Production Engineering Project Repo

Production Engineering Project Report Manufacturing of Piano BallPoint pen (with Clutch) by using Injection Molding Class - Mechanical (S.E) Section - B Batch - 2011-2012 Group members 1- Syed Wajahat Hasan (ME-075) 2- Danial Sohail (ME-089) 3- Syed Osaid Ul Haq (ME-102) 4- Ranjeet Kumar (ME-104) 5- Owais Ali (ME-105) P.E Project by ME-75, 89,102,104,105 1
2. Index S No. Contents Page Number 1 Injection Molding 03 2 Formation of Pen by Injection Molding 05 3 Cleaning and Finishing Process 06 4 Pen Assembly 07 5 Quality Control 07 6 Recommendation of Process 08 7 Materials Used 08 8 Overall Cost 10 9 Bill of Material (BOM) 12 10 Mold Views 13 11 Pen Image 15 12 Pen Views 16 13 Clutch Views 18 P.E Project by ME-75, 89,102,104,105 2
3. INJECTION MOLDING Injection molding is a common process used for high volume production of thermo plastic resin parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. It is a manufacturing process for producing parts by injecting material into a mold. Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the cavity. Its typical cycle time ranges between 1 and 60 sec. A single mold may contain multiple cavities (when the parts produced are smaller in size) so that multiple parts are produced during each cycle. The mold is expensive and it is mostly used for mass production. Injection molding machine An injection molding machine has two parts. They are: 1) Injection unit 2) Clamping unit P.E Project by ME-75, 89,102,104,105 3
4. 1. Injection unit: The injection unit consists of a hopper used for feeding plastic granules into the barrel. The barrel has heaters or heating jackets on the outside to melt the material as it flows from one end of the screw to the other. The heating jackets maintain a temperature of about 400-600 Fahrenheit or 200-300 centigrade. If the material being used is thermo plastic instead of thermo setting then plastic pellets must be preheated because once they solidify, their molecular property changes. On the inside of barrel there is screw which has threads on its outer surface. This screw is connected to a motor which rotates the screw. It is used for mixing the melted material and it also acts as a plunger which moves forward to inject the material into the plastic mold. There is a non-returning valve at the forward end of the screw which prevents the molten material from returning during the injecting process. It is also known as reciprocating screw. This screw also maintains a pressure of ranging from 35Mpa to 140Mpa. P.E Project by ME-75, 89,102,104,105 4
5. 2. Clamping unit: The clamping unit consists of 4 plates. These plates are usually made up of metal and their melting point is higher than the melting point of plastic . One plate is fixed and the others are movable so that the mold can be closed or opened. It holds the segments of the mold in proper alignment. The mold is kept closed during injecting process and opened when the part is cooled. The clamping unit is attached to a mechanism of hydraulics which close the plates with a certain pressure so the plates do not open during injection of the material with high pressure. Cooling channels are provided so that material is cooled and cycle time is reduced. Formation of pen by Injection molding process Initially the mold of piano pen is closed and raw material is fed by means of hopper. It then enters the barrel and reciprocating screw pushes the material forward and it is heated by means of heating jackets. The material is superheated and mixed together to make sure that the plastic is fluid enough to fill each cavity of the mold. When the material is brought to the right temperature, it is pushed through the nozzle into the mold by means of sprue or gates. Sprue directs the molten material into the mold. Trapped air in the mold can escape through air P.E Project by ME-75, 89,102,104,105 5
6. vents that are grounded into the parting line of the mold. If the air is not allowed to escape the molten material will not completely fill the mold. The mold contains a core which also acts as the ejector pin. Continuous pressure is applied by the plunger to compensate for the contraction of material during solidification. After filling the mold completely the material begins to cool down as it comes in contact with cold surface of the mold. When the part is solidified, the plates are opened and the ejector pin (core) is retracted and the finished material is separated from the core. Meanwhile the Non returning valve is retracted and fresh charge is introduced into forward end of the barrel. After the part is removed from the mold, the plates are closed again and the whole process is repeated. Cleaning and finishing process After the mold cavity is expended and the pen drops down from the mold, a worker collects it from there and then cleaning and finishing process begins Initial Cleaning: As the part is removed from the mold by means of an automatic system(i.e part falls of the mold) and is then collected in container where workers gather them and sprue and runner are cleaned off from the part by means of profile cutters or small saws. The extra plastic present on the surface of the body is completely undesirable and it has to be purged. The extra part is then further removed by means of a hand file, but since it is time consuming so it is less desirable, and the manufacturers usually rely on cutting just by profile cutters. And as we can predict from the surface of specifically piano ball pen, that they are not hand filled. The workers also select random pieces from the pile of pens to find out if any part has been over filled during injection of material by an error or accident, which P.E Project by ME-75, 89,102,104,105 6
7. may have caused the refill nib hole to get jammed. In this case, the hole has to be cleared by using small nails or in some cases small drills. In some cases injection point also gives of unwanted rough patch, the injection point of piano pen is located at the back of the pen holder on the body of the pen. If the point is rough above the tolerance level of the manufacturer the point has to filed by using small files. Further processing: The pen cover is then washed thoroughly to enhance the shinning of the piece and is then send to bath in a special plastic polishing material, in order to enhance the transparency and glossy look of the cover. The name of manufacturer (Piano) is then painted on the holder of the pen by using special stamps and is the piece is then left undisturbed for a while for drying so the name of piano becomes permanent. Assembly: The pen is then fully assembled and ink refill, spring along with clutch is then added into the body of the pen. The pen is then passed through a Quality Control Unit where the requirements of manufacturer or company are tested on their desired scale. Quality Control: The Quality Control unit is active during every part of the process but as pen is being formed in bulk quantity the manufacturer cannot check individually each pen. The main task of the QC is to sort out the defected pieces which may have arrived during the injection process due to human error, voltage change, difference in humidity etc. The selected pieces undergo special treatment and then brought them back to the chain. P.E Project by ME-75, 89,102,104,105 7
8. The QC is active mostly during the last phase of the process when the pen is fully assembled. The workers randomly select the pieces .The selected piece is then measured thoroughly in all dimensions to make sure that the piece is up to the manufacturer’s design. Although we don’t know much about the quality department of Piano pen manufacturer but we can say by observations that they are more prone to errors as compared to that of a foreign manufacturer. Why use injection molding? For producing piano ball pen, injection molding is recommended because of the following reasons 1) Multiple pens can be produced in a single cycle. 2) Complex parts can be easily produced 3) Cycle time is less 4) Economical process for mass production Materials used for making pen Plastic granules are used for making the shells of the pens. Following are the materials that are most commonly used for making the body of pen: Polypropylene (PP): This polymer is hard, tough and easily moldable. It is mostly used in the barrels of use - and - throw models. A random copolymer PP is also used in the barrel of Ocean Gel Pen model because of its transparency. High Density Polyethylene (HDPE): HDPE is used for making mostly caps, plugs and adopters of ball pens of various models. This polymer is useful in those areas, where flexibility and strength both are equally needed. Polystyrene (PS): Polystyrene is a very versatile plastic that can be rigid or foamed. General-purpose polystyrene is clear, hard and brittle. It has a relatively P.E Project by ME-75, 89,102,104,105 8
9. low melting point. This is suitable for injection molding applications. This material is used for making transparent barrels for many models of ball pens. Styrene Acrylonitrile Copolymer (SAN): This material is used for making transparent barrels of expensive pen for its greater strength and clarity. Poly Acetal: This is a novel material because of its toughness and huge compressive strength. It is mostly used for the mechanism of the Pen. ABS (Acrylonitrile Butadiene Styrene): This is a terpolymer(a polymer made from the mixture of three polymers) and useful for its toughness and lower density among all engineering plastic materials. It is mostly used for making clips, plugs and knobs for many models. It is an excellent choice for the electroplating application in different parts of ball pen. TPE

Kết quả (Anh) 1:

Production Engineering Project Report Manufacturing of Piano BallPoint pen (with Clutch) by using Injection Molding Class-Mechanical (s. e.) Section-B Batch-2011-2012 Group members 1-Syed Wajahat Hasan (ME-075) 2-Danial Sohail (ME-089) 3-Syed Osaid Ul Haq (ME-102) 4-Ranjeet Kumar (ME-104) 5-Owais Ali (ME-105) p. E Project by ME-75, 89.102 1 .105 .1042. Index S No. Contents Page Number 1 Injection Molding 2 03 Formation of Pen by Injection Molding 05 3 Cleaning and Finishing Process 06 4 Pen Assembly 07 5 Quality Control 07 6 Recommendation of 7 08 8 08 Used Materials Process Overall Cost 10 9 Bill of Material (BOM) 12 10 11 13 15 Liverpool 12-Views Image Pen Pen Views 16 13 Clutch Views 18 p. E Project by ME-75 89.102, .104 .105 23. INJECTION MOLDING Injection molding is a common process used for high volume production of thermo plastic resin parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, plastic raw material, and a mold. It is a manufacturing process for producing parts by injecting material into a mold. Material for the part is fed into a heated barrel, mixed, and forced into a mold Cay where it cools and hardens to the configuration of the Cay. Its typical cycle time ranges between 1 and 60 sec. A single mold may contain multiple cavities (when the parts produced are smaller in size) so that multiple parts are produced during each cycle. The mold is expensive and it is mostly used for mass production. Injection molding machine, An injection molding machine has two parts. They are: 1) the Injection unit 2) Clamping unit p. E Project by ME-75, 89.102 .104 .105 34.1. Injection unit The injection unit consists of a hopper used for feeding plastic non GMO soybean into the barrel. The barrel has heaters or heating jackets on the outside to melt the material as it flows from one end of the screw to the other. The heating jackets maintain a temperature of about 400-600 Fahrenheit or 200-300 centigrade. If the material being used is thermo plastic instead of thermo setting plastic pellets then must be preheated because once they solidify our, their molecular property changes. On the inside of barrel there is screw which has threads on its outer surface. This screw is connected to a motor which rotates the screw. It is used for mixing the melted material and it also acts as a plunger which moves forward to inject the material into the plastic mold. There is a non-returning valve at the forward end of the screw which prevents the molten material from returning during the injecting process. It is also known as reciprocating screw. This screw also maintains a pressure of 35Mpa ranging from to 140Mpa. P. E Project by ME-75, 89.102 .104 .105 45.2. Clamping unit: The clamping unit consists of 4 plates. These plates are usually made up of metal and their melting point is higher than the melting point of plastic. One plate is fixed and the others are movable so that the mold can be closed or opened. It holds the segments of the mold in proper alignment. The mold is kept closed during injecting process and opened when the part is cooled. The clamping unit is attached to a mechanism of hydraulics which close the plates with a certain pressure so the plates do not open during injection of the material with high pressure. Cooling channels are provided so that material is cooled and cycle time is reduced. Formation of pen by Injection molding process Initially the mold of piano pen is closed and raw material is fed by means of hopper. It then enters the barrel and reciprocating screw pushes the material forward and it is heated by means of heating jackets. The material is superheated and mixed together to make sure that the plastic is fluid enough to fill each Cay of the mold. When the material is brought to the right temperature, it is pushed through the nozzle into the mold by means of the sprue or gates. Sprue directs the molten material into the mold. Trapped air in the mold can escape through air P. E Project by ME-75, 89.102 .104 .105 56. vents that are well-grounded into the parting line of the mold. If the air is not allowed to escape the molten material will not completely fill the mold. The mold contains a core which also acts as the ejector pin. Continuous pressure is applied by the plunger to compensate for the contraction of material during solidification. After filling the mold completely the material begins to cool down as it comes in contact with the cold surface of the mold. When the part is solidified, the plates are opened and the ejector pin (core) is retracted and the finished material is separated from the core. Meanwhile the Non returning valve is retracted and fresh charge is introduced into the forward end of the barrel. After the part is removed from the mold, the plates are closed again and the whole process is repeated. Cleaning and finishing process After the mold Cay is expended and the pen drops down from the mold, a worker collects it from there and then cleaning and finishing process begins Initial Cleaning: As the part is removed from the mold by means of an automatic system (i. e part falls of the mold) and is then collected in containers where workers gather them and sprue and runner are cleaned off from the part by means of profile cutters or small saws???. The extra plastic present on the surface of the body is completely undesirable and it has to be purged. The part is then further removed by means of a hand file, but since it is time it is less time-consuming than desirable, and the manufacturers usually rely on cutting just by profile cutters. And as we can predict from the surface of specifically piano ball pen, that they are not hand filled. The workers also select random pieces from the pile of pens to find out if any part has been over filled during injection of material by an error or accident, which Ward E Project by ME-75, 89.102 .104 .105 67. may have caused the refill nib hole to get jammed. In this case, the hole has to be cleared by using small nails or in some cases small drills. In some cases injection point also gives of unwanted rough patch, the injection point of piano pen is located at the back of the pen holder on the body of the pen. If the point is rough above the tolerance level of the manufacturer the point has to filed by using small files. Further processing: The pen cover is then washed thoroughly to enhance the shinning of the piece and is then send to bath in a special plastic polishing material, in order to enhance the transparency and glossy look of the cover. The name of manufacturer (Piano) is then painted on the holder of the pen by using special stamps and is the piece is then left undisturbed for a while for drying over the name of the piano becomes permanent. Assembly: The pen is then fully assembled and ink refill, spring along with clutch is then added into the body of the pen. The pen is then passed through a Quality Control Unit where the requirements of manufacturer or company are tested on their desired scale. Quality Control: The Quality Control unit is active during every part of the process but as pen is being well-formed in bulk quantity at the manufacturer cannot check individually each pen. The main task of the QC is to sort out the defected pieces which may have arrived! during the injection process due to human error, the voltage change, difference in humidity etc. The selected pieces undergo special treatment and then brought them back to the chain. P. E Project by ME-75, 89.102 .104 .105 78. The QC is active mostly during the last phase of the process when the pen is fully assembled. The workers randomly select the pieces. The selected piece is then measured thoroughly in all dimensions to make sure that the piece is up to the value of design. Although we don't know much about the quality of the Piano pen manufacturer but we can say by observations that they are more prone to errors as compared to that of a foreign manufacturer. Why use injection molding? For producing piano ball pen, injection molding is recommended because of the following reasons 1) Multiple pens can be produced in a single cycle. 2) Complex parts can be easily produced 3) Cycle time is less 4) Economical process for mass production Materials used for making Plastic pen non GMO soybean are used for making the shells of the pens. Following are the materials that are most commonly used for making the body of pen: Polypropylene (PP): This polymer is hard, tough and easily moldable. It is mostly used in the barrels of use-and-throw models. A random copolymer PP is also used in the barrel of Ocean Gel Pen model because of its transparency. High Density Polyethylene (HDPE): HDPE is used for making mostly caps, plugs and adopters of ball pens of various models. This polymer is useful in those areas, where flexibility and strength both are equally needed. Polystyrene (PS): Polystyrene is a very versatile plastic that can be rigid or foamed. General-purpose polystyrene is clear, hard and brittle. It has a relatively p. E Project by ME-75, 89.102 .104 .105 89. low melting point. This is suitable for injection molding applications. This material is used for making transparent barrels for many models of ball pens. Styrene Acrylonitrile Copolymer (SAN): This material is used for making transparent barrels of expensive pen for its greater strength and clarity. Poly Acetal: This is a novel material because of its toughness and compressive strength huge. It is mostly used for the mechanism of the Pen. ABS (Acrylonitrile Butadiene Styrene): This is a terpolymer (a polymer made from the mixture of three polymers) and useful for its toughness and lower density among all engineering plastic materials. It is mostly used for making clips, plugs and knobs for many models. It is an excellent choice for the electroplating application in different parts of ball pen. TPE

Kết quả (Anh) 2:

Production Engineering Manufacturing Project Report of Piano BallPoint pen (with Clutch) by using Injection Molding Class - Mechanical (SE) Section - B Batch - 2011-2012 Group members 1. Wajahat Syed Hasan (ME-075) 2. Danial Sohail (me- 089) 3. Syed Ul Haq Osaid (ME-102) 4 Ranjeet Kumar (ME-104) 5. Owais Ali (ME-105) PE Project by ME-75, 89,102,104,105 1
2. Index S No. Contents Page Number 1 03 2 Injection Molding by Injection Molding Formation of Pen Cleaning and Finishing Process 05 3 06 4 07 5 Quality Control Assembly Pen 07 6 08 7 Recommendation of Process Materials Used 10 9 08 8 Overall Cost Bill of Material (BOM) 12 10 13 11 Mold Views Pen Pen Image 15 12 16 13 Clutch Views Views 18 PE Project by ME-75, 89,102,104,105 2
3. Injection molding Injection Molding is a common process used for high volume production of thermo plastic resin parts. A wide variety of products are manufactured using injection molding, mà trong size vary greatly, compLexity, and application. The injection molding process requires the use of an injection molding machine, plastic raw material, and a mold. It is a manufacturing process for producing parts by injecting material Into a mold. Material for the part is fed Into a heated barrel, mixed, and forced Into a mold cavity where it cools and hardens to the configuration of the cavity. Its typical cycle time ranges 1 and 60 sec giữa. A single mold multiple cavities chứa garment (khi parts are smaller in size Produced) over multiple parts are Produced khi có each cycle. The mold is expensive and it is mostly used for mass production. An injection molding machine injection molding machine has two parts. They are: 1) Injection unit 2) Clamping unit PE Project by ME-75, 89,102,104,105 3
4. 1. Injection unit: The injection unit Consists of a hopper for feeding plastic granules used Into the barrel. The barrel has heaters or heating jackets on the outside to melt the material as it flows from one end to the other of the screw. The heating temperature of about jackets Maintain a 200-300 400-600 Fahrenheit or centigrade. If the material being used is thermo setting plastic thay thermo plastic pellets then preheated vì Phải chúng solidify once, ask for their property molecular changes. On the inside of the barrel there is screw has threads on its mà outer surface. This screw is connected to a motor rotates the screw mà. It is used for mixing the melted material and it cũng Acts as a plunger moves forward to inject the mà Into the plastic mold material. There is a non-returning valve at the forward end of the screw prevents the molten material mà khi returning from the injecting process. It is known as reciprocating screw cũng. This maintains a pressure of screw cũng ranging from 35MPa to 140Mpa. PE Project by ME-75, 89,102,104,105 4
5. 2. Clamping unit: The clamping unit Consists of 4 plates. These plates are made ​​up of metal Thường có melting point and the melting point is Higher coal of plastic. One plate is fixed and the others are compared rằng movable mold closed or opened can be. It holds the segments of the mold in proper alignment. The mold is kept closed and opened khi injecting process khi part is cooled. The clamping unit is attached to a mechanism of Hydraulics mà close the pressure plates compared with A Certain plates do not open the injection of the material khi with high pressure. Cooling channels are given below vì is cooled material and cycle time is reduced. Injection molding Formation of pen by the mold of piano Initially process is closed and raw material pen is fed by means clustering of hopper. It then Enters the barrel and reciprocating screw pushes the material forward and it is heated by means clustering of heating jackets. The material is superheated and mixed together to make sure the plastic is fluid rằng enough to fill each cavity of the mold. When the material is Brought to the right temperature, it is pushed through the nozzle Into the mold by means clustering of sprue or gates. Directs the molten material sprue Into the mold. Trapped air in the mold can escape through air by PE Project ME-75, 89,102,104,105 5
6. Vents được grounded vào Parting line of the mold. If the air is not allowed to escape the molten material will not completely fill the mold. The mold contains a core mà Acts as the ejector pin cũng. Continuous pressure by the plunger is áp to compensates for the contraction of the material khi solidification. After filling the mold begins to cool completely down the material as it comes in contact with the cold surface of the mold. When the part is solidified, the plates are opened and the ejector pin (core) is retracted and the finished material is separated from the core. Meanwhile the valve is retracted Non returning for fresh charge is introduced Into the forward end of the barrel. After the part is removed from the mold, the plates are closed again and the whole process is repeated. Cleaning and finishing process is expended After the mold cavity and the pen drops down from the mold, a worker there and then hợp it from cleaning and finishing process begins Initial Cleaning: As the part is removed from the mold by means clustering of an automatic system ( ie part of the mold falls) and is then thập Workers gather in containers where sprue and runner are added and cleaned off from the part by means clustering of profile cutters or small saws. The extra plastic on the surface of the present body is completely undesirable and it has to be purged. The extra part is then Further unaligned by means again of a hand file, but since it is time Consuming less desirable than it is, and the manufacturers rely on cutting Thường just by profile cutters. And as WE CAN predict specifically from the surface of ball pen piano, that chúng not hand filled. The Workers am also select random pieces from the pile of pens to find out if any part over filled khi bị injection of material by an error or accident, mà PE Project by ME-75, 89,102,104,105 6
7. unfortunately have caused the refill nib hole to get jammed. In this case, the hole has to be cleared by using small nails or small trường in some drills. In some Cases of unwanted injection point cũng Gives rough patch, the injection point of the pen is located at the piano back of the pen holder on the body of the pen. If the point is above the tolerance level rough of the manufacturer has to filed by the point using small files. Further processing: The pen is then washed thoroughly cover to Enhance the shinning of the piece and is then send to bath in a special plastic material polishing, in order to Enhance the transparency and glossy look of the cover. The name of manufacturer (Piano) is then painted on the holder of the pen by using the special stamps and is then left undisturbed piece is for a while for drying over the name of Piano Becomes permanent. Assembly: The pen is then fully assembled and ink refill, spring clutch is then added along with the body of the pen Into. The pen is then passed through a Quality Control Unit where the requirements of manufacturer or ask for their company are tested on the scale desired. Quality Control: The Quality Control unit is active every part of the process khi but as pen is being formed in bulk quantity the manufacturer can not check individually each pen. The main task is to sort of the QC out the defected pieces mà khi có Arrived vì the injection process to human error, voltage change, difference in humidity etc. The selected pieces undergo special treatment and then added back to the chain Brought. PE Project by ME-75, 89,102,104,105 7
8. The QC is the last active mostly khi phase of the process is fully assembled khi pen. The Workers selected randomly select the pieces .The piece is then measured in all dimensions to thoroughly make sure rằng piece is up to the manufacturer's design. Although do not know much about chúng the quality department of Piano pen manufacturer but WE CAN drunk by observations mà more prone to errors chúng as sánh to a foreign manufacturer của. Why use injection molding? For piano producing ball pen, injection molding is recommended vì những lý 1) Multiple pens can be Produced in a single cycle. 2) Complex parts can be Easily Produced 3) Cycle time is less 4) Economical process for mass production of Plastic Materials used for making granules are used pen for making the shells of the pens. Following are the materials commonly used for được nhất making the body of the pen: Polypropylene (PP): This polymer is hard, tough and Easily moldable. It is mostly used in the barrels of use - and - throw models. A random copolymer PP is used in the barrel cũng of Ocean Gel Pen vì its model transparency. High Density Polyethylene (HDPE): HDPE is used mostly for making caps, plugs and adopters of ball pens of various models. This polymer is ích những in which areas, where flexibility and strength Equally cả are needed. Polystyrene (PS) Polystyrene is a very versatile plastic or foamed rigid có thể. General-purpose polystyrene is clear, hard and brittle. It has a Relatively PE Project by ME-75, 89,102,104,105 8
9. low melting point. This is Suitable for injection molding applications. This material is used for making transparent barrels for many models of ball pens. Acrylonitrile Styrene Copolymer (SAN): This material is used for making transparent its barrels of expensive pen for greater strength and clarity. Poly Acetal: This is a novel material toughness vì its compressive strength and huge. It is mostly used for the mechanism of the pen. ABS (Acrylonitrile Butadiene Styrene): This is a terpolymer (a polymer made ​​from the mixture of three polymers) and ích for its toughness and lower density materials Among all engineering plastics. It is mostly used for making clips, plugs and knobs for many models. It is an excellent choice for the electroplating application in parts of ball pen khác. TPE