Fabrication of Gear Type Injection Moulding Achine
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DESIGN FABRICATION OF GEAR TYPE INJECTION MOLDING MACHINE
PROTOTYE:
ABSTRACT:
The project deals about the injection moulding machine.The main principle is to compress the
plastic material in a barrel and the compressing motion is developed by rotating the gear box
arrangement .The plastic material is heated by the heater surrounding by the barrel .Then it is
converted in to molten state .Then molten plastic is injected through the nozzle in barrel to the
dye by the compressing force .After completing this process, we will get the product from the
die.commercial products like bushes,couplings,switches etc., can be produced. Here we have
fabricated the gear type injection molding machine. Its a new innovative concept. This
equipment has been mainly developed for molding the plastic materials in plastic molding
industries. This equipment is very useful in make the injection molding process. In this
equipment we are using the rack and pinion, motor, heater and control unit for making of such
operations. The performance of plastic gears in wide variety of power and motion transmissionapplications is rather limited due to weak mechanical properties and divergent mechanism of
failures. A methodical simulation is carried out to analyze the gear performance with various
gating system types, gate locations, and processing parameters via grey-based Taguchi
optimization method. With the obtained optimum results in simulation stage, the flow patterns of
polymer melt inside the mould during filling, packing, and cooling processes are studied and the
plastic gear failures mechanism related to processing parameters are predicted. The output results
in the future can be used as guidance in selecting the appropriate materials, improving part and
mould design, and predicting the performance of the plastic gear before the real process of the
part manufacturing takes place.
INTRODUCTION:
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Gears have been in use for more than three thousand years and commonly utilized in
power and motion transmission under different loads and speeds. Due to the fiscal and
practical advantages, the demand of using plastics in gearing industry is significantly
increased and indubitably continues in the future. In comparing with metal gears, plastic
gears have several advantages such as light weight, noiseless running, resistance to
corrosion, lower coefficients of friction, and ability to run under none lubricated conditions
[1, 2]. Plastic gears can be produced by hobbing or shaping, likewise to metal gears or
alternatively by injection moulding. With the continuous expansion of technology, plastic
injection moulding bears itself to considerably more economical means of mass production
to meet the rapidly rising market demand of plastic gearing in various applications.
Injection moulded plastic gears have been used with success in the automotive industry,
office machines, and household utensils, in food and textile machinery, as well as a host of
other applications areas [3]. Unlike metal gears, the potential uses of plastic gear, however,
are rather limited due to weak mechanical properties, poor heat conductors, and tendency
to undergo creep [4]. Apart from that, the plastic gear tooth experiences complex stresses
during service and can fail by divergent mechanism.
Apart from material selection, a proper part or mould design also plays a major role in
getting the most out of plastic gears. A high quality moulded plastic gear starts with the
design and construction of a high quality plastic gear mould. The mould shall always haveproper cooling channels, venting, properly sized gates and runners, ample coring and
ejection capabilities, quality mould surface finish, precision fits and tolerances,
concentricity between mould components, and proper mould material selection. Any
misjudgment in the part and mould design can lead to disastrous consequences on the
plastic gear produced and cause subsequent modifications in the production line, indirectly
incurring high production cost [13]. In the research conducted by Luscher et al. [14], the
number of gates, if kept small, was shown to have a strong influence on the periodicity of
both run-out and long-term transmission error on moulded polyketone gears. However, the
gating scheme had minimal influence on the total magnitude of the errors for the same
gears.
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As plastic materials exhibit extremely convoluted properties, the complexity of the
moulding process makes it very challenging to attain the desired gear part properties. The
intricacy of injection moulding process in producing a wide range of parts with complex
shape including those with tight tolerances [15, 16] has created a very intense effort to keep
the quality characteristic of moulded plastic gear under control. Even if it is possible to
select an optimal material for a specific gear task based on the properties such as strength,
wear, stiffness, damping, and noise production, due to the complexity of injection moulding
process which involving many processing parameters, such as pressure, temperature, and
time, improper setting of processing parameters could negatively affect the final quality of
the moulded plastic gear. In fact, the optimum properties of the plastic material with the
most innovative part and mould design cannot be achieved and become meaningless
without optimum processing parameters during the gear manufacturing. In addition, poor
processing practices relying on experience, intuition, or trial and error in obtaining
information regarding the processing parameters will also create the conditions for gear
failure modes that could not be predicted or accounted for by even the most prudent of
designers.
FABRICATION TECHNIQUES:
`, softening, tempering, stability, the size and shape are important in describing the
method. These methods are different kinds of plastics. Broadly speaking the method may be
discussed under the following headings,
1. MOULDING PROCESS
2. FOAMING PROCESS
MOULDING PROCESS:
In this process the plastics are fabricated under the effect pressure and heat and both
thermoplastics and thermosetting plastics may be starting materials.
INJECTION MOULDING:
Thermoplastics are produced by this method. In this the material is softened by
heating and the hot softened plastic is forced under high pressure into the mold, when it is
set by cooling and the mold is ejected. Injection molding (injection moulding in the UK) is a
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manufacturing process for producing parts by injecting material into a mould. Injection
moulding can be performed with a host of materials, including metals,glasses,elastomers,
confections, and most commonly thermoplasticand thermosettingpolymers. Material for
the part is fed into a heated barrel, mixed, and forced into a mould cavity, where it cools
and hardens to the configuration of the cavity.[1]:240
After a product is designed, usually by
an industrial designer or an engineer, moulds are made by a mouldmaker from metal,
usually either steel or aluminum, and precision-machined to form the features of the
desired part. Injection moulding is widely used for manufacturing a variety of parts, from
the smallest components to entirebody panelsofcars.Advances in 3D printing technology,
using photopolymers which do not melt during the injection moulding of some lower
temperature thermoplastics, can be used for some simple injection moulds.
Parts to be injection moulded must be very carefully designed to facilitate the moulding
process; the material used for the part, the desired shape and features of the part, the
material of the mould, and the properties of the moulding machine must all be taken into
account. The versatility of injection moulding is facilitated by this breadth of design
considerations and possibilities.
Injection Process
With injection moulding, granular plastic is fed by gravity from a hopper into a heated
barrel. As the granules are slowly moved forward by a screw-type plunger, the plastic is
forced into a heated chamber, where it is melted. As the plunger advances, the melted
plastic is forced through a nozzle that rests against the mould, allowing it to enter the
mould cavity through a gate and runner system. The mould remains cold so the plastic
solidifies almost as soon as the mould is filled
I njection moulding cycle
The sequence of events during the injection mould of a plastic part is called the injection
moulding cycle. The cycle begins when the mould closes, followed by the injection of the
polymer into the mould cavity. Once the cavity is filled, a holding pressure is maintained to
compensate for material shrinkage. In the next step, the screw turns, feeding the next shot
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to thefront screw.This causes the screw to retract as the next shot is prepared. Once the
part is sufficiently cool, the mould opens and the part is ejected.
FOAMING PROCESS:
This involves the blowing of a volatile organic liquid, which is entrapped into a polymer
network resulting in the formation of foamed plastics. Foamed polystyrenes are produced in this
process.
COMPONENTS OF GEAR TYPE INJECTION MOULDING MACHINE:
GEAR BOX:
A gearbox is a mechanical method of transferring energy from one device to another and is used
to increase torque while reducing speed. Torque is the power generated through the bending or
twisting of a solid material. This term is often used interchangeably withtransmission.
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Located at the junction point of a power shaft, the gearbox is often used to create a right angle
change in direction, as is seen in a rotary mower or a helicopter. Each unit is made with a
specific purpose in mind, and the gear ratio used is designed to provide the level of force
required. This ratio is fixed and cannot be changed once the box is constructed. The only
possible modification after the fact is an adjustment that allows the shaft speed to increase, along
with a corresponding reduction in torque.
In a situation where multiple speeds are needed, a transmission with multiple gears can be used
to increase torque while slowing down the output speed. This design is commonly found in
automobile transmissions. The same principle can be used to create an overdrive gear that
increases output speed while decreasing torque.
Manual transmission is available in two different systems: sliding mesh and constant mesh. The
sliding mesh system uses straight cut spur gears. The gears spin freely and require driver
manipulation to synchronize the transition from one speed to another. The driver is responsible
for coordinating the engine revolutions to the road speed required. If the transition between gears
is not timed correctly, they clash, creating a loud grinding noise as the gear teeth collide.
GEAR BOX TRANSMISSION:
A machine consists of a power source and a power transmission system, which provides
controlled application of the power. Merriam-Webster defines transmission as an assembly of
parts including the speed-changing gears and the propeller shaft by which the power is
transmitted from an engine to a live axle.[1]
Often transmissionrefers simply to the gearboxthat
usesgearsandgear trainsto providespeedandtorqueconversions from a rotating power source
to another device. The transmission reduces the higher engine speed to the slower wheel speed,
increasing torque in the process Conventional gear/belt transmissions are not the only
mechanism for speed/torque adaptation. Alternative mechanisms include torque convertersand
power transformation
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.
MAIN SHAFT PULLEY:
A shaft is an element used to transmit power and torque, and it can support reverse bending
(fatigue). Most shafts have circular crosssections, either solid or tubular. The difference betweena shaftand an axle is that the shaft rotates to transmit power, and
that it is subjected to fatigue. An axle is just like a round cantilever beam, so it is not subjected to
fatigue.
Shafts have different means to transmit power and torque. For example, it can use gears,
sprockets, pulleys, etc., and also have
some grooves to keep these elements rigid and avoid their vibration, such as key seats, retaining
ring grooves, etc. Also, to be able to
avoid vibration of the elements, and assure an efficient transmission of power and torque, some
changes in the cross-section of the shaft can be made
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The nomenclature is not always clear cut and there is often an overlap of function and therefore
of definition.In general, a ROTATING member used for the transmission of power.
Shaft Diagram
Belt (mechanical):
A belt is a loop of flexible material used to mechanically link two or more rotatingshafts,
most often parallel. Belts may be used as a source of motion, totransmit powerefficiently,
or to track relative movement. Belts are looped overpulleysand may have a twist between
the pulleys, and the shafts need not be parallel. In a two pulley system, the belt can either
drive the pulleys normally in one direction (the same if on parallel shafts), or the belt may
be crossed, so that the direction of the driven shaft is reversed
RACK AND PINION SHAFT:
A rack and pinion is a type of linear actuator that comprises a pair of gears which convert
rotational motion into linear motion. A circular gear called "thepinion"engages teeth on a linear
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"gear" bar called "the rack"; rotational motion applied to the pinion causes the rack to move,
thereby translating the rotational motion of the pinion into the linear motion of the rack.
For example, in a rack railway, the rotation of a pinion mounted on a locomotiveor a railcar
engages arackbetween the rails and forces atrainup a steep slope.
Pinion shafts are present in most gear train assemblies. The pinion shaft transfers the input of
drive shafts (commonly known as cranks) to generate the work for which gear trains are
designed. Pinion gears transfer the drive motion to linear gear assemblies or to 90 bevel gear or
miter gear assemblies. W.M. Berg's high quality pinion shafts are typically single-piece
assemblies manufactured from one piece of steel stock.
NOZZLE:
A nozzleis a device designed to control the direction or characteristics of afluidflow (especially
to increase velocity) as it exits (or enters) an enclosed chamber orpipe.
A nozzle is often a pipe or tube of varying cross sectional area, and it can be used to direct or
modify the flow of a fluid (liquidorgas). Nozzles are frequently used to control the rate of flow,speed, direction, mass, shape, and/or the pressure of the stream that emerges from them. In
nozzle velocity of fluid increases on the expense of its pressure energy.
WORKING PRINCIPLE:
The injection-moulding process is best suited for producing articles made of thermoplastic
materials. Here, the equipment cost is relatively high but the main attraction is the amenability
of the injection-moulding process to a high production rate. In injection molding, a definite
quantity of molten thermoplastic material is injected under pressure into a relatively cold mold
where it solidifies to the shape of the mould.
The injection moulding machine is shown in the process consists of feeding the
compounded plastic material as granules, pellets or powder through the hopper at definite time
intervals into the hot horizontal cylinder where it gets softened. Pressure is applied through a
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hydraulically driven piston to push the molten material through a cylinder into a mould fitted at
the end of the cylinder. While moving through the hot zone of the cylinder, a device called
torpedo helps spread the plastic material uniformly around the inside wall of the hot cylinder
sand thus ensures uniform heat distribution. The molten plastic material from the cylinder is
then injected through a nozzle material from the cylinder is then injected through a nozzle into
the mould cavity.
The mould used, in its simplest form, is a two-part system. One is a movable part and the
other stationary. The stationary part is fixed to the end of the cylinder while the movable part
can be opened or locked on to the stationary part. By using a mechanical locking device, the
mould is proper held in position as the molten plastic material is injected under a pressure as
high as 1500kg/cm. The locking device has to be very skillfully designed in order to withstand
high operating pressures. Further more, a proper flow of the molten material to the interior
regions of the mold is achieved by preheating the mould to an appropriate temperature. Usually,
this temperature is slightly lower than the softening temperature of the plastic material under
going moulding.
After the mould is filled with the molten material under pressure, then it is cooled by cold
water circulation and then opened so as to eject the molded article. The whole cycle could be
repeated several time either manually of in an automated mode.
Base contains the side support, supporting arm and other equipments of this project. The base
contains the molding die on it. The rack and pinion arrangement is mounted on the supporting
arm. The rack is guided by the guide arrangement in this equipment. The raw material is poured
into the barrel, then the heater is switched on and the particular time the Rack and pinion
arrangement is working by the motor get power from automatically through the control unit, the
rack and pinion moves up to down then the molded plastic forcedly moves to the molding die.
The molding die is split able to two parts. So finish the molding process then cool the molding
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die to the required time and remove the molded specimen from the die. This equipment is easily
operateable, used for injection molding needed plastic parts manufacturing industries.
Injection molding is the most important molding method for thermoplastics. It is based on
the ability of thermoplastic materials to be softened by heat and to harden when cooled.
The process thus consists essentially of softening the material in a heated cylinder and
injecting it under pressure into the mold cavity, where it hardens by cooling. Each step is
carried out in a separate zone of the same apparatus in the cyclic operation.
A diagram of a typical injection-molding machine is shown in Figure PP.6. Granular
material (the plastic resin) falls from the hopper into the barrel when the plunger is
withdrawn. The plunger then pushes the material into the heating zone, where it is heated
and softened (plasticized or plasticated). Rapid heating takes place due to spreading of the
polymer into a thin film around a torpedo. The already molten polymer displaced by this
new material is pushed forward through the nozzle, which is in intimate contact with the
mold. The molten polymer flows through the sprue opening in the die, down the runner,
past the gate, and into the mold cavity. The mold is held tightly closed by the clamping
action of the press platen. The molten polymer is thus forced into all parts of the mold
cavities, giving a perfect reproduction of the mold.
The material in the mold must be cooled under pressure below Tm or Tg before the mold is
opened and the molded part is ejected. The plunger is then withdrawn, a fresh charge of
material drops down, the mold is closed under a locking force, and the entire cycle is
repeated. Mold pressures of 8,000000 psi (56212 kg/cm2) and cycle times as low as 15
sec are achieved on some machines.
Note that the feed mechanism of the injection molding machine is activated by the plunger
stroke. The function of the torpedo in the heating zone is to spread the polymer melt into
thin film in close contact with the heated cylinder walls. The fins, which keep the torpedo
centered, also conduct heat from the cylinder walls to the torpedo, although in some
machines the torpedo is heated separately.
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Injection-molding machines are rated by their capacity to mold polystyrene in a single shot.
Thus a 2- oz machine can melt and push 2 oz of general-purpose polystyrene into a mold in
one shot. This capacity is determined by a number of factors such as plunger diameter,
plunger travel, and heating capacity.
The main component of an injection-molding machine are (1) the injection unit which melts the
molding material and forces it into the mold; (2) the clamping unit which opens the mold and
closes it under pressure; (3) the mold used; and (4) the machine controls.
PP.5.1 Types of Injection Units
Injection-molding machines are known by the type of injection unit used in them. The oldest
type is the single-stage plunger unit (Figure PP.6) described above. As the plastic industry
developed, another type of plunger machine appeared, known as a two-stage plunger (Figure
PP.7a). It has two plunger units set one on top of the other. The upper one, also known as a
preplasticizer, plasticizes the molding material and feeds it to the cylinder containing the second
plunger, which operates mainly as a shooting plunger, and pushes the plasticized material
through the nozzle into the mold.
GEAR
Molded Gear Transmission
Molded plastic gears have very little in common with machined gears other than the factthat both use the involute for conjugate action. The differences are quite fundamental.
Machined gears are cut to size with specialized machinery designed specifically for the
task. Molded gears are formed in gear cavities that are usually cut with wire Electrical
Discharge Machines (EDM). These cavities are sized so that the molded gear will shrink to
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the proper size after molding. One cavity might be expected to form more than a million
molded gears.A molding insert tool along side the molded gear
And the gear cavity
A gear cutting manufacturer is charged with the task of cutting gears within
tolerance with every piece made. The gear mold is charged with the task of making one
nearly perfect gear cavity and then processing each gear from that cavity within tolerance
for every piece made. This small but significant difference leads to many other variations.
The differences begin as soon as the choice for molded gears is made.
Design
Molded gears invariably must operate in molded housings. This single fact has
significant consequences. Molded housings and the shafts in them are rarely going to have
the precision tolerances that a machined transmission can provide. The housings and gears
will shrink and expand due to moisture and temperature, perhaps at different rates. The
strength, hardness, and even efficiency of the plastic material will also vary due to local
conditions. Surface toothtemperatures will rise under load, which affects plastic properties.
All of these variables and more dictate a need for custom design of gear teeth.
The advantage the plastic gear designer has is in the application. Most plastic
transmissions are unique. A gear mesh can be designed strictly for its intended function
with a single mating gear. Additionally, the molded gear can be optimized with very little
regard for tooling. Wire EDMs can generate machined patterns with the precision of
CAD. A gear cavity can be made with micron tolerances. Given the fact that traditional
hobs are not required,Diametral Pitch or Module are unimportant specifications. The
involute base circle is the variable ofimportance. Pressure angles can be adjusted in an
analog fashion to balance strength and depth of tooth engagement. Custom designed gearswill offer a great improvement in performance, quietness, and allowable tolerances than
standard gearing.
Comparison of Standard Gear Mesh to Custom Shape Formed Gears
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Molded gears can be made in many forms and varied sizes.
Very Fine Pitch Gear
The Gear Molding Tool
With the gear mesh designed and toleranced, the next step is tool construction. Gear
tooling
must be precise with excellent thermal stability, hardened sleeves and surfaces, exact gear
cavity formation, and designed for high-pressure injection molding. The gear cavity itself
must
be specifically designed for the selected molding material.
There is no way to accurately predict the actual shrinkage for molded plastic gears in a
specific
application. This is due to a number of factors. Most importantly, plastic does not shrink
from
the cavity in an isotropic fashion. The main body of the gear will shrink in a manner that
may be
similar to manufacturers estimations, but the individual tooth is surrounded by steel and
its
cooling pattern will differ from the macroscopic pattern of the larger mass.
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Distinct shrink rates for general plastic gears
A good method to determine shrink requires to two-step approach. Shrink factors are
estimated
for the gear in question. After the tool is made and the first gears are molded, they are then
profile inspected for exact involute geometry. The individual shrink rates are then
determined, a
new cavity is made to the measured shrink and the final gear geometry is properly sized.
Only
profile inspection will be able to accurately determine involute shrinkage. Gear roll testing
may
give some idea of shrinkage anomalies, but it can also give misleading indications.
Sometimes heavily glass filled material is selected for gears due to its low shrink rate.
Shrinkage
then becomes less of an issue in mold design. This approach can also cause its own
problems.
Unfilled engineering resins such as nylon and acetal mold into very precise shapes, albeit
with
shrinkage. Glass filled materials will have knit lines where injection flow fronts merge.
These
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knit lines can cause distortion at the tooth surface as well as localized weak spots on the
gear.
Glass filled gears will generally be much more abrasive during their life than equivalent
unfilled
gears. Generally, filler should only be used when a specific need has been established that
outweighs potential problems.
Mold Processing
All molding is not equivalent. All molding machines are not equivalent. Gears require mold
processing that is exact and repeatable. In general, virgin resin is used for high accuracy
gears.
Even with virgin resin, the material must be of correct dryness, its melt temperature must
be
controlled exactly and repeatably. Injection pressures must be established precisely. The
interaction of the mold tool and process control must also be taken into account.
As plastic is injected at high temperature and pressure, the melt must displace air in the
gear
cavity. Vent paths must be created to allow air to escape, but must be thin enough to stop
the
resin from venting as well. If the vents are too small, gas will be trapped and burning could
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result. If the vents are to big, plastic melt will flow through and cause flash on the part. It is
often advisable for the gearing customer to visit the molding facility before placing the final
order. Just a cursory inspection of molding equipment, general plant cleanliness, inspection
capabilities, and personnel, can help to evaluate their potential for successful molding and
control. For instance, it will be very difficult to mold precision gears in a non-temperature
controlled environment. Molding precision gears in 90% humidity at 100F is fraught with
difficulty.
Inspection
Over the years gear inspection has been refined to discover most errors that trouble cut
gearing.
A profile scanning inspection of the involute profiles is usually done for only a few teeth
around
the gear. Metal gears are produced on turning machinery and patterns can be expected
from
tooth to tooth. Plastic molded gears can have large solitary errors anywhere on any surface
of the
gear. Furthermore, the molding process can introduce a much different kind of error than
in
traditional manufacture.
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Since any molded gear will shrink, the involute profile is a target, not a given value.
Whether
one considers Diametral Pitch, Module, base pitch, pressure angle or any other involute
feature
as the controlling geometry, this feature will be a variable in the actual part. It is necessary
to
set realistic tolerances for these truly variable features.
The Involute Shrinkage of a Molded Gear
Typical errors in a Molded Part
The only way to be certain that a plastic molded gear is within tolerance is by scanning the
involute profile and determining the actual physical geometry of the gear. The molded part
can
be completely out of specification and still give acceptable roll test results. Below is a profile
inspection of such a gear. The involute base circle was very far off the defined value. The
gear
had 64 teeth and a master used to measure the gear had 64 teeth. With such a large
number of
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meshing teeth in roll testing, there was almost no tooth-to-tooth error. The gear simply
appeared
large, even though the base circle was small. The molder thinned the teeth, brought the
gear into
good specification with a roll test, and supplied parts to the customer. The parts
immediately
failed when meshed with a cut metal gear of correct size.
Badly Shrunk Plastic Molded Gear To prevent this type of error the gear must be
completely specified with each variable toleranced.
One such method is recognized by the AGMA in the recently completed Information guide
for
Inspection of Molded Plastic Gears.
NUMBER OF TEETH
BASE PITCH (BASIC DIMENSION)
BASE CIRCLE DIAMETER +/-
BASE CIRCLE TOOTH THICKNESS +/-
ROOT DIAMETER** +/-
OUTSIDE DIAMETER +/-
INVOLUTE FORM DIAMETER max
TIP RADIUS max
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CENTER DISTANCE WITH MASTER GEAR Tbd
MASTER GEAR SPECIFICATION Tbd
TOOTH-TO-TOOTH COMPOSITE ERROR max
PROFILE FORM TOLERANCE (fi) max
**ROOT TROCHOID MUST BE DIRECTLY GENERATED
(RE: AGMA STANDARD 1006-A97 APPENDIX F)
OPERATING DATA
NOMINAL OPERATING DIAMETRAL PITCH
NOMINAL OPERATING MESH ANGLE
NOMINAL OPERATING TOOTH THICKNESS
Suggested Gear Data Specification for Molded Gears
In this approach the base circle geometry of the gear is used as the fundamental control.
The
indirect specification of Diametral Pitch and Pressure Angle are included in the operating
data
field as a reference for traditional analysis.
Gear roll testing is almost always the best way to assure consistency of the molded part in
production. Rather than simply describe allowable Total Composite Error (TCE) or Tooth-
to-
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Tooth error (TTE), the actual center distance with a given master can be specified with
indicated
+/- tolerances. This will provide an easy method to assure that the gears are molding the
same
day after day. Roll tests of sample gears can be gathered to assure both the general form
and the
absolute size of the gears are within tolerance. Roll testing for plastic gears is more like
establishing a roll test signature and confirming that the parts conform to that signature
day
after day.
Typical Roll Test Signature of 10 Molded Gears
The future for plastic molded gears is quite promising. Materials are improving greatly.
Molding
machinery is becoming more accurate. Inspection equipment is now capable of measuring
these
unique parts with great precision. In the future, plastic can be expected to replace metal
gears in
lighter duty applications. They are and will continue to find uses in areas that cannot be
served
by metal gears.
In order to reach these new potentials, every step must be taken correctly and every
advantage
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exploited. The result will be a remarkable new generation of power transmission products.
Prototype Injection Molding
We provide a wide range of prototype injection molded components (featuring plastic gears)
using methods that best meet your requirements.
Our Start to Part(STP) team provides rapid delivery of parts with minimal tool grooming and
limited inspection data to ensure that you have good parts quickly.
Our Production I ntent Prototype service delivers production capable tooling and parts. This
method of prototyping takes into account a customer's need for greater inspection data and the
highest quality of parts.
Comparative Features
While the original concept of the STP acronym was Start To Part, the intent of the group isSteps To Production. Yet it differs from conventional production-quality tooling, as follows:
Production Intent Prototyping
Tooling is owned by the customer and in most cases has customer tool design approval
Tooling is either self contained, in a common frame, or is a single cavity pull-ahead in the
production mold.
Molding process is optimized for tolerances as well as cycle time, which may or may not be
applicable to a production tool.
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QA: full SIR, PPAP, and capability studies are applicable and are made available to the
customer, usu. OEM
Normal delivery
ABA-PGT "Start To Part:
Tooling is owned by ABA-PGT
Tooling is a cavity set in an ABA-PGT owned universal frame
Process optimization is minimized in lieu of speed, yet dimensional characteristics are
monitored for accuracy. Some operator assembly and machining operation may be
incorporated.
Sample inspection reports (SIR) are performed for OD, ID, OAL and gear data. Capability is
reserved for production.
Rapid parts delivery
Applications:
Medical Applications
ABA-PGT works with customers in providing solutions for Surgical Instruments, Biopsy
Instrumentation, Robotics, Dental Implant products, and more...
Automotive Applications
In Automotive, we develop and supply products for Electrical Throttle Controls, Steering
Systems, Instrument Clusters, Window and Door Latch systems, and more.
Business Machine Applications
Whether it is helping to move money in a currency exchange unit, making sure that your
important report prints out right the first time, providing photocopies that are clean and crisp, or
a postal mail machine processing your mail for delivery, ABA-PGT offers cost-effective
solutions for these and many other paper path applications
Miscellaneous Applications
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Water pumps, Small engine transmission, irrigation sprinklers, HVAC, Fractional Motors, Water
& Gas meters, Actuators, Consumer Appliances...
Truth be told...ABA-PGT provides solutions to over 50 different applications.
Injection Molding Machine Control
The FACTSTotal Injection Molding Control (TMC)system integrates and centralizes control
of the entire Injection Molding machine. TheTMC Systemis applicable for all new or existing
injection Molding machines typically larger than 500 ton.
The TMC System provides full integration of the blow molding machine including
control/monitoring of:
Extruder Speed and Temperature
Platen Temperature
Platen Movement
Complete Form Cycle
Control of Injection, Pack & Hold Steps
All Machine Sequence Logic
In addition to our Injection Molding Control System, FACTSprovides:
Heater and Drive Enclosure Assemblies
Drive and Motor Upgrades
Hydraulic Power Package
Total Information Manager
APPLICATIONS:
Batch Mixing Control Systems:
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The FACTS Total Mixing Control (TMC) System for batch processes integrates and
centralizes control of the entire mixing and compounding process. The TMC System is
applicable for all new or existing mixing lines.
The TMC Systemprovides full integration of all line equipment including control/monitoring
of:
Material Handling Systems
Oil Ingredient Weights
Bulk Compound Weights
Minor Compound Weights
Mixer Speed and Temperatures
Mix Time, Temperature and/or Energy
Extruders
Pelletizers
Drop Offs
Batch Offs
In addition to ourTotal Mixing Control System, FACTSprovides:
Recipe Management
Job Scheduling
Weigh Belt Manager
Total Information Manager
Structural Foam Machine Control
TheFACTSStructural Foam Machine Control System integrates and centralizes control of
the entire Structural Foam machine. The Structural Foam Control Systemis applicable for all
new or existing Structural Foam machines.
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The Machine Control Systemprovides full integration of the structural foam machine including
control/monitoring of:
Extruder Speed and Temperature
Platen Temperature
Platen Movement
Complete Form Cycle
Control of Injection, Pack & Hold Steps
All Machine Sequence Logic
In addition to our Structural Foam Machine Control System, FACTSprovides:
Heater and Drive Enclosure Assemblies
Drive and Motor Upgrades
Hydraulic Power Package
Total Information Manager
Thermoformer Machine Control
The FACTS Total Thermoformer Control (TTC) System for In-Line and Roll Fed
Thermoformers integrates and centralizes control of the Thermoforming machine. The TTC
Systemis applicable for all new or existing thermoforming machines.
The TTC Systemprovides full integration of the forming machine including control/monitoring
of:
Oven Temperatures
Index Position
Platen Position Movement
Complete Form Cycle
Eject Functions
All Machine Sequence Logic
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In addition to our Total Thermoforming Control System, FACTSprovides:
Heater and Drive Enclosure Assemblies
Servo Drive and Motor Upgrades
Trim Press Integration
Total Information Manager
Hose, Pipe and Tubing Extrusion Line Control
The FACTS Total Line Control (TLC) System for Hose, Pipe & Tubing Extrusion
lines integrates and centralizes control of the entire extrusion process. The TLC System isapplicable for all new or existing hose, pipe or tubing processes.
The TLC System removes islands of automation and provides full integration of all line
equipment including:
Letoffs
Feed Systems:
o
Volumetrico Gravimetric
Extruder Speeds & Temperatures
Cold Start Protection
Automatic Melt Pump Control
Screen Changers
Internal Air Support Systems
Sizing Tanks
Lappers/Braiders
Gauging:
o Laser Micrometer
o UltrasonicDatasheet 1532-00
http://www.facts-inc.com/wp-content/uploads/2012/04/1532-00-IOW-Gauge-Print.pdfhttp://www.facts-inc.com/wp-content/uploads/2012/04/1532-00-IOW-Gauge-Print.pdfhttp://www.facts-inc.com/wp-content/uploads/2012/04/1532-00-IOW-Gauge-Print.pdfhttp://www.facts-inc.com/wp-content/uploads/2012/04/1532-00-IOW-Gauge-Print.pdf -
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Pullers/Capstans
Cutters
Wind-ups/Take-ups
In addition to our Total Line Control System, FACTSprovides:
Heater and Drive System Assemblies
Motor Replacements
Total Information Manager
MERIT
The daily using components can be easily made.
The cost of the project is very less.
High electricity consumption.
Textile products can be produced.
Less skilled labour is enough.
Different shape of the components can be made according to the die what are
used.
Double-cylinder balanced injection system;
.Multi-stage pressure &speed injection;
Back pressure adjustment device;
Low pressure mold protection;
.Single hydraulic core pulling and inserting;
hydraulic ejector knock-out;
Advantage:
1. T Slot Platen;
2.Machine Weight more than most factory.
3.Machine base use rectangular Tube.
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4pcs safe door are moveable,maintain the machine more easy;
5.Hydraulic tank is moveable,more easy to clean the tank,
6.heating band is made by cermics,use life is long
7.prepare more spare parts for customer
DISADVANTAGES
Additional Cost is required for Gear box and motor.
Heating coil consumes high current
Conclusion:
The findings of fabrication experiment reveal that the advancement of the simulation packages
is capable of simulating the scenarios of the polymer melt without conducting the real
experiment. As in this study, MPI software is a useful tool to predict volumetric shrinkage and
deflection of the moulded gear under different process conditions. The integration of the grey-
based Taguchi optimization method and numerical simulation provides designers and engineers
with a systematic and efficient approach to identify the most significant processing parameters
on the quality characteristics of the final moulded gear out of numerous processing variables
with minimal simulation trials required. Through a series of analysis and optimization, it was
found out that gate types and locations have a great influence on the filling pattern or the
transient progression of the polymer flow front within the feed system and mould cavity.
Predicting and visualizing the filling pattern in mould cavity using simulation packages before
the real manufacturing process takes place reduces the incurring high production cost due to
subsequent mould modification in production line as well as minimizing the potential aesthetic
issues in the moulded gear.