly heating

chambers with efficient heat transfer technology
 Very consistent product quality due to smooth Bi-axial rotation
 Highest production due to lowest cycle time
 Uniform heating of the mould with forced air circulation in heating
chamber
 Uniform distribution of material hence possible to produce tank with
lesser weight
 Best compatibility in market due to lowest production cost per tank
 Straight-arm with four mould carrying carrier plates for economical
working
 Lowest rejection rate due to sound & proven technology
 Machine controls are equipped with necessary interlocking, safety
devices with indicators and alarm
 Environment friendly burners suitable for LPG/CNG/OIL/Duel fuels
which is most fuel efficient

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 Flexibility to produce double & triple layer tanks due uniform distribution
of material
 AC variable drives of reputed make for all Minor & major axis’s for
minute & accurate speed control
 Powder coated electrical control panel with dust proof construction &
with all switch gears of either imported / highly reliable
 Control panel is equipped with AC drives, Digital indicators,
temperature controller, timer, & advance automation circuit for entire
process control & all necessary safety features
 Mould indexing facility

(3) Fix Oven Type Rotomoulding Machine :-

Fig. 1.7.3: Fix Oven Type Rotomoulding Machine[2]

Unique Features:

• Specially designed for the space saving chambers with efficient heat
transfer technology.

 State of the art technology in designing the insulation panels for better
working environment.
 Straight-arm with four mould carrying carrier plates for economical
working.

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 Machine controls are equipped with necessary interlocking, safety

devices with indicators and alarm.
 Microprocessor based machine control panel with digital display.
 PLC on specific request.
 Variable speed a/c motors are for major and minor speed controls.
 Mould indexing facility.
 Environment friendly burners suitable for LPG/CNG/OIL/Duel fuels.

(4) Shuttle Machine :-

Fig. 1.7.4: Shuttle Machine

Unique Features:

• Specially designed for the energy saving, environment friendly heating

chambers with efficient heat transfer technology.

 State of the art technology in designing the insulation panels for better
working environment.
 Straight-arm with four mould carrying carrier plates for economical
working.
 Machine controls are equipped with necessary interlocking, safety
devices with indicators and alarm.
 Microprocessor based machine control panel with digital display.
 PLC on specific request.

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 Variable speed a/c motors are for major and minor speed controls.
 Mould indexing facility.
 Environment friendly burners suitable for LPG/CNG/OIL/Duel fuels.

1.8 Advantages :-

 Economic Tooling Costs

 One-piece construction; virtually stress-free-totally enclose parts or
with openings
 Weight reduction - as compared to most metals
 Uniform wall thickness - no thinning in the extremities
 Thickness can be varied if required
 Variety of finishes and colour
 The ability to produce multi-wall mouldings
 Design flexibility - from small and intricate to large and complex
 Metal inserts as integral parts
 Economical for short production runs and prototypes as well as volume
production
 Minor undercuts are possible - with no draft angles required
 Short lead-time
 Resistance to stress-cracking and corrosion
 Excellent load-bearing properties
 Variety of materials

1.9 Applications :-

1.9.1 Household & Commercial :-

 Water Tanks ( Vertical & Horizontal )

 Refuse containers & Bins, Buckets, Barrels & Drums
 Telephone Booths & Cabins
 Book cases and Recks
 Insulated Ice Boxes

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 Show cases & Display stands

 Building Interior & Exterior
 Gadern & Pool Furniture
 Traffic barriers, Dividers

Fig. 1.9.1: Application of industries

1.9.2 Industrial :-

 Oil tanks & Chemical tanks

 Containers & Waste Bins
 Septic tanks & Insulated tanks
 Oil Dispensing tanks
 Special pupose tanks
 Special pallets
 Material Handling Trolleys

1.9.3 Automobiles :-

 Bins for Auto Parts

 Special Pallets
 Fuel tanks & Bumpers
 Crates for cylinder
 Suction Ducts & Pumps Filter
 Guards, Front Console & Panel

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1.9.4 Agriculture :-

 Various Tanks for Water Storage

 Spray Tanks & Septic Tanks
 Underground Tanks
 Feed Trays & Cultivator
 Poultry Feeder & Composter
 Refuse Containers
 Water Troughs & Grain Storage
 Animal Shed
 Drainage Chamber

1.9.5 Playing Equipments :-

 Toys & its various parts

 Plyaing Components & their body
 Playing Statios
 Rockers & Slides
 Tri-Cycles
 Indoor Pools

1.9.6 Marine Application :-

 Floating docks & desks

 Boats & Kayaks
 Tanks & Floats

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Chapter 2
Literature survey

2.1 Literature review related to particle filled polyethylene

composites used in the technology of rotational moulding :-

Peter BÚTORA, Antonín NÁPLAVA et all……

The submitted article discusses rotational moulding technology and filled

plastics. For testing, linear low density polyethylene filled withtalc was used.
The materials tested varied way of mixing the filler into the polymer. For the
prepared samples wereevaluated by tensile, elongation, melt flow index,
density, Shore hardness and Vicat softening temperature. Experiments
showed that, in principle, itis possible to produce rotational moulding
technology filled thermoplastics.

Experiments showed that, in principle, it is possible to produce rotational

moulding technology filled thermoplastics. However, it is necessary to choose
optimal parameters of the polymer filler and the size of the particles, their
dispersion and density. To increase the adhesion of the polymer matrix and
filler and thus the increased compactness of the final product, we focused
attention on improving the dispersion of filler in the polymer used double
screw homogenization equipment used in the manufacturing of thermoplastic
composites with conventional particulate filler.

The results obtained suggest that it will be filled with more efficient production
of plastics: reduced price while maintaining the required mechanical
properties.

Further experiments will focus on increasing the filler content. Mould

modifications were due to different shrinkage of the base material and filler.

2.2 Literature review related to rotational moulding of flax

fiber reinforced thermoplastics :-

J. Ward, S. Panigrahi, L.G. Tabil et all…..

Flax fibers are being combined with thermoplastic materials then rotationally
moulded into useful products. Flax fibbers are very strong and this property is
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being added to the composite parts. Using flax fibbers with linear low-density
polyethylene thermoplastic reduces the mass of the biocomposite due to its
low density, increases its stiffness and also reduces the final product costs.
Some of the problems that need to be overcome are the processing of the
biocomposites, weight percentages of fiber in biocomposites, fiber cutting and
mixing in thermoplastic resin. Rotational moulding is a different process and
one that has not been studied in depth. This paper describes the process of
rotational moulding composite parts and some of the problems that were
encountered.

Flax fiber has a very promising future inthe rotational moulding industry.
Plastic manufacturing is one of the few billion dollar industries, and flax fibers
have the potential to break into this lucrative industry. The research we are
conducting at the University of Saskatchewan will hopefully speed up or
enhance the fibers potential. One of the main points of this research is that it
is intended to help the flax growers and rural areas in particular.
Saskatchewan farmers are currently undergoing a severe drought coupled
with very low commodity prices. The flax fiber is already being produced and
can be obtained relatively cheap compared to glass fiber reinforcements.

2.3 Literature review related to conventional rotomoulding

machine :-

WOOD RICHARD ROY

A rotational moulding machine including three mould manipulator

arrangements (10) and a rotatable carrousel (44) on which the manipulators
(10) are mounted for indexed rotation between heating (62), cooling (64) and
mould loading stations (66). The manipulators (10) each include a rectangular
frame (18), stub axles (28, 30) on the frame (18) which are rotatable in
supports on the carousel on a first axis (A), mould locating means (42) in the
frame (18) which is rotatable on a second axis (B) normal to the first and
means (20, 22) for manipulating a mould (40) in the frame (18) on both axes.

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Fig. 2.3: conventional rotomoulding

The machine includes a crane beam (58) over the carrousel which overlies
the heating and cooling station positions on the carrousel, a heating chamber,
a wall enclosure, and crane means for lowering the heating chamber (68) and
wall enclosure over manipulators on the carrousel at the heating and cooling
stations and for lifting them clear of the manipulators to enable them to be
indexed to the next station.

2.4 Literature review related to rotational moulding method

and apparatus :-

Romero da la Mora, Mario Antonio

The traditional rotomolding process is made in open flame with the
disadvantage that the thickness of wall is not homogenous.as the heating of
the mould is irregular .on the country, the process of rotomolding in
furnace,allow the achievement of great quality articles with homogenous
thickness wall. When it comes to manufacturing articles with multiple
layers,the use of afurnace is impractical as once the first layer is formed the
next load of material to molten generally implies the removal of mould from
furnace alternatively in order to avoid the removal of the mould form the
furnace a gate from the furnace is opened and thermoplastic material is
introduced either by means of the bin or box commonly named drop box or by
means of any spray device generally, the feeding stage , especially with the
use of drop box may be plastified before being poured into the mould. The

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above implies delays in the overall process,losses of heat from the furnace
and thus .greater energy expenditure. The feeding stage becomes further
limiting, when it comes to manufacturing several articles of several layers in a
single cycle.

The invention refers to a process and apparatus for manufacturing plastic

articles through the rotational moulding method and is more particularly
addressed to a process and apparatus of rotomolding in furnace for
manufacturing containers with multiple layers.

2.5 Literature review related to method for printing and

decorating products in a rotomolding process :-

Stevenson, Michael J.

This invention comprises imparting a moulded pattern of printed characters,

decoration and the like in the surfaces of rotomolded products. The method is
employed during the rotomolding process and briefly comprises precoating
the interior surfaces of the mould cavity with a thin coating of an oil
suspension of pigments. The coating can be applied to the interior mould
surfaces by brushing, spraying, screen printing and the like to deposit a thin
coating of the oil suspension of pigment. The coating thickness is no greater
than about 0.005 inch and the oil has a sufficient viscosity, typically greater
than about 80 Saybolt seconds at 100° F. to insure that the layer does not
migrate or drain from the surface after its application. The oil suspension of
pigment is applied to the surface in one or more treatments as required to
deposit single or multiple colours desired for the appearance of the finished
product. After application of the oil-pigment suspension, the mould cavity is
charged with powdered plastic, typically with high density polyethylene, the
cavity is closed by joining the halves of the mould and conventional
rotomolding techniques are employed to obtain the moulded product.

There is disclosed a method for the imprinting and decorating rotomolded

products. The method comprises the application to the interior surfaces of the
mould of a viscous suspension of pigment in a preselected pattern. The
suspension is applied to the mould surface in an oil carrier using a vegetable,

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animal or mineral oil that is inert under the moulding conditions and that has a
sufficient viscosity at the moulding conditions to maintain the film on the
mould surfaces. The pattern of the pigment suspension is applied by spraying,
brushing, screen printing and the like and, after its application; the
conventional rotomolding can be practiced. In this method, the powdered
plastic, typically high density polyethylene, in powder form is charged to the
mould, the mould is closed and placed in an oven heated to from 500° F. to
about 800° F. while rotating the mould along two axes, to tumble the plastic
powder against the heated side of the mould where the powder consolidates
into an integral moulded wall of a plastic shape. The invention provides a very
high line or character definition preferably using finely subdivided pigments.

2.6 Conclusion derived from literaturereview :-

[1] Use LLDPE material with talc for easy removal of product from mould.

[2] Using flax fiber with LLDPE material increase the stiffness and also
reduces the final product cost.

[3] By using proper heating we can get homogenous wall thickness of product

2.7 Objective of present work :-

Primary objective of the project was to design, built and test a Rocking Type
Rotational Moulding Machine to be used to produce small components of
plastic. This involves ensuring that the output product quality is
consistent.Following are the objectives of this Project:

 To improve technique of rotomoulding.

 Improve the wall thickness of product.
 Better product quality.
 To reduce the lead time.
 To achieve good surface finish.

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Chapter – 3

Problem Definition & Work Plan

3.1 Problem definition :-

In conventional rotomolding machine there were problem like uneven material

distribution which cause uneven thickness, microscopic holes and poor
surface finish. It also having large production time due to melting, pouring and
moulding is done using different equipment which is solved here by Using
only one equipment Rock and Roll Rotomolding Machine.

With discussion with guide about this project, we are decided to undertaken
with Rocking Type Moulding Machine as a Final year project due to following
reasons:

 With roto-moulding process it is possible to create one piece,

seamless and stress free plastic products with superior surface
finish of any size large or small, in every possible shape.
 Accent of the rotational moulding process point to its low production
cost and unlimited design possibilities.

 As the construction of this proto type is simple and much many

components can be manufactured by own.

 The materials are easily accessible.

 The output can be obtained as a finished product.

 Required resources are easily available.

 Design is simple.

 Cost is less comparatively to any other.

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3.2 Work plan

Task JAN JAN FEB FEB FEB MAR MAR MAR MAR
15 15 15 15 15 15 15 15 15

Topic Search
& Internet
surfing

Literature
Review &
PSAR

Design
generation in
AutoCAD

Market
survey and
material
collection
Fabrication
all
components

Assembly of
model

Experiment &
result of
project

Report
Writing

This indicates present work.

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Chapter – 4

Design Of Parts

4.1 Design drawing of rotomoulding machine :-

Fig. 4.1.1: Design of main frame& base frame

Fig. 4.1.2: Design of burner frame

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Fig. 4.1.3: Design of dead center & live center

Fig. 4.1.4: Assembly of frame, burner andcenter

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Fig. 4.1.5: complete design of model with mould

4.1.1 Software used :-

 AutoCAD

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4.2 Material specification used for fabrication of

components :-

Sr.No. Part Name Specification Qty.

01 Base Frame m.s. Square pipe- 1 Nos.

250mmx250mm

02 Main Frame m.s.Sq.flat- 250mm x 1 Nos.

100mm

03 Acceleration Shaft m.s.Round Dia100mm 1 Nos.

04 Main Shaft m.s.round dia 100mm 1 Nos.

05 Burner m.sround,pipe 3 Nos.

06 DC Geared Motor 12V, DC Geared 1 Nos.

Motor,10 rpm

07 Springs Helical 2 Nos.

08 Mould Aluminium 1 Nos.

Table 4.2: Material specification

4.3 Machining process used for fabrication :-

 Lathe Machine
 Drill Machine
 Power hacksaw Machine
 Welding Machine
 Bench Grinder
 Polishing machine

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4.4 Fabrication of components :-

(1) Base frame

(2) Main frame
(3) Mould
(4) Burner
(5) Motor
(6) Live and Dead center

Fig. 4.4.6: Main frame

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Fig. 4.4.7: Mould

Fig. 4.4.8: Burner

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Fig. 4.4.9: Motor

Fig. 4.4.10: Live and Dead center

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4.5 Assembly of machine :-

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Fig. 4.5: Assembly of machine

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4.6 Flow Process Chart :-

SCHART NO :1 SHEET :1 SUMMARY

MATERIAL ACTIVITY PRESENT SAVING

ACTIVITY : WELDING, TURNING, OPERATION O 05

MILLING, BORING

TRANSPORT ⇨ 05
METHOD : PRESENT

DELAY D 02

INSPECTION ⧠ 05

STORAGE ⧨ 02

DISTANCE 155 MTR

LOCATION : SHOP – A TIME 1190 MIN

CHARTED BY : SAHIL PATEL

APPROVED : JAIMIN PATEL
DATE : 16/03/2015

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SR DESCRIPTION QT DISTANC TIME SYMBOL REMARK

NO Y. E MIN
MTR
O ⇨ D ⧠ ⧨

1 MATERIAL LYING IN STORE 1 - - •

2 TRANSPORTED TO HEXO 1 10 5 •
CUTTING MACHINE
3 AWAIT HEXO MACHINE 1 - 10 •
4 CUTTING OPERATION 1 - 60 •
5 INSPECTION 1 - 15 •
6 TRANSPORTED TO LATHE 1 15 5 •
7 AWAIT LATHE MACHINE 1 - 30 •
8 OPERATION 1 - 60 •
9 INSPECTION 1 - 10 •
10 TRANSPORTED TO MILLING 1 10 10 •
MACHINE
11 OPERATION 1 - 60 •
12 INSPECTION 1 - 30 •
13 TRANSPORT PARTS INTO 1 35 10 •
ASSEMBLY SHOP

14 ASSEMBLY THE PARTS 1 - 60 •

15 INSPECTION 1 - 30 •
16 TRANSPORTED TO PAINT 1 25 10 •
SHOP
17 FITTING BURNERS ON 1 - 30 •
STRUCTURE AND OTHERS
18 INSPECTION 1 - 10 •
19 READY TO DISPATCH 1 25 - •

TOTAL 120 445

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4.7 Outline Process Chart :-

MOULD STRUCTURE ASSEBMLY

BORING CUTTING ASSEMBLE THE
ON LATHE OPERATION MATERIAL
MACHINE ON HEXO
MACHINE

INSPECTION INSPECTION INSPECTION

MACHINING ON BOLTING THE

LATHE MACHINE WELDING MOTOR ON
STRUCTURE

INSPECTION INSPECTION GIVE CONNECTION

TO MOTOR

WELD BURNER
WITH BASE

PAINTING

FINAL INSPECTION
AND TESTING

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Chapter – 5
Results & Conclusion
5.1 Results :-
As Per Our Requirement Rock and Roll Rotomoulding Machine is fabricated.
It is Shown in Figure Below.

Fig. 5.1: Experimental Setup

 As Per Requirement We have Given the Electric and Gas Connection

to the machine.
 Grising or Oiling inside the mould for easy removal of product.
 Then poured material in to the mould.

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Fig. 5.2: Poured the Material

 Fit the mould on machine between Live and Dead center.
 Turn on the Electric supply and Gas burner.
 Heated up the mould 5 to 6 minute.

Fig. 5.3: Heating the mould

 Rock the machine 5 to 6 times.

 Then switch off Electric supply and Gas burner.
 Take mould from the machine and Cooled up in Water.

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Fig. 5.4: Cooling the mould

 After Cooling open the mould and Remove Final product from it.

Fig. 5.5: De-moulding the mould

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Fig. 5.6: Final product

 Uniform Wall thickness of product.

Fig. 5.7: wall thickness of product

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5.2 Conclusion :-

The Rock and Roll Rotomoulding Machine which is used for the producing
hollow parts like water tanks, toys, pipes, etc. As Per Design the
Rotomoulding machine is fabricated. After experiment by using LLDPE
material we get the uniform wall thickness on periphery of product. And Good
Surface Finish by Rotating mould at 10-15 minutes at 10 rpm Temperature
About 120 ℃ to 160 ℃ temperature.

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Chapter 6
Scope For future Work
 We can improve project by using automation.
 We can use Electric burner instead of Gas burner.
 We can make different useful product which is used for chemical
storage in industry by using HDPE material By Rock and Roll
Rotomoulding machine.
 Using electric motor and gear setup we can Rock the machine easily.

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REFERENCES
Papers
[1] Peter BÚTORA, Antonín NÁPLAVA, Martin RIDZOŇ, Jozef BÍLIK, Viktor
TITTEL, “Particle Filled Polyethylene Composites Used In The Technology Of
Rotaional Moulding” 2011.

[2] J. Ward, S. Panigrahi, L.G. Tabil, W.J. Crerar , T. Powell, “Rotational

Molding of Flax Fiber Reinforced Thermoplastics” Paper No: MBSK 02-209
An ASAE Meeting Presentation.

Patent
[3] Wood Richard Roy (EP1585622), 2005 “A Rotational Moulding Machine”.

[4] Romero da la Mora, Mario antonio, U.S. Patent Us20130026684, 2010.

“Rotational Moulding Method and Apparatus”.

[5] Stevenson, Michael J., U.S. Patent 4252762, 1978. “Method for Printing
and Decorating Products in a Rotomolding Process”.

World wide web

[6] http://www. Wekipedia.org/in

[7] http://www.Naroto.com

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APPENDIX
LLDPE (Linear Low Density Poly Ethylene) physical properties are as below:

Density 0.92 𝑔𝑚/𝑐𝑚3

Tensile strength 20 mpa

Maximum operating temperature 50 ℃

Water absorption 0.01 %

Melting temperature 120 to 160 ℃

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