PA4204 Plastics Product and Mould Design Syllabus:

PA4204 Plastics Product and Mould Design Syllabus – Anna University PG Syllabus Regulation 2021

OBJECTIVES:

 To understand basic concepts of product design
 To learn the design concepts for various mould elements.
 To acquire knowledge about various moulds for different processing techniques
 To learn the basic design aspects related to Injection Mould, Compression Mould, Transfer Mould, Blow Mould.
 To learn the basic design aspects related to extrusion dies

UNIT I PRODUCT DESIGN

Principles & Methodical approach for Product Design – Product Design Appraisal- Tooling Aspects on Product Design – Cost Analysis for Product Design. Features: Geometry Features- Wall thickness, Taper & Draft, Radii, Fillets, Ribs, Bosses Holes, Undercuts –External & Internal- Moulded threads Inserts – Shrinkage- Assembly Features – Fits &Tolerances – Snap Fits – Hinges – Types -Design of Integral hinges – Welding – Bonding. Structural Elements: Design of Tension bars, Columns, Beams, Pipes, Plates and Shells- Design of Joints – Bolted joints and bonded joints- Design of plastics under Static load & dynamic load Design of plastic Gears, Bearings, springs.

UNIT II INJECTION MOULD DESIGN

Introduction–Elements of Injection Mould – Factors considered for Mould Design- -Shot Capacity Plasticising Rate -Clamping Force- Injection Time – Cooling Time – Number of Cavities –Layout of Cavities. Design of Injection mould systems–Parting surface and its types – Core–Cavity – Bolster construction methods for core & cavity-Guide pillar- Guide bush – Sprue bush – Locating Ring Standard Mould System – Mould alignment – Mould Assembly – Mould Clamping. Feed System: Sprue – types of sprue – Runner – types of runner – cross section and size of runner –runner layout – balancing of runners – Gates – Gate location and balancing – types of gates – Mould Venting.

UNIT III EJECTION & COOLING SYSTEM DESIGN

Ejection System: Requirements – Elements of Ejection system – Ejector grid, Ejector plate assembly, Ejection techniques – Ejection from fixed half – Sprue Pullers- Ejection Force Calculation – Ejection Assembly Actuation. Mould Temperature Control System: Introduction -Heat Transfer Fluids- Chillers Temperature Controllers – Factors Affecting the Cooling Cycle -Cooling Efficiency – Mould Cooling Variables -Cooling Calculations -Cooling of Integer type mould plates – Cooling of Insert Bolster assembly -cooling of other mould parts- connections of cooling channels and seals. Types of Injection Moulds: Cold Runner – Hot Runner – Hand – Semi Automatic – Automatic Two plate – Three Plate – Moulds for Internal & External Undercuts.

UNIT IV DESIGN OF COMPRESSION & TRANSFER MOULD

Compression Mould Design: Introduction -Types – Open flash, Semi-positive, Positive moulds Bulk factor – Design of loading chambers and Pressure pad – Calculations of Flash thickness, Projected area, Compression Pressure, Clamping Force, No. of impressions- Design of heating system – Advantages , Disadvantages and Applications Compression Mould. Transfer Mould Design: Introduction -Types – Design of Pot and Plunger – Calculations of Projected area, Transfer Pressure, clamping force – Design of Pressure pad and Feed system-Advantages, Disadvantages and Applications of Transfer Mould

UNIT V DESIGN OF OTHER MOULDS & DIES

Blow Mould Design: Introduction-Types of blow moulds-Blow ratio – Parison design–Pinch off design – parting line-mould cooling-mould alignment. Rotational Mould Design: Introduction – Construction Advantages, Disadvantages and Applications. Extrusion Die Design: Principles of extrusion – construction of die – die geometry – die swell–die land design – sizing die -Advantages, Disadvantages and Applications.

TOTAL: 60 PERIODS

OUTCOMES:

At the end of the course, students will be able to
 Understand the basics of plastics product design.
 Understand the basics of plastics mould design.
 Acquire knowledge about various moulds for different processing techniques.
 Apply the basic design aspects related to Injection Mould, Compression Mould, Transfer Mould, Blow Mould
 Apply the basic design aspects related to extrusion dies

REFERENCES

1. Robert A. Malloy, “Plastic Part Design for Injection Moulding”, Hanser Publishers, Munich Vienna, New York, 1994.
2. Peter Jones, the Mould Design Guide, Smithers Rapra Technology Limited, Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK, 2008,
3. Belofsky, H, “Plastics Product Design and Processing Engineering, Hanser Publishers, Munich Vienna New York, 1994.
4. Dym J.B Injection Mould & Moulding A practical manual, Springer, 2nd ed. XVIII, 396P, 1987.
5. Nayak, Sanjay K, Pratap C. Padhi, and Y Hidayathullah. Fundamentals of Plastics Mould Design. New Delhi: Tata McGraw Hill Education, 2012.
6. Glanvill, Alan B, and E N. Denton. Injection-mould Design Fundamentals. New York: Industrial Press, 1965.
7. Unger, Peter. Gastrow Injection Molds: 130 Proven Designs. Munich: Hanser, 2006.
8. R.D. Beck “Plastics Product Design”, Van Nostr and Reinhold, New York,1980