Internship Report

A comprehensive study of manufacturing processes for Plastic

molded & press auto parts.

By

Yash Kshatriya
ME
PDPM IIITDM Jabalpur

To

Yogesh Shinde
Manager
Malhar Auto Industries

Dr. Sujoy Mukherjee

Assistant Professor
PDPM IIITDM Jabalpur

Mechanical Engineering.

INDIAN INSTITUTE OF INFORMATION

TECHNOLOGY, DESIGN AND MANUFACTURING
JABALPUR.

1
 Jan 2024-Feb 2024
ACKNOWLEDGMENT

I'd like to use this chance to show my sincere gratitude to Dr. Sujoy Mukherjee for his
comments on reports and internship guidance, as well as to Mr. Yogesh Shinde, whose
guidance and support throughout my internship helped me to comprehend my project and
improve upon it.

Signature-

Date-
23/02/2024

2
 TABLE OF CONTENTS
S.no Topic Page no.
1 Company Introduction 4-6
1.1 About the Company
1.2 Infrastructure
1.3 Products
1.4 Customers
2 Roles & responsibilities 7
3 Raw Materials 8-10
3.1 Poly Vinyl Chloride (PVC)
3.2 Nylon 6
3.3 Polypropylene (PP)
3.4 Tri Propylene Glycol (TPG)
3.4 Master Batches
4 Manufacturing Processes 10-21
4.1 Injection Molding.
4.2 Blow Molding.
4.3 Rotational Molding.
4.4 PVC Extrusion.
5 Mold Designing Work. 22
6 Stamping Cell
7 Results & Conclusion.

3
 1. COMPANY INTRODUCTION

1.1 About the company:

Malhar Auto Industries takes pleasure in introducing our group, engaged in the manufacture and supply of
Engineering Plastic Molded Components & all types of Automobiles. We are an ISO 9001-2008 & IQCS
certified company engaged in manufacturing Injection Moulding Auto Parts and PVC Extrusion Pipe and
Extrusion Profile for Automotive, Agriculture & Electrical sectors.
Established in 1988 in 15000 Square ft. space with a cornerstone of 100% customer satisfaction goal. We
have been satisfying customers having big brand names of Indian Industry & Multinational groups. The
company has a clean manufacturing environment. Suitable manufacturing facilities are provided for
producing High-quality components.

1.2 Infrastructure
1) CNC Machine 60-ton to 600-ton capacity. 2) Cooling tower.
3) PVC flexible extrusion machine. 4) Cooling tower and chiller machine.
5) PVC granules mixture machine. 6) Spring making machine.

Cooling Tower Spring Machine

CNC Machine Extrusion Machine

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1.3 Products:
1.3.1 Injection Molded Auto Parts.

Splash Shield Battery Tray

Storage bin mat bolero Fog lamp bolero

1.3.2 Injection Molded Plastic Parts

5
 Bag Cover Fasteners

PVC pipes Clips

1.4 Customers.

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 2. ROLES AND RESPONSIBILITIES.

During the internship tenure, following were my key responsibilities at Malhar Auto Industries:
● Learning about various manufacturing processes (Stamping, Injection molding,
Extrusion, Blow molding, Assembly).
● Analyzing in depth the problems that occur in the field while executing any process &
their solutions.
● Learning about the execution manufacturing principles.
● Learning about various Auto Parts and manufacturing processes and use.
● Learning about raw materials used in industry & their mechanical & chemical properties.

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 3. RAW MATERIALS

3.1 Poly Vinyl Chloride (PVC):

Chemical Composition:
● PVC is a synthetic polymer made from the polymerization of vinyl chloride monomers.
● Its chemical formula is (C2H3Cl) n, where "n" represents the number of repeating units in the
polymer chain.
Mechanical Properties:
● PVC is a thermoplastic material, meaning it can be softened and molded when heated and
solidified upon cooling.
● It is known for its excellent durability, toughness, and chemical resistance.
● PVC exhibits good weatherability, making it suitable for outdoor applications.
● The material is inherently flame-retardant and has good electrical insulation properties.
● PVC can be formulated to be flexible or rigid based on the desired application.

Types of PVC:

● Flexible PVC: Contains plasticizers to impart flexibility and elasticity. It is commonly used in
applications requiring softness and bendability, such as flexible hoses, inflatable products, and
certain types of bags.
● Rigid PVC: Does not contain plasticizers and is characterized by its stiffness and rigidity. It is
widely used in applications requiring structural strength, such as piping, window profiles, and
rigid containers.

Parts Manufactured:

● VIP bag cover (Process: Injection molding)

● Pipes/tubes (Process: Extrusion)

3.2 Nylon 6:

Chemical Composition:
● Nylon 6, also known as polycaprolactam, is a semi-crystalline polyamide formed by the
ring-opening polymerization of caprolactam.
● Nylon 6 is represented by the chemical formula (C6H11NO) n.
Mechanical Properties:
● Nylon 6 exhibits high tensile strength and impact resistance, making it suitable for applications
requiring durability and toughness.
● It has good flexibility and resilience, allowing it to withstand repeated bending and flexing
without losing its mechanical properties.

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 ● While nylon 6 has good heat resistance, it may soften or deform at elevated temperatures,
limiting its use in high-temperature applications.

Parts Manufactured:
● Grommet cover (Process: Injection Molding)

3.3 Polypropylene:
Chemical Composition:
● Polypropylene (PP) is a thermoplastic polymer that belongs to the polyolefin group.
● The chemical formula of polypropylene is (C3H6) n.
Mechanical Properties.
● Polypropylene exhibits high tensile strength, making it suitable for structural applications.
● Polypropylene is resistant to many chemicals, acids, and alkalis, making it suitable for use in
corrosive environments.
● PP has a flexural strength typically ranging from 30 to 50 MPa. Flexural strength measures a
material's ability to resist deformation under bending loads.
● PP typically has a Shore hardness ranging from 70 to 110 on the Shore D scale. Shore hardness
measures a material's resistance to indentation or scratching.
Parts Manufactured.
● Battery Case (Process: Injection Molding)

3.4 Tri Propylene Glycol (TPG)

Chemical Composition:
● Tri propylene glycol has the chemical formula C9H20O4 and is a triol, meaning it contains three
hydroxyl (-OH) groups.
● It is a member of the glycol ether family and is derived from propylene oxide.
Mechanical Properties:
● TPG is a viscous liquid at room temperature, and its viscosity can vary depending on temperature
and concentration. Higher concentrations typically result in higher viscosity.
● TPG can be used as a plasticizer in polymer formulations to improve flexibility, workability, and
processability. In injection molding, it may be added to polymer resins to modify their properties
and enhance moldability.
Parts Manufactured:
● Storage bin mat.

3.5 Master Batches.

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Pigments or Additives: The main component of a master batch is the pigment or additive that imparts color
or desired properties to the final product. This could include colorants, UV stabilizers, antioxidants, flame
retardants, lubricants, and more.
Color Masterbatches: These contain pigments or dyes dispersed in a carrier resin to impart specific colors
to the polymer.
Additive Masterbatches: These contain additives such as UV stabilizers, antioxidants, slip agents,
antibacterial agents, flame retardants, or processing aids. Additive masterbatches are used to enhance the
performance, durability, or processing characteristics of polymers in various applications.

PVC

Master batches

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 4. MANUFACTURING PROCESSES

4.1 Injection Molding.

CNC Machine:
CNC injection molding machines are automated manufacturing devices that use computer-controlled
systems to precisely control the injection molding process. They can produce high-quality parts with tight
tolerances and complex geometries. CNC injection molding machines are highly versatile and can
accommodate a wide range of materials, including thermoplastics, thermosets, and elastomers. They can
also produce parts of various sizes and complexities, making them suitable for diverse applications across
industries. CNC control systems enable precise control over the injection molding process, resulting in parts
with tight tolerances and consistent dimensions. This precision is crucial for applications where part fit and
function are critical, such as automotive and medical devices.

Basic Structure and processing factors.

Injection molding is a manufacturing process used to produce plastic parts in large quantities. Injection
molding is a manufacturing process that involves injecting molten plastic material into a mold cavity under
high pressure and temperature to produce plastic parts. This process is widely used in various industries such
as automotive, aerospace, medical, and consumer goods, among others.
The basic structure of an injection molding machine includes the following components:
1.Injection unit: This component is responsible for melting and injecting the plastic material into the mold. It
consists of a screw or plunger that moves forward to push the material into the mold cavity.
2.Clamping unit: This component holds the mold in place and applies pressure to keep it closed during the
injection process. It also opens and closes the mold for part ejection.
3.Control system: This component controls the temperature, pressure, and other parameters of the injection
molding process. It ensures consistent quality and helps prevent defects.

4.Heating and cooling systems: Injection molding requires precise temperature control to ensure proper
melting of the plastic material and efficient cooling of the molded parts. Heating systems maintain the
temperature of the mold and the plastic material, while cooling systems rapidly cool the molded parts to
facilitate their removal from the mold.

5.Ejection system: Once the plastic part has been formed inside the mold cavity, it needs to be ejected from
the mold for further processing or packaging. The ejection system typically consists of ejector pins or plates
that push the molded part out of the mold cavity once the clamping unit opens. This system must be
carefully designed to avoid damage to the part during ejection and ensure smooth operation of the injection
molding process.

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12
 Injection Unit Filling unit

Clamping unit Control unit

There are several factors that can affect the injection molding process and the quality of the final product.
Some of the most important factors include:
1.Material selection: The choice of material will depend on the requirements of the final product, including
its mechanical properties, temperature resistance, and chemical resistance.

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2.Mold design: The design of the mold will depend on the shape and size of the part to be produced, as well
as the required tolerances and surface finish.
3.Injection pressure: The injection pressure determines how quickly the plastic material fills the mold cavity
and affects the final part quality.
4.Injection speed: The speed at which the plastic material is injected into the mold affects the flow rate and
pressure distribution.
5.Cooling time: The cooling time determines how long the plastic material remains in the mold cavity before
it solidifies. This affects the part quality, including its dimensional accuracy and warpage.
6.Mold temperature: The mold temperature affects the flow rate and cooling time of the plastic material, as
well as the final part quality.
7.Process control: The injection molding process can be controlled through various parameters, including
the temperature, pressure, and cycle time. Overall, injection molding is a complex process that requires
careful consideration of many factors to ensure high-quality and consistent parts. Proper material selection,
mold design, process control, and part design are all essential to achieve successful injection molding
production.
Working principle:
1) Mixing: Raw material and additives (color, stabilizers) are mixed uniformly to get a good quality
product. Mixing is done using a vertical or horizontal mixture machine.
Vertical Mixture Machine:
A vertical mixer machine is a type of industrial mixer used in the plastics industry to mix and blend
plastic materials and additives together. As the name suggests, these machines have a vertical
orientation, with a vertical mixing shaft and a series of blades or paddles attached to the shaft.
● Plastic pellets, powders, and additives are loaded into the cylinder.
● The screw rotates, scooping materials from the bottom and lifting them upwards. As it
reaches the top, the material is thrown outwards and cascades back down.
● This continuous lifting, throwing, and folding action thoroughly mixes and blends the
ingredients throughout the cylinder.
● After a set mixing time, a homogenous mixture with evenly distributed components is
achieved.
● The mixed material is emptied through a valve at the bottom of the cylinder.

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Vertical Mixture Machine

2)Material Preparation and Melting: The process initiates with the loading of mixed raw thermoplastic
material into a hopper. The CNC-controlled injection molding machine then feeds these materials into a
heated barrel, where they undergo controlled heating to their specific melting point. The CNC system
precisely regulates barrel temperatures and screw rotation speed to ensure uniform melting and viscosity.
3)Injection Phase: Once the material reaches the optimal molten state, the CNC-controlled screw
mechanism or reciprocating plunger drives the molten material into a precisely designed mold cavity. The
CNC system governs the injection speed, pressure, and volume, accurately controlling material flow and
cavity filling to achieve the desired part geometry and dimensions.
4)Cooling and Solidification: Following injection, the CNC system activates cooling mechanisms within
the mold to rapidly extract heat from the molten material, promoting solidification. Temperature sensors
embedded in the mold provide real-time feedback to the CNC system, allowing precise regulation of cooling
rates and uniform solidification throughout the part.

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● Cooling system in the company.
● In our plastic manufacturing facility, the integration of a chiller machine with a cooling tower
● plays a pivotal role in the efficient cooling of CNC molds. This system functions by utilizing the
● chiller machine to circulate chilled water through the cooling channels within the molds,
● thereby dissipating heat generated during the injection molding process. The cooling tower, in
● turn, facilitates the removal of excess heat from the chiller's coolant through evaporative cooling,
enhancing the efficiency of the overall cooling process.

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 ● Coolant Circulation: The chiller machine pumps a coolant, typically water or a water-glycol
mixture, through a closed-loop system.

● Heat Absorption: The coolant absorbs heat from the process it's cooling, such as CNC molds
in plastic manufacturing, as it passes through them.
● Heat Transfer: The coolant then flows through evaporator coils inside the chiller machine,
where it transfers heat to a refrigerant gas.
● Compression and Condensation: The refrigerant gas is compressed by a compressor,
increasing its temperature and pressure. It then flows through condenser coils, where it
releases heat to the surrounding air or a water loop.
● Expansion and Evaporation: The high-pressure refrigerant is passed through an expansion
valve, where it rapidly expands, lowering its temperature. This chilled refrigerant then flows
through the evaporator coils again, absorbing heat from the coolant and completing the cycle.
● Coolant Recirculation: The now-chilled coolant is pumped back to the process it's cooling,
where it absorbs more heat and continues the cycle.

This continuous process maintains a consistent temperature in the process of being cooled, ensuring
optimal performance and product quality.

5)Ejection Phase: Upon solidification, the CNC system orchestrates the opening of the mold and actuation
of an ejector mechanism. This mechanism applies controlled force to the part, facilitating its removal from
the mold without causing damage. CNC-controlled ejector pins or plates ensure precise ejection timing and
movement.

6)Cyclic Operation and Process Optimization: The injection molding process operates cyclically, with the
CNC system orchestrating sequential phases to produce multiple parts within each cycle. Advanced CNC
controllers employ algorithms and predictive modeling techniques to optimize process parameters
dynamically. These systems continuously analyze sensor data, adjust injection parameters, and optimize
cooling cycles in real-time to enhance part quality, minimize cycle times, and maximize production
efficiency.
7)Quality Monitoring and Control: Throughout the injection molding process, the CNC system monitors
critical parameters such as melt temperature, injection pressure, cooling rates, and part dimensions using an
array of sensors and feedback mechanisms. Any deviations from predefined tolerances trigger immediate
adjustments to process parameters, ensuring consistent part quality and adherence to specifications.

In summary, the working principle of injection molding CNC machines revolves around precise control of
material processing parameters, coordinated action of machine components, and real-time monitoring and
optimization of process variables to achieve high-quality, repeatable production of plastic parts.

Advantages of injection molding:

1. High efficiency: Injection molding allows for high-speed production of parts with relatively low
labor costs, making it a highly efficient manufacturing process.

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 2. Complex geometries: It can produce intricate and complex shapes with high precision, allowing
for the creation of detailed parts and components.
3. Material versatility: Injection molding can accommodate a wide range of materials, including
thermoplastics, thermosetting plastics, elastomers, and metals, providing versatility in product
design and functionality.
4. Minimal material waste: The process is highly efficient in terms of material usage since excess
material can often be recycled and reused, reducing waste and cost.
5. Enhanced strength and durability: Injection molded parts typically exhibit excellent strength,
durability, and dimensional stability, making them suitable for a wide range of applications,
including automotive, aerospace, medical, and consumer goods.

Disadvantages of injection molding:

1. High initial investment: Setting up an injection molding operation requires significant capital
investment in machinery, molds, and infrastructure, which can be a barrier to entry for small
businesses or startups.
2. Long lead times: The design and fabrication of molds can take weeks or even months, resulting
in longer lead times for production compared to other manufacturing processes.
3. Limited flexibility: Once a mold is created, making changes to the design can be costly and
time-consuming, limiting flexibility in product design and iteration.
4. Part size limitations: Injection molding is best suited for small to medium-sized parts, and
producing very large parts can be impractical or prohibitively expensive.
5. Environmental considerations: While injection molding can be efficient in terms of material
usage, it still generates waste in the form of scrap material and energy consumption, and some
plastics used in the process may not be easily recyclable. Environmental concerns regarding
plastic pollution and waste disposal are important considerations for injection molding
operations.

Products Manufactured.

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4.2 Blow Molding.

Blow Molding Machine.

Blow molding machine is also known as hollow blow molding, is a kind of rapid development of plastic
processing methods. A blow molding machine is a machine which blows the plastic to the mold cavity with
certain shape using wind when the liquid plastic starts to spray out. Blow molding machines can be divided
into extrusion blow molding machines, injection blow molding machines and special structure blow molding
machines. Blow molding is a highly efficient manufacturing process primarily utilized for producing a
diverse range of hollow plastic components such as bottles, containers, and tanks. Its methodology involves
several intricate steps aimed at precision molding and rapid production. Here's a detailed technical
breakdown of the blow molding process.

Working principle:
1)Extrusion: The process initiates with the extrusion of thermoplastic material, typically in pellet form,
within an extruder barrel. Within this barrel, the pellets are subjected to high temperatures and pressures,
melting them into a viscous state. The molten plastic is then forced through a specialized die head, shaping it
into a long, hollow tube known as a parison. The dimensions and properties of the parison are meticulously
controlled to ensure uniformity in the final product.

2)Mold Clamping: Following extrusion, the mold clamping phase commences. This step involves the
closure and securing of the mold, which is designed to define the desired shape of the final product. Molds
can be fabricated from various materials such as metals or durable plastics and are constructed in two halves
that securely fit together. The clamped mold forms a sealed cavity, precisely mirroring the intended
geometry of the product.

3)Blow Molding: The parison, now in place between the two halves of the mold, undergoes the blow
molding process. Compressed air is introduced into the prison, exerting pressure internally and causing it to
expand uniformly against the contours of the mold cavity. This controlled inflation results in the plastic
material assuming the precise shape of the mold. The technique can be executed in single or multiple steps,
depending on the intricacy and design complexity of the final component. For more sophisticated shapes,
stretch blow molding techniques may be employed, involving gradual stretching and blowing of the parison
to achieve the desired geometry.

4)Cooling and Solidification: Once the plastic has conformed to the mold's shape, the cooling and
solidification phase ensues. The mold, containing the newly formed part, undergoes a cooling process to
expedite the solidification of the plastic material. Cooling duration varies depending on factors such as the
size, thickness, and material composition of the part. This phase is critical in ensuring dimensional stability
and structural integrity in the final product.

5)Mold Opening and Part Removal: Upon completion of the cooling process, the mold is opened, and the
finished part is ejected. Depending on specific requirements, the ejected part may undergo additional
trimming or finishing operations to achieve the desired surface quality and dimensional accuracy. These
post-processing steps may include trimming excess material, surface polishing, or incorporating features
such as threads or handles.

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 In summary, blow molding stands as a cornerstone in plastic manufacturing, offering unparalleled
efficiency and versatility in producing hollow plastic components. Its intricate process, encompassing
extrusion, mold clamping, blow molding, cooling, and finishing, facilitates the creation of a diverse array of
high-quality plastic products across various industries.

Advantages of blow molding:

1. Blow molding is a highly efficient manufacturing process, particularly for large-scale production
runs. It allows for rapid production of hollow plastic parts with relatively low production costs
compared to alternative methods like injection molding.
2. Blow molding offers significant design flexibility, enabling the creation of complex shapes and
intricate geometries with minimal tooling requirements. This versatility allows manufacturers to
meet diverse product specifications and adapt to changing market demands.
3. Blow molded parts are typically lightweight yet durable, making them ideal for applications
where strength-to-weight ratio is critical. This advantage is particularly beneficial in industries
such as packaging, automotive, and consumer goods.
4. The blow molding process ensures consistent wall thickness throughout the molded part,
minimizing material usage and optimizing structural integrity. This uniformity contributes to the
overall quality and performance of the finished products.
5. Blow molding can accommodate a variety of thermoplastic materials, including polyethylene
(PE), polypropylene (PP), polyethylene terephthalate (PET), and others. This versatility allows
manufacturers to select materials tailored to specific performance requirements, such as chemical
resistance, UV stability, or food-grade compliance.
6. Blow molding machines can produce high production speeds, enabling manufacturers to meet
tight production deadlines and fulfill large volume orders efficiently. This makes blow molding
particularly suitable for industries with high-demand cycles.

Disadvantages of blow molding:

1. While blow molding offers versatility in material selection, it may not be suitable for all types of
thermoplastics. Some materials may exhibit poor melt flow characteristics or insufficient
elasticity, limiting their suitability for the blow molding process.
2. Despite its cost-effectiveness for large production runs, the initial tooling costs for blow molding
can be significant. The design and fabrication of molds tailored to specific product geometries
require skilled craftsmanship and precision machining, which can add to the overall production
expenses.
3. While blow molding typically results in uniform wall thickness, achieving precise control over
wall thickness variations can be challenging, particularly for complex geometries or thin-walled
parts. Variations in wall thickness may affect part performance and structural integrity.
4. The surface finish of blow molded parts may exhibit slight imperfections or irregularities,
particularly in areas where the plastic material contacts the mold surfaces. Additional finishing
processes may be required to achieve desired surface textures or aesthetics.
5. While blow molding offers design flexibility, certain design features may pose challenges in
terms of moldability and process feasibility. Complex geometries, sharp corners, or intricate

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 details may require specialized mold designs or secondary operations, adding complexity and
cost to the manufacturing process.
6. Like other plastic manufacturing processes, blow molding generates waste materials such as
scrap plastic and trimming waste. Proper disposal and recycling of these materials are
7. essential to mitigate environmental impact and promote sustainability. Additionally, the choice of
materials and production processes should consider environmental considerations such as
recyclability and biodegradability.

Blow mold machine. Blow molded bottle

Mold position below nozzle Closed mold under blow molding by ejector

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4.3 Rotational Molding.
Rotational molding, also known as rotomolding or rotocasting, is a manufacturing process used to produce
hollow plastic parts with complex shapes and seamless construction. The process involves heating and
rotating a hollow mold filled with plastic resin to distribute the material evenly and create a uniform
thickness in the finished product.

Working Principle.

The working of a rotational molding machine can be described in the following steps:
1. Preparation: The mold is prepared by coating it with a release agent to prevent the plastic material
from sticking to the surface. The required amount of plastic resin is weighed and placed inside the mold.
2.Heating: The mold is placed inside the oven and heated to the required temperature, which is typically
between 350 and 400 degrees Fahrenheit. The plastic resin melts and coats the interior of the mold.
3.Rotation: The rotating arm begins to rotate the mold around two perpendicular axes, which distributes
the molten plastic evenly and creates a uniform thickness in the final product.
4.Cooling: The mold and the plastic material inside it are cooled using a water spray or air flow. The
cooling process solidifies the plastic material and prepares it for removal from the mold.
5.Ejection: The mold is opened, and the finished product is removed from the mold. The excess material is
trimmed off, and the finished product is inspected for quality. Overall, the rotational molding process is a
highly versatile and cost-effective method for producing complex, hollow plastic parts with consistent quality
and excellent durability.

Two rotational axes with mold and oven Control Panel of rotomolding Machine.

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200 liters tank mold Product formed my rotomolding.

4.4 PVC Extrusion

PVC extrusion is a manufacturing process used to produce continuous lengths of plastic products with
a consistent cross-section. Here's how the PVC extrusion process typically works:

1. Raw Material Preparation: The process begins with the preparation of PVC resin, along with
any additives or modifiers required for the specific properties desired in the final product.
These additives may include plasticizers, stabilizers, pigments, or fillers. The raw materials are
mixed and blended thoroughly to create a homogenous mixture.
2. Feeding: The blended PVC compound is fed into the extruder hopper. The hopper serves as a
reservoir for the raw material and feeds it into the extruder screw.
3. Melting and Mixing: Inside the extruder, the PVC resin and additives are heated and mixed
together. The extruder screw rotates, conveying the material forward while subjecting it to high
temperatures and pressure. This combination of heat, pressure, and mechanical action melts
the PVC resin and blends it with the additives to form a homogeneous molten mass.
4. Extrusion: The molten PVC compound is forced through a specially designed die at the end of
the extruder. The die shapes the molten material into the desired cross-sectional shape, such as
a tube, pipe, profile, or sheet. The die also helps to control the dimensions and surface finish of
the extruded product.
5. Cooling: After exiting the die, the extruded PVC product passes through a cooling system.
Cooling may involve air cooling, water cooling, or a combination of both, depending on the
specific requirements of the product. Rapid cooling helps solidify the PVC material and
maintain its desired shape and dimensions.
6. Sizing and Cutting: Once the extruded PVC product has cooled and solidified sufficiently, it
may pass through sizing or calibration equipment to ensure precise dimensions and tolerances.
After sizing, the continuous length of extruded product is cut into individual pieces of the
desired length using cutting equipment, such as saws or guillotine cutters.
7. Finishing and Quality Control: Depending on the application, the extruded PVC products may
undergo additional processing steps, such as surface treatment, printing, or assembly. Quality

23
 control measures are implemented throughout the extrusion process to ensure that the
finished products meet the required specifications and standards.

Overall, PVC extrusion is a versatile and efficient manufacturing process for producing a wide range of
plastic products used in various industries, including construction, automotive, packaging, and
consumer goods.

5. Mold Designing Work.

Injection molding mold for basket injection molding.

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Left Plate Right Plate.

Supporter plate Side Plate.

25
 Final Product.
6. Stamping Cell.

Press machine :
is a machine that changes the shape of a workpiece by application of pressure.
Press machines can be classified according to :
• their mechanism: hydraulic, mechanical, pneumatic
• their function: forging presses, stamping presses, press brakes, punch press, etc.
• their structure, e.g. Knuckle-joint press, screw press
• their controllability: conventional vs. servo-presses

Working of Press Machine:

The working principle of a press machine is to change the rotational power from the
electrical motor to the translational power which drives the mechanism of pressing work.
The energy wellspring of the mechanical press machine is typically a motor.

Parts of Press Machine:

• Die Holder Plate
• Bolster Plate
• Ram
• Locking Plate
• Electric Motor
• Flywheel
• Gear
• Solenoid Valve
• Balancer
• Crank shaft
• Connecting Rod

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SAFETY:
Machine presses can be hazardous, so safety measures must always be taken. Bi-manual
controls (controls the use of which requires both hands to be on the buttons to operate) are a
very good way to prevent accidents, as are light sensors that keep the machine from working if
the operator is in range of the die.

Operations Performed on a Press Machine:

• Blanking and piercing: are shearing processes in which a punch and die are used to
produce parts from coil or sheet stock. Blanking produces the outside features of the
component, while piercing produces internal holes or shapes.
• Forming: Sheet metal forming involves manufacturing processes in which the shaping is
carried out without changing the mass, volume and material composition.
• Dimpling: The dimpling process is a novel cold-roll forming process that involves
dimpling of a rolled flat strip prior to the roll forming operation. This is a process
undertaken to enhance the material properties and subsequent products' structural
performance while maintaining a minimum strip thickness.
• Restrike: The restrike die's function is to finish forming features that could not be
obtained in a previous operation.

Riser: Precision-ground block or plate used to raise the die shoe to facilitate proper shut height
as well as scrap removal. Usually used in pairs. Also called die rail, parallel, riser, and slug rail.
Shut Height: The shut height of an upright press is the distance from the top of the bed to the
bottom of the slide with stroke down and adjustment up.
WHAT IS SMED?
● SMED (Single-Minute Exchange of Die) is a system for dramatically reducing the time it takes
● to complete equipment changeovers. The essence of the SMED system is to convert as many
● changeover steps as possible to “external” (performed while the equipment is running), and to
● simplify and streamline the remaining steps. The name Single-Minute Exchange of Die comes
● from the goal of reducing changeover times to the “single” digits (i.e., less than 10 minutes).
Lubricator
A lubricator adds controlled quantities of tool oil into a compressed air system to reduce the
friction of moving components. Most air tools, cylinders, valves, air motors, and other air
Driven equipment requires lubrication to extend their useful life.
Using an airline lubricator solves the problems of too much or too little lubrication that arise
with conventional lubrication methods such as a grease gun or oil. Airline lubricators also
supply the right kind of lubricant for the tools used.

Types of Dies:

1. Progressive Dies
These sheet metal dies are designed to perform more than one cutting operation in one stroke.
However, there are different stages that help to attain the final results. The punched out sheet
progresses from one stage to another in a rather complex but precise manner to complete the
punching operation. Usually, the blanking is designed to be the last operation of all the
progressive dies.

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Benefits of Progressive dies
• The force required in every stroke is reduced due to using staggering the punches
methodology or providing the shear.
• On the other hand, the operations are performed in different stages and so the combination
of design and manufacturing of punch and die is much easier even if the number of
operations are more.
• There are also certain drawbacks of using progressive dies in operations that do not
necessarily require complex design, setup, and alignment precision, and also where not
more than one operation is needed. So it is best to work with the manufacturer to get a clear
understanding before opting for one option.

2. Transfer Dies
Transfer dies are similar to progressive dies but the main difference is that the blanking will
usually be the first operation. As a result, the blank which is produced in the first stage will then
be traveling from one stage to another to complete the process. The blank is manually or
mechanically moved from one stage to the other.
Benefits of Transfer dies
• When compared to the progressive dies, the operations are more economical.
• Large parts can be handled with ease and these dies also add a lot of versatility to the
stamping process.

3.Combination Dies
When the sheet metal dies manufacturer combines forming and cutting operations and performs
one stroke at one stage then this is called a combination die.
Benefits of Combination dies
• These dies provide both the forming and cutting operations at a time in the process. As a
as a result, the production rate of the metal is much higher when compared to the other options.
• This helps the manufacturer be economic while producing large quantities of finished
products for the clients.
• These dies are used in specific stamping projects where the two operations are performed
on the sheet metal.

4. Compound Dies
These dies are used when there is a need to perform more than one cutting operation in one stroke.
With the help of these dies, there is a possibility to produce one component for one stroke and
This also helps to keep the production rate high. The sheet metal dies used by the manufacturers
usually vary from project to project, so it is best to get a clear picture on the advantages and the
type of die being used to design your desired component.
Benefits of Compound dies
The force required for the compound dies is higher and is best opted for when the number of
operations are less than 3.

5. Multiple Dies
In all the above dies, there is a possibility to produce only one component per stroke. However,
when there is a need to produce more than one component per stroke then the sheet metal dies
manufacturer opts for multiple dies. The dies are kept in parallel and these are called as multiple

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dies.
Benefit of Multiple dies
• As there are multiple dies, it is possible to produce more components in a shorter period of
time.
• This ensures that the cost is lower and still there is a high rate of production.

The above were some of the most commonly used sheet metal stamping dies that are used in the
industry. Although the benefits are many, there are still certain drawbacks if the dies are not used for
appropriate projects. It is crucial to rely on the manufacturer's recommendation on the dies to be
used. In order to get the best results, it is important to ensure that the manufacturer has good
experience, reputation, and technology in sheet metal dies. There are many manufacturers that
promise the best but there are only a few that have the capability and desire to deliver the best results
at all times. A little research and spending time to understand this aspect clearly will help you attain
the best results in your next sheet metal die stamping project.

Cycle Time: Cycle Time is the amount of time a team spends working on producing an item, up
until the product is ready for shipment. It is the time it takes to complete one task. This includes
time spent producing the item and the wait stages (amount of time the task is left ‘waiting’ on
the board) between active work times.
Lead Time: Lead time is the time measured from the moment a client puts in an order to when

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the final product gets delivered.
This can be easily understood by thinking of the total time it takes for the client to receive the
product from the moment they put in the order to the moment they receive the shipment.
Lead Time is Cycle Time plus the additional amount of time it takes for production to begin
and the time it takes to deliver the finished product.

Takt Time: Takt Time in German means rhythm. It is the steady ‘beat’ that production must
follow to satisfy the demands of the customer.
Takt time is the rate at which manufacturing processes and systems need to complete the
production in order to meet the customer's request. Therefore, this is less of measuring the total
time it takes to complete a segment or the entirety of the production.
Takt time measures the pace at which work must be done to deliver what has been promised.
Takt time can be measured manually or can be automated with takt time solutions.

Tonnage Calculation:

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TPM:

TPM (Total Productive Maintenance) is a holistic approach to equipment maintenance that

strives to achieve perfect production:
• No Breakdowns
• No Small Stops or Slow Running
• No Defects
In addition it values a safe working environment:
• No Accidents

TPM emphasizes proactive and preventative maintenance to maximize the operational

efficiency of equipment. It blurs the distinction between the roles of production and
maintenance by placing a strong emphasis on empowering operators to help maintain their
equipment.

The implementation of a TPM program creates a shared responsibility for equipment that
encourages greater involvement by plant floor workers. In the right environment this can be
very effective in improving productivity (increasing up time, reducing cycle times, and
eliminating defects).

Defects in sheet metal operations:

1. Blanking: Dent mark, half-cut, line mark, burr.
2. Piercing: Burr, whole oblong, oversize, undersize.
3. Forming: Forming ht. not okay, thinning, cracking, scoring marks.
4. Restrike: Tool mark.
5. Dimpling: Crack, dimple size not okay, dimpling shift

Washer Die Design Work:

Designed a die for making a m6 washer

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32
70 Tons Press Machine 30 Tons Press Machine

Washer Die

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Blank sheet Scrap

Washer Manufactured

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 RESULTS & CONCLUSIONS

1. Optimizing Manufacturing Processes: Through the exploration of injection molding and blow
molding techniques, this internship elucidated the critical role of process optimization in
achieving efficient and high-quality production. Understanding the intricacies of material
behavior, mold design, and process parameters is essential for maximizing productivity and
minimizing defects in plastic component manufacturing.
2. Integration of Advanced Technologies: The internship underscored the significance of
integrating advanced technologies, such as CNC-controlled machinery and automated systems, in
modern manufacturing facilities. Leveraging these technologies enables precise control over
production variables, ensuring consistency, repeatability, and adherence to stringent quality
standards.
3. Focus on Material Science: Deepening insights into the mechanical and chemical properties of
raw materials, including polymers and additives, elucidated the pivotal role of material science in
manufacturing. Tailoring material formulations to specific application requirements enhances
product performance, durability, and suitability for diverse end-use scenarios.
4. Continuous Improvement and Innovation: The internship experience emphasized the
importance of fostering a culture of continuous improvement and innovation within
manufacturing organizations. By embracing emerging technologies, implementing best practices,
and encouraging experimentation, companies can drive operational efficiency, product
innovation, and market competitiveness.
5. Towards Sustainable Manufacturing: In an era of increasing environmental awareness, the
pursuit of sustainable manufacturing practices emerges as a strategic imperative. Adopting
eco-friendly materials, minimizing waste generation, and optimizing energy usage contribute to
reducing environmental impact while enhancing long-term sustainability and corporate
responsibility.

In summary, the internship at Malhar Auto Industries provided valuable insights into the technical intricacies
of plastic component manufacturing processes, emphasizing the importance of process optimization,
technological integration, material science, innovation, and sustainability in driving success and excellence
in the field of modern manufacturing.

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