Design Guidelines Injection Moulding

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PRESENTATION BY MR ANSHUMAN KUMAR AGGARWAL DIRECTOR INDIAN DIECASTING INDUSTRIES, ALIGARH

Transcript of Design Guidelines Injection Moulding

Page 1: Design Guidelines Injection Moulding

PRESENTATION

BY

MR ANSHUMAN KUMAR AGGARWAL

DIRECTOR

INDIAN DIECASTING INDUSTRIES, ALIGARH

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INDIAN DIECASTING

I N D U S T R I E S

ISO:9001

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Journey of: Indian Diecasting Industries

Founded by Shri Pramoad Kumar Aggarwal ji with self made pneumatic hot chamber diecasting machine

Added Aluminium Diecasting and developed more than 1000 parts for Automotive OEMs, MNCs

1965 2013

Manufactures 1 Million parts consuming 20-25 MT Zn and 40-60 Tons Al every month.

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About: Indian Diecasting Industries

1. We are a knowledge based and environment friendly company

2. We are not a bulk producers. 3. We manufacture premium quality diecast parts in

complex shapes and designs with minimal porosity, hardware surface finish and wall thickness less than 1mm within close limits in areas of angularity, perpendicularity, concentricity, center distances, parallelism, run outs and eccentricity.

4. Presently ISO:9001 certified, going for TS:16949

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Industries Served By: Indian Diecasting Industries

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Customers: Indian Diecasting Industries We are Tier-1 / Tier-2 Suppliers to following OEMs / MNCs:

Automotive (Tier-2 Suppliers to): •TVS •New Holland •Hero Honda •Fiem •Mahindra & Mahindra •Varroc •Pricol •Mitsubishi •Lombardini •Continental •Autolek •Tafe •Veethree

•Home Appliances: •Videocon •Whirlpool

•Electric Switch-Gear: •Schneider Electric •Havells •Legrand •Indo Asian •Standard Electricals •Anchor

•Home Appliances: •Videocon

•Bathroom Fittings: •Roca •Misc-Small

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Infrastructure: Indian Diecasting Industries

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Images of Few Critical Zinc Diecast Parts Developed By:

Indian Diecasting Industries

10 Sliders 186 Dimensions All within tolerance

External Threads with 6g Go/NoGo Bore Dia within 0.018MM As Cast

Dia 0.9MM 10 MM Deep As Cast

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Images of Few Critical Al Diecast Parts Developed By:

Indian Diecasting Industries

Max Thickness 0.5 MM Weight 0.9 Grams

Hyper Eutectic Al Alloy (B390) having Si>18% For Exports to Automotive OEM

First shot success rates DME Mould Base Used Made on DMG-VMC

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Images of Few Critical Dies Developed By:

Indian Diecasting Industries

With Chiller

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Sharing of Learning & Improvements By

Indian Diecasting Industries, Aligarh Through United Nations Common Fund for Commodities (UN CFC) project

Managed By

The International Zinc Association( IZA)

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Team Indian Diecasting Industries

is thankful to

Mr Joseph Annets

(World’s most renowned Zinc Diecasting Expert)

For sharing his hard earned experience in suggesting improvements and answering

hundreds of our questions.

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Visits of Mr Josef Annets to: Indian Diecasting Industries

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Diamond Handle: Problem of Micro Porosity at Parting Line

Diamond Handle-Casting

Parting Line

Diamond Handle-After Parting Line Grinding

Problem of Micro Porosity observed after grinding or buffing

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54 mm2

Gate Area 80 mm2

Main Runner Start Area 176 mm2

Sprue End Area

Main Runner End Area 60 mm2 Sprue Start Area

176 mm2

Nozzle Area Dia 8=50 mm2

Diamond Handle: Root Cause Analysis of Problem

Section Area (mm2)

Nozzle –Dia 8mm 50

Sprue upper 176

Sprue base 176

Main runner start 81

Main runner end 60

Gate 54

Are

a S

hould

decre

ase fro

m N

ozzle

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ate

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ot

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ere

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Diamond Handle: Root Cause Analysis of Problem

During running there was big variations of temperature at different areas of die

Moving Insert (Deg Celcius) 130 to 145

Fix Insert (Deg Celcius) 170 to 197

Sliding Cores (Deg Celcius) 255 to 260

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Diamond Handle: Changes Made in Die

Change in Nozzle Design

Earlier After Modification

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Diamond Handle: Changes Made in Die

Change in Sprue Design

Earlier After Modification

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Diamond Handle: Changes Made in Die

Change in Nozzle Fitment in Fix Half of Die

Earlier After Modification

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Diamond Handle: Changes Made in Die

Change in Diffuser design

Earlier After Modification

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Diamond Handle Evaluating Modifications

Section Area (mm2)

Before

Area (mm2)

After

Nozzle Dia 8 = 50 Dia 11 = 95

Sprue upper 176 83

Sprue base 176 83

Main runner start 81 81

Main runner end 60 60

Gate 54 54

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54 mm2 54 mm2

Gate Area 81 mm2 81 mm2

Runner Start Area

176 mm2 83 mm2

Sprue End Area

Runner End Area 60 mm2 60 mm2

Sprue Start Area 176 mm2 83 mm2

Nozzle Area 50 mm2 95 mm2

EARLIER DESIGN DESIGN AFTER MODIFICATION

Diamond Handle: Evaluating Modifications

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Diamond Handle: Evaluating Modifications

Variations in temperature at different areas of die was controlled as below

Earlier After Modification

How?

Moving Insert (Deg Celcius)

130 to 145 150 to 170 Focused 1 spray nozzle

Fix Insert (Deg Celcius)

170 to 197 160 to 175 Focused 1 spray nozzle

Sliding Cores (Deg Celcius)

255 to 260 170 to 185 Focused 1 spray nozzle

on each slider

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Other Benefits After Modifications: Improvement in Yield

Re Introduction to Yield:

Shot Wt: 200 Gms Part Wt: 100 Gms

Casting Yield = 100/200 = 50%

= +

Runner / Overflow / Sprue Wt: 100 Gms

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Part Name: Handle Diamond Monthly Production: 40,000 Pcs

Earlier

After Modification Shot Weight=Part Wt (168) + Runner/Overflow Wt (137)

= 305 Gms Shot Weight=Part Wt (168) + Runner/Overflow Wt (80)

= 248 Gms

Yield: (168/305)X100=55% Yield: (168/248)X100=68%

Material Requirement: 0.168Kg/Pc X 40,000Pcs=6,720Kg Material Requirement: 0.168Kg/Pc X

40,000Pcs=6,720Kg Melting Lot (Kg) Casting (Kg) Recycle (Kg) Melting Lot (Kg) Casting (Kg) Recycle (Kg)

6,720.000 3,696.000 3,024.000 6,720.000 4,569.600 2,150.400

3,024.000 1,663.200 1,360.800 2,150.400 1,462.272 688.128

1,360.800 748.440 612.360 688.128 467.927 220.201

612.360 336.798 275.562 220.201 149.737 70.464

275.562 151.559 124.003 70.464 47.916 22.549

124.003 68.202 55.801 22.549 15.333 7.216

55.801 30.691 25.111 7.216 4.907 2.309

25.111 13.811 11.300 2.309 1.570 0.739

11.300 6.215 5.085 0.739 0.502 0.236

5.085 2.797 2.288

2.288 1.259 1.030

1.030 0.566 0.463

0.463 0.255 0.209

12,217.803 6,719.791 5,498.011 9,882.005 6,719.764 3,162.242

Total Melting 12,218 Kg Total Melting 9,882 Kg

Total Casting 6,720 Kg Total Casting 6,720 Kg

Other Benefits After Modifications: Improvement in Yield

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SAVINGS-AFTER IMPROVING YIELD SAVING IN FUEL

Total Melting (Earlier @ 55% Yield) 12,218 Kg

Total Melting (After Improving Yield to 68%) 9,882 Kg

Less Melting Done 2,336 Kg

Average LPG Consumption in Zinc Melting/Holding Crucible 3 Kg/Hr

Melting Crucible / Pot Capacity 180 Kg

Time required to melt 180 Kg 1.5 Hrs

LPG Required to melt 2335.798 Kg Zinc 58.4 Kg

LPG Rate 80 Rs/Kg

LPG Savings 4672 Rs

SAVING IN BURNING LOSS Less Melting Done 2,336 Kg

Average Burning Loss 5%

Zinc Alloy Rate (May'2013) 140 Rs/Kg

Material Saving by doing lesser melting 116.8 Kg

Amount saved by doing lesser melting 16352 Rs

Other Benefits After Modifications: Improvement in Yield

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• 19% saving in material recycling.

• 19% saving of LPG Gas.

• Reduction in material handling

• 1% material saving due to reduced burning losses

• Contribution to Environment by saving Fuel & Material

CONCLUSION

Other Benefits After Modifications: Improvement in Yield

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Diamond Handle: Further Proposed Improvements

Shot Wt: 230Gms Part Wt: 168 Gms Runner/Sprue Wt: 62 Gms

Casting Yield = 168/230 = 73%

Will get increased further from existing 68% to 73%

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Improvements in Runner Design-Mounting Plate (2nd Die)

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Development of New Part: Ring Result-High Quality finish from 1st Shot

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Development of New Part: Heat Sink Result-High Quality finish from 1st Shot

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THANK YOU

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Any Question?