DJF51092 TOOL DESIGN

MINI PROJECT

CLASS: DTP5B

LECTURER: PN. ZALAIDA BINTI TALIB

GROUP MEMBERS:

NAME MATRIC NUMBER

MOHAMAD AINUDDIN BIN ROSLI 24DTP21F1018
MUHAMMAD HAZAN SHAWTI 24DTP21F1043
MUHAMMAD FAZLI AIMAN BIN MOHAMAD ZALINA 24DTP21F1010
RAZIN KHAN BIN MOHAMAD RASHIDDIN FARID KHAN 24DTP21F1007

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TABLE OF CONTENTS

Introduction…………………………………………………………..3

Content

 Type of Mould………………………………………………….3

 Material used…………………………………………………...3

 Core, Cavity, Insert and Parting Line…………………………..4-10

 Step to do Core, Cavity and Parting Line………………………11-12

 Feed System in Mold (Sprue, Runner, Gate System)…………..13-15

 Step to do Feed System…………………………………………16-18

 Detail Drawing of Mold………………………………………...19-20

 Detail Exploded Drawing of Mold……………………………...21

 Sustainable Elements to increase Tool Life……………………..22

Conclusion……………………………………………………………..22

References……………………………………………………………..23

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INTRODUCTION
Name product: Exhaust Hanger Mount

The exhaust system runs from the front of your vehicle to the back and require hangers to
ensure that the parts and piping are held in place. Hangers are made of rubber and stretched
between hooks in order to secure the exhaust system. The rubber also reduces noise and
friction.

CONTENT

TYPE OF MOULD
Injection moulding is a highly versatile and efficient manufacturing process for
producing a wide range of plastic components. It begins with the preparation of plastic resin,
which is melted and then injected into a mould cavity. This mould is usually composed of two
halves, the cavity side, and the core side, and is designed to replicate the desired shape of the
final part. As the molten plastic enters the mould, it cools and solidifies, taking on the precise
form of the mould. Once the plastic has fully solidified, the mould opens, and the newly
formed part is ejected.

Injection moulding is characterized by its precision, repeatability, and ability to

produce complex geometries with tight tolerances. It is a cost-effective solution for mass
production and is widely employed in industries such as automotive, electronics, medical
devices, and consumer goods due to its efficiency and high-quality results. The process can
also be adapted for sustainability by using recycled materials, optimizing cooling systems,
and reducing waste in the production cycle.

MATERIAL USED

Rubber moulds are employed for casting various materials, including plastics, resins, and
metals. These moulds are popular for creating small to medium-sized parts and components

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with precise detail. Rubber moulds are often reusable, which is cost-effective for mass
production.

CORE, CAVITY, INSERT AND PARTING LINE

1) CORE

2) CAVITY

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 3) CORE PLATE

4) CAVITY PLATE

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 5) TOP CLAMPING PLATE

6) BOTTOM CLAMPING PLATE

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 7) EJECTOR PLATE

8) EJECTOR RETAINER PLATE

9) SUPPORT PLATE
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 10) LOCATING RING

11) SPACER BLOCK

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 12) RETURN PIN

13) HOPPER

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 14) SCREW

STEP TO DO CORE, CAVITY AND PARTING LINE

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FEED SYSTEMS IN MOLD
The function of the mould feed system is to make the high temperature melt under
high pressure go into the mould cavity to fulfil that. The style and quantity of gate and feed
style often determine the specifications of plastic mould base. Whether the design of the gate
system is reasonable will directly affect the appearance, internal quality, dimension precision
and moulding cycle of the moulded plastic parts.

The feed system of the mould is a section of the melt flowing passage from the nozzle
of the injection moulding machine to the cavity, it can be divided into two main types, cold
runner system and hot runner system.

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 1. SPRUE

The sprue is a round, tapered hole which leads the plastics material from the nozzle of the
heating cylinder of the injection moulding machine to the distributing runners in the mould.

2. RUNNER

A runner is a channel cut into the mould that allows plastic material to flow from the nozzle
to the cavity. A change in pressure is expected whenever.

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 3. GATE SYSTEM

The “gate” is the opening in a mould through which the molten plastic is injected into the
final part. It is the boundary between part and scrap. The location, size, and shape of the gate
can have a significant effect on everything from the structural integrity to the visual
appearance of a finished piece.

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STEP TO DO FFED SYSTEM

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DETAIL DRAWING OF MOLD
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 1) EXHAUST HANGER MOUNT

3D CAD MODEL

2D Drawing Model

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MOLD DRAWING

3D CAD MODEL

2D CAD MODEL

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EXPLODED DRAWING

ASSEMBLY DRAWING

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SUSTAINABLE ELEMENTS TO INCREASE TOOL LIFE

1. Tool Material and Coatings

Utilize high-quality tool materials, such as carbide or high-speed steel, and consider
using coatings like TiN (titanium nitride) or TiAlN (titanium aluminum nitride) to
enhance tool durability and reduce friction.
2. Cutting Fluids
Implement effective cutting fluid management. Proper lubrication and cooling can
extend tool life by reducing friction and heat. Using eco-friendly cutting fluids or
coolants can make this practice more sustainable.
3. Tool Path Optimization
Implement efficient tool paths to minimize unnecessary tool movements. Toolpath
optimization reduces wear and tear on the tool and saves energy.
4. Recycling and Sustainability Initiatives
Consider sustainability programs that involve the recycling of worn-out tools or
promoting the use of tools made from recycled materials.

CONCLUSION

In conclusion, the plastic moulding project represents a significant

achievement, showcasing the successful design, development, and
production of a wide range of high-quality plastic and rubber
components. Throughout the project, several critical elements have
been addressed to ensure its success. However, The choice of high-
quality plastic materials, including considerations for recycling and
sustainability, played a vital role in producing durable and eco-
friendly plastic components. Sustainable practices were adopted to
extend the life of the moulds and reduce tooling costs, contributing to
the economic viability of the project.
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REFERENCES

1. https://youtu.be/T5Pm_A81JsE?si=nkitMzRGUbu4SzzR
2. https://youtu.be/60VeLgwe3Wc?si=fhc6ykz1BIxJSATG
3. https://www.bing.com/ck/a?!
&&p=6381cef487849734JmltdHM9MTY5ODYyNDAwMCZ
pZ3VpZD0wZmJhMWYzYS0zMDRlLTYwODctMzYyMi0
wZjhjMzFkYzYxMzUmaW5zaWQ9NTIyMQ&ptn=3&ver=
2&hsh=3&fclid=0fba1f3a-304e-6087-3622-
0f8c31dc6135&psq=rubber+injection+molding+wikipedia&
u=a1aHR0cHM6Ly9lbi53aWtpcGVkaWEub3JnL3dpa2kvS
W5qZWN0aW9uX21vdWxkaW5n&ntb=1
4. What is Injection Moulding? – Definition, Types and Materials -
TWI (twi-global.com)

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