MAJOR PROJECTS / AMR SCHEMES:

Some of the major projects / schemes / latest technologies to improve production from concept to commissioning (implemented or in the process of implementation) carried out by Design and Engineering department are indicated below:

Use of excellent materials for plastic production

Water enrichment for cooling purpose

Ensuring availability of utilities like cooling water during total & extended power failure.

Implementation of water pumping scheme through recycling.

Implementation of automation in various units of plastic manufacturing.

Replacing the oldmolding machines with latest moundingmachines at Continuous Casting Department.

Up gradation / modernization to increase the speed of machine and there by production.

Modification of water box for proper work maintenance.

Augmentation of used water system to facilitate up for cooling during manufacturing.

Expand plastic plant capacity to 5 million ton by 2011-12 with the mission to attain 10 million ton capacity in two subsequent phases

Wipe out accumulated losses by 2010-11

Be amongst top five lowest plastic producers in the world by 2010-11

Achieve customer satisfaction levels on par with world class organizations by 2010-11

Make CIPET the employer of choice by caring for employees. Develop people As knowledge workers by 2010-11 and achieve an improvement of 5 percent Points in employee satisfaction levels every alternate year

Be ranked as an excellent business organization by 2010-11

Ensure zero effluent discharge by 2010-11 and contribute to improving Quality of life (health, literacy and water) in at least one village every year

Last few years have been tumultuous for plastics and petrochemical sector due to steep rise in oil prices, which has adversely affected the global economies. However, considering the feed stock advantage and abundance of oil reserves newer petrochemical complexes are being established in Middle-east countries. i.e. Oman, Saudi Arabia, UAE, etc. It is projected that by the end of 2010, Ethylene capacity in Middle-East would reach to about 35 million tons per annum and Polypropylene (PP) capacity to touch about 7 million tonnes per annum. The US Petrochemical sector may lose Export competitiveness as most of the Ethylene capacities in USA are Ethane based, which are not cost competitive and are capable to produce only Polyethylene (PE). Similarly, the revamping of European Petrochemical Complexes would be imperative as they are based on old and expensive technology and are not cost competitive with the Middle-East companies having the biggest advantage of raw material at their door-step. China, Middle-East and India would be the major global players, where expansion and augmentation of existing petrochemical capacity would take place in the next 5 years.

Worldwide Plastics Industry witnessed a steady growth in the year 2007 which is reflected in the increased consumption figures of all types of Plastics materials.

Asia has been worlds largest plastics consumer for several years, accounting for about 30% of the global consumption excluding Japan, which has share of about 6.5%. Next to Asia is North America with 26% share, then Western Europe with 23% share in the global market.

The key growth segment remains Packaging which accounted for over 35% of the global consumption. Amongst the individual Plastics Materials, Polyolefin accounted for 53% of the total consumption, (PE with 33.5%, PP with 19.5%) followed by PVC 16.5%, PS-8.5%, PET & PU - 5.5%, Styrene copolymers (ABS, SAN, etc) 3.5% other engineering & high performance & speciality plastics, blends, alloys, thermosetting plastics 13%.

In recent years, significant aspect of plastics material growth globally has been the innovation of newer application areas for plastics such as increasing plastics applications in automotive field, rail, transport, defence & aerospace, medical and healthcare, electrical & electronics, telecommunication, building & infrastructure, furniture, etc.

Plastics have become the key drivers of innovations & application development. Polymer-Electronics is one such area which has opened up new avenues for plastics; from organic light emitting diodes to electro-optical and bio-electrical complements, from low-cost plastic chips to flexible solar cells. New plastics can conduct electricity and emit light. While polymers will not replace silicon as semiconductors, they do offer completely new opportunities for low-priced mass-manufactured products. Radio-frequency identification (RFID) tags in smartcards for identification and access control, payment and ticket systems, price labels, product tracking systems in the logistics chain or packaging that monitors product quality many things are in offing. Growth-trend of plastics has proved that there has been a quiet Plastics revolution taking place in the material sector.

INTRODUCTION OF INDUSTRY/ORGANISATION

Central institute of Plastics Engineering and Technology (CIPET) is an autonomous Institute under the Ministry of Chemicals and Fertilizers, Government of India. CIPET centers are located at Chennai, Ahmadabad, Bhopal , Guwahati Hyderabad, Lucknow, Panipat, Jaipur &Mysore. CIPET centers across the country are very well equipped with State of art infrastructure and machinery in testing , processing, tooling , calibration and CAD/CAM/CAE to develop the manpower for plastics and allied industries in terms of Training, Technical services .R&D and consultancy.

CIPET has been actively involved in inculcating awareness about environment and Plastics waste management issues at National and International level. To address various environmental issues and to create an awareness about "Plastics & Environment", CIPET has conducted series of National Seminars in different parts of the country:Indian Centre for Plastics in the Environment(ICPE) and Central Institute of Plastics Engineering & Technology (CIPET) have brought out a comprehensive monograph entitled "Plastics for Environment & Sustainable Development" with an objective to propogate advantages of Plastics in modern society by focusing on various contentious issues concerning sustainability of Plastics materials and assessment of the impact on environment.CIPET laboratory have equipments;

Differential scanning calorimeter Universal testing machine Impact tester Thermogravemetric Analyzer HDT!VST Tester Abrasion Tester Surface and volume resistivity tester

U.V Weatherometer MFI testing machine Density by density gradient column HAAKE Rheocord 9000 Injection moulding machine Extrusion Machine Compression Machine Absorption Spectroscopy Carbon black content equipment Rockwell hardness testing machine Environmental chamber for conditioning CNC Machine for Mechanical work Viscometer

Central institute of plastics Engineering and Technology (CIPET) is an institute under the department of Chemicals and Petrochemicals, Ministry of Chemicals and fertilizers , Government of India . CIPET Head Quarters was established at Madras in 1968 with UNDP assistance .this is the only institute of its kind in India where all the facilities like design. Tooling, processing and CAD/CAM/CAE, Testing , consultancy, advisory and Development services.

In order to meet the growing demand of trained man power and technical services in Northern region in general and the state of Uttar Pradesh, CIPET Lucknow was the first Established in 1986-87 by Government of India with the assistance of Government of Uttar Pradesh for supporting the plastics &allied industries in the state . CIPET LUCKNOW has NABL accreditation as well as BIS recognition for conducting plastics materials and products testing for quality assurance.

The centre of CIPET has been equipped with state-of-the-art machinery in the area of mould/product design and development, CAD, plastics processing and testing/quality control .Apart from developing training man power and technical services for plastics industries Specializes in application development in the field of auto mobile and teletronics .

CIPET Centre at Lucknow was established in 1986-87 by Government of India with the assistance of Government of Uttar Pradesh for supporting the plastics & allied industries in the state. CIPET Lucknow has been contributing its valuable service to the industry and helped in the growth of Plastics Industry in the region.

Accreditation and Quality Management System

The Plastics Testing Centre of the Institute accredited by NABL, Department of Science and Technology, Govt.of India for performing Mechanical and Chemical Tests on raw material and plastics productsRecognition by Bureau of Indian Standards (BIS) for the Testing and evaluation of plastics materials and productsThe Indian plastic processing industry is highly fragmented and comprises 25,000 firms. Barring 10% - 15% of the firms, which can be classified as medium scale operations, all the units operate on a small-scale basis.

The top 100 players account for just 20% of the industry turnover. The total number of players in the sector is more than 25,000. However, the degree of fragmentation, worldwide, is a large and despite the small size of operations of the players, they are able to operate profitably. Further, the high growth in demand ensures that the market is able to absorb the excess capacity in quick time. Overall, the degree of competition can be considered high in the Indian plastic processing industry.

The sector has a significant presence of the unorganised sector, which accounts for more than 70% of the industry turnover. More than 95% of the firms in the industry are partnership, proprietorship or private limited companies. Further, these small companies get significant advantages in taxes. These firms thus provide significant level of competition to the organised sector companies, which combined together are making losses. The organised sector companies thus need to build up significant brand image to survive against the competition from the unorganised sector. The key organised sector players include Nilkamal Plastics Limited and Supreme Industries Limited.

TABLE 1- Current Indian Petrochemicals Capacities (in KT)

Producer & LocationPPHDPELDPEHD/LLPTAPSPVC

RIL, Hazira350--400--300

RIL, Jamnagar600---800--

RIL Patalganga60---300--

IPCL, Nagothane60-80220---

IPCL, Vadodara75-80---55

IPCL, Gandhar-160-----

GAIL, Auriya-100-160--150

HPL, Haldia210200-260---

BRPL, Bongaigaon-------

Finolex, Pisranpar------130

LG Poly, Vizag-----80-

Supreme, Mumbai-----240-

ChemPlast, Metturdam------60

DCW, Sahupuram------60

BASF Styrenics, Bharuch-----60-

DCM, Shriram, Kota----400-35

RPRL, Abu-----16-

Mitsubishi, Haldia-------

TOTAL135546016010401500360790

Grand Total5665

Typical Polymer consumption pattern of different polymers

PolymerKT

LDPE/EVA275

LLDPE5501745

HDPE920

PP1300

PVC1000

PS225

PET Film135

Bottle100235

SAN/ABS90

Polyamide35

Polycarbonate72

Polyacetal8125

PET/PBT7

Others3

Thermoset100

Total4820

To manufacture finished products, polymers are processed through various types of techniques namely extrusion, injection moulding, blow moulding and rotomoulding. Various products manufactured through these processes are highlighted in the following exhibit.

Classification of Plastic Products by Type of process used

ExtrusionFilms and Sheets, Fibre and Filaments Pipes, Conduits and profiles, Miscellaneous applications

Plastic ProductsInjection MouldingIndustrial Injection Moulding, Household Injection Moulding and Thermo-ware/ Moulded luggage

Blow MouldingBottles, containers, Toys and Housewares

Roto mouldingLarge circular tanks such as water tanks

The polymer consumption in India according to various processes is provided as follows :

Process(%) Share in Total consumption in India

Extrusion60.0

Injection Moulding25.0

Blow Moulding / Stretch Moulding06.0

Rotomoulding01.0

Other Processes08.00

Statistics of Plastics Industries in India :

Current Status

Major Raw Material Producers15 Nos.

Processing Units25,000 Nos.

Turnover (Processing Industry)Rs.85,000 Crores

Capital Asset (Polymer Industry)Rs.55,000 Crores

Raw Material Produced approx5.3 MMT

Raw Material Consumed approx5.1 MMT

Employed Direct/Indirect3.3 Million

Export Value approxUS $ 1.90 Billion

Revenue to Government approx.Rs.7300 Crores

By 2011 - 12

Demand Potential12.5 MMT

Additional Employment4.0 Million

Investment PotentialRs.84,000 Crores

VISION 2015 Indian Plastics Industry :

Consumption of Polymers @ 15% CARG18.9 Million tonnes

Turnover of plastics IndustriesRs.1,33,245 crores

Additional Employment Generation7 Million

Requirement of AdditionalPlastics Processing Machines68113 Nos

Additional Capital InvestmentIn Machines (2004-2015)Rs.45,000 crores

For more information on Indian Plastics Industry, please visit

Plastindia Foundation -www.plastindia.org

All India Plastics Manufacturers Association -www.aipma.net

Indian Plastic Federation -www.plasticfederation.org

Organization of Plastics Processors of India -www.oppindia.org

The Plastics Export Promotion Council -www.plexconcil.org

Deputy Director(head of institute)

Chief Manager (professor) (looks after academic & placement activity)

Manager (asst. professor) (head of departments)

Sr. tech officer (sr. lecturer) (faculty member)

Technical officer (lecturer)(faculty member)

Mud flap for automobile industries

Steering seals

Defense application products

Telephone buttons

Telephone dial tone button

Soap and tooth brush case

Polythene bags for 1-5 kg

ACTIVITES

Tooling on CNC machines-CNC milling. CNC lathe CNC EDM for different machining jobs receive from reputed customers.

Engraving by pantograph.

Fabrication of single impression injection mould for domestic products.

Development of mining props from plastic materials.

Consultancy provided on setting up of HDFC pipes manufacturing plant.

Climating testing of plastic products.

Characterization of lamination rolls terminal logic.

Technical evaluation and study of the properties of HDFC and PP.

Testing and quality assessment of plastic materials and products as per national and international standards.

Formulation and supplement of testing standards.

Design and development of testing equipments as per testing requirements.

3-Dimentional solid modeling

Process simulation and mould design.

3D digitizing and 2D digitizing.

Required designNo.of pieces/timeSelection of machineNo.of cavitiesSelection of modulePlacement of cavitiesSelection of gatingset temperaturecontrol placement of cavityModelingMachine placementBooking and loadingdelivery

(BASED ON STUDY AND OBSERVATION IN DIFFERENT DEPARTMENTSTS AND SECTIONS)

(FIRST WEEK IN CIPET)

PROCESSING DIVISION

Plastic Processing has broad range of practical training facilities in the form of conventional processing machines. In addition to the training activities the processing division is also competent enough to undertake mould providing and moulding jobs in different processing machines.

The following customer services are provided by processing division:

Job-work on moulding of plastic products and providing of mould To conduct tailor-made/modular training programs on the specific topics as per the requirements of plastic industry. To organize Awareness Orientation & Entrepreneurship Development Program (EDP5) on Plastic Processing Techniques Consultancy and Advisory services to the plastic industries To provide consultancy services to the new entrepreneurs on Setting up of a Plastic Industry

FACILITIES AVAILABLE

Modern Injection Moulding Machines of following manufacturers:- JSW- Japan, ELECTRONICA- India, ENGEL- Austria, WINDSOR- India Multilayer Blow Film Plant of Dr. Collin Germany Pipe & Blown Film Extruders-Kolsite, India Extruder for Tubing -DGP-Windsor Compression Moulding Machine Thermoforming Machine Rotational Moulding machine Blow Moulding Machine FRP-Demonstration Facility

PLASTICS

Materials derived from carbon are termed as organic materials . range of the organic materials is in thousand owing to vast variety of hydro carbons and their derivatives .organic materials may be natural or synthetic . from nature we obtain inform of crude oil . after fractional distillation in different stages we obtain petrol diesel kerosene petroleum jelly etc.

A plastic is the name given to a materials which is a mixture of resin catalyst accelerator and pigment. Resin forms a major part this mixture and hence the properties of plastic are mostly governed by the properties of resin used.

Plastics are classified in to two categories.

1.Thermosetting Plastic2.Thermoplastic

1.thermosetting plastic- they have a three dimensional network of primary bonds in all the directions. These types of plastics. On applications of heat first become soft and then hard and after that they can not be soften against by application of heat. This permanent hardening called curing is a chemical change. egphenolics, epoxies, melamine, and bakelite etc. they generally require both heat and pressure be moulded into any shape if intensely heated, they breakdown by degradation.

2.thermoplastics- their chain molecules are secondary bonded which break more readily due to increase in thermal energy. They become soft when heated ( generally with pressure ) but require cooling to set into a definite shape. Since no chemical hardening action takes place the shaped articles re-soften on reheating. Only a physical change is involved with them .e.g. cellulose polystyrene, polyvinylchloride, nylon, Teflon, polysulfone, acrylic, polyurethane, acetal etc.

MACHINE NAME- TEXAIR

SPECIFICATIONS

It is a screw type injection moulding machineModel name : JTS-40

INJECTION MOULDING CYCLE

1.Mould opening2.Mould closing3.Mould safety4.Mould locking5.Injection unit forward6.Injection7.Hold down time8.Refilling9.Injection unit reverse! cooling10. Mould opening11. Ejection

Injection unitscrew diameter:-32mmL/D ratio:-20:1Screw stroke:-145+5Maximum swept volume:-100ccShot capacity:-40gmsMaximum screw speed:-200rpmNumber of heating zone:-4

Clamping unitClamping force :-40 tonsMaximum mouldopening :-250mmMaximum height of mould: -300mmDay light :- 550mmNumber of tie bars:- 4Distance between tie bars: 305 x 225 mm x mPlaten size : 450 x 395 mm

Maximum hydraulic ejection force :- 3 tonsMaximum stroke of hydraulic ejector :- 60mm

SEMI AUTOMATIC INJECTION MOULDING MACHINE SP-130

SPECIFICATIONS

Screw diameter : 45 mmInjection stroke : 190 mmLID ratio : 20:1Screw speed : 0-205 rpmPlasticizing capacity : 75 kg/hrsMaximum calculated shift volume : 300ccMaximum rate of injection : 175 cc/secInjection pressure : 2200 kg/cmRefraction stroke : 200 mmNozzle contact force : 6.2 tonsHopper capacity : 4.5 liters

Locking unit :-Mould clamping force:-130tonsSize of mould platen:-585x585Distance b/w tie bar:-380x380Diameter for tie bar:-70mmMinimum mouldheight :-200mmMaximum mould opening:-550mmMaximum day light:-750mm

TECHNICAL DATA

Screw dia:-50mmL/D ratio:-24:1Drive motor:-20/2HP, 1500/150RPM Dc motorScrew speed:-12-120RPMMain speed reducer:-worm reducing gear box having reductionRatio:-15:1Thrust capacity:-30.000hrs at 100rpmB-10 life of bearing 375 kg/cm ( 5300psi ) head pressure in hrsHopper block:-water cooling typeHeating zones on barrel :-3-5 KW each

Cooling blower motor hp:-1 number of 0.1HPNumber of die zones:-3Heating capacity:- maximum capacity to be 3 KW for each zoneElectrical supply :-415V+5%, 50 C/S phase, neutral andCooling water:-inlet, 1/2 BSP-1 Numbers, outlet BSP-2 Numbers

(SECOND WEEK IN CIPET)

TESTING LAB

The Plastic Testing Centre (PTC) in CIPET is well equipped with all modern plastic testing facilities. These facilities are being utilized effectively to improve the standard and quality of plastic materials .The PTC has been providing very useful services to the plastic conversion industries by testing of raw materials and finished products like pipes, containers etc. The testing services also include identification and characterization, composition of materials etc. The centre is closely associated with Bureau Of Indian Standards (BIS) for establishing standards and to issue certificates for various plastic materials and products .The PTC also has an interaction with International Standard Organization (ISO) in the formulation of standards.

The PTC in CIPET is recognized by following organization

1. Bureau of Indian Standards2. Department of Family Welfare, Govt. of India3. Department of Science & Technology, Govt. of India4. Various state Government departments for quality assurance5. Underwriters Laboratories Inc., USA6. American Association for Laboratory Accreditation on behalf of Asia Pacific Laboratory Accreditation and Co-operation (AP LAC)

The PTC is presently in the process of getting NABL Accreditation.The PTC provides basic service to the industries and Government Agencies for Quality through:

Identification and characterization of Plastics and composites Testing and quality assessment of plastic materials and products as per national and international standards Formulation and Supplementation of Tests standards Design & development of testing equipments as per testing requirements. Undertakes development projects and special assignments

TYPE OF TESTING

To determine the mechanical properties of materials certain tests are carried out .depending on the nature of tests. These are grouped into following categories.

Non destructive tests Destructive tests

In non destructive tests the materials of their specimens are not broken. In destructive tests. The specimens of materials or fractured or deformed.

Soft and weak material

Low modulus. Low yield stress. Moderate elongation at break point.

E.g. Polytetrafluoroetsylene ( PTFE ) is a good example of one such type of plastic material.

Soft But Tough Material

Low modulus Low yield stress very high elongation high stress at break

e. g. polyethylene is a classic example of these types of plastics

Hard & Brittle Material

High modulus Low elongation It may or may not yield before breaking

e.g. one such type of polymer in this group general purpose phenolics .

Hard & Strong Material

High modulus High yield stress

High ultimate strength Low elongation e.g.polyacetal is a good example of this class of materials.

Hard and tough Material

High modulus High yield stress High elongation at break High ultimate strength E.g. Polycarbonate ( PC ) is considered hard & tough material.

Type of Mechanical properties

Short term mechanical properties Long term mechanical properties Surface term mechanical properties

TENSILE TEST

Tensile test in a broad sense is a measurement of the ability of a material to with stand forces that tend to pull it apart and to determine to what extent the material stretches before breakingSignificance:- To produce data for the control and specification of polymers.To provide useful data for plastics engineering designpurpose.

Standard:- ASTM D 638 , ISO 527-1Factor:-Temp. , RH Speed, Grips & Specimen preparation.

Resistance of plastic material against the tension called tensile strength.

Test specimen:-Dumb- bell shaped.

Specimens:-

Film:-cutting punchSheet:-counter formingFoam:-cutting punchLiquid:-coastingThermostat:- C. M., I M. T. M.

Thermoplastic

Factor affecting the test results

Temperature:-Tensile strength and modulus are decreased while elongation is increased as the temp increase.

Rate of straining:-As the strain rate is increased the tensile strength and modulus increases . However the elongation is inversely proportional to the strain rate.

Humidity:-Tensile strength is increased as the humidity decrease.

FLEXURAL TEST

The ability of a material to withstand bending forces applied perpendicular to the longitudinal axis.

Significance:-The polymer used in the form of a beam and if the services failure occurs in bending.

Standard:-ASTM D 790, ISO 178Factor:- Temp. , RH, speed and specimen preparation.

Factor Affecting the Test ResultTemperature:-At higher testing temperature flexural strength and modulus values are significantly lower.

Speed:-At higher speed flexural strength is also high.

Molecule orientation:-The molecule orientation in the specimen has a significant effect on the test result.

COMPRESSION TEST

Compression Strength: We describe the behavior of the material when it is subjected to a compressive load at a relatively low and uniform rate of loading.

Significance:To provide standard data for R&D.-To know about deformation in compression for engineering application

Standard- ASTM D 695 , ISO 178

Factor :- Temp. , RH , speed & specimen preparation

Compressive Properties:-ASTMD-695

Test specimen size:-For rectangular specimen = x x 1 inchFor cylindrical specimen = inch diameter and 1 inch long

IMPACT TEST

In manufacturing of locomotive wheels, coins, and connecting rods etc., The components are subjected to impact loads. These loads are applied suddenly. The stressed induced in components is many times more than the stressed produced by the gradual load. Hence the material should be able to sustain such loads. Therefore impacts test are performed to access shock absorbing capacity of materials subjected to suddenly applied shock loads.These capabilities are expressed as

1. Rupture energy2. Modulus of rupture3. Notch impact strength

In this test a notched specimen placed as a beam is given an impact, and the energy required to propagate the specimen is measured. The impact test is performed on Izod Testing Machine. Specimen is broken by swing of hammer.

Types of Impact Test

1. Pendulum Impact Izod Charpy Tensile2. High Rate Tension Impact Test3. Free weight Drop Impact Test4. Instiented impact test

Significance :- to provide information about toughness & brittleness of the metals Standard :- ASTM D 256, 5628 , 5420 , 1709.

IMPACT TEST

Charpy Impact Test:-

Specimen size : - 127 x 12.7 x 6.4 mm= 5 x x 1/8 inchesSpecimen thickness : - 1/8 inchNotch = 2.54 mm depth

Izod Impact Test

Specimen size : - 635 x 12.7 x 6.4 mm= 5 x x 1/8 inchesSpecimen thickness : - 1/8 inch

FACTORS AFFECTING IMPACT STRENGTH

Rate of loading Notch sensitivity Temperature Orientation Processing condition and type Degree of crystallinity and molecular weight

Method of loading

TYPES OF LONG TERM MECHANICAL PROPERTIES

Creep properties ASTMD 2990 Stress -Relaxation properties Fatigue resistance ASTMD-671 Creep properties ASTMD- 2990

The permanent deformation of material under the steady load as a function of time is called creep. a very common experience in which the length of our waist belt increases after some duration is due to creep effect. It is thermally actuated process.Creep occurs at room temperature in many materials such as lead , zinc etc. For an insight , consider zinc whose melting point is 420 C. Its creep rate is considerably above a temperature I.e. at about 4 C only.Consideration of creep is very important in application such as

1. Industrial belts2. Blade of gas turbines3. Blade of steam turbines4. Piston of I.C engines5. Polymeric and elastomeric constructions6. Rocket & missiles7. Nuclear reactors8. Tubes of heat exchangers etc

Creep is sometime desirable also in metal forming operations such as hot rolling , extrusion , forging. These process are carried out at high temperatures where deformation follows creep law. The forces required in operations are reduced due to raise temperature.The values are refered as tensile creep compression creep or flexural creep.

TENSILE CREEP

Tensile Creep is measured by applying constant load of a tensile test specimen and measuring its extension as a function of time.In order to show initially mark the specimen at two points which is considered

as a gauge length as specified time interval & measured the distance between marks at specified time interval.thepercent creep strain is determined by dividing the extension by initial guage length and multiplying by 100

FLEXURAL CREEP

Flexural creep measurement are also made by applying a constant load to the standard flexural test specimen and measuring at mid span is measured using dial indicator gauge

r = 6 x D x d x 100/l

r = maximum percent creep strain ( in un)D = maximum deflection at mid span (in un)d = depth (in)l = span (in)

FACTORS AFFECTING THE CREEP RESISTANCE

Temp. Is inversly proportional to the creep resistance I.e. if temp. Is high then creep is low.

1. Humidity creep resistance2. Plasticizer creep resistance3. Filler creep resistance4. Cross linking creep resistance5. Cross linking -% of creep resistance filler loading

STRESS - RELAXATION PROPERTIES

The gradual decrease in with time under a constant deformation is called strain. Test specimen and preparation : Injection molded - dia 12.82, 9.06, or 6.40 mm. Specimen from sheet or plate.Specimen for compression test - according to the ASTM - D-695

FATIGUE RESISTANCE - ASTMD-671

The behavior of materials under fluctuating and reversing loads is known as fatigue. This behavior is different from that under steady load. Fatigue is however not a dynamic effect. The rate loading is usually not a factor in fatigue behavior. Fatigue behavior is experienced by all material whether metals, plastic, concretes or composites. The main effect of fatigue on the properties of the materials are

1. Loss of ductility2. Loss of strength3. Enhanced uncertainity in strength and service life of materials

Fatigue occurs at stresses well within elastic limits.A fatigue life is defined as the no. of cycles of deformation required to bring about the failure of the test specimen under a given set of oscillating condition.,

Stress = 1/No of cycle

TYPE OF FATIGUE TEST

Flexural Fatigue Test (ASTMD-.671)Flexural fatigue test is the ability of material to resist detoriation from the cyclic stress is measured in this test by using a fixed cantilever type testing machine.

Tensile Fatigue Test :- Unlike the flexural fatigue test which uses the constant deflection principle. The tensile fatigue test is conducted under constant load condition.Factor Affecting the Fatigue Resistance1. Temp. fatigue resistance2. Humidity fatigue resistance3. Thermal conductivity = 1 ....Fatigue endurance limit4. Fatigue resistance = 1..Stress

SPECIMEN PREPARATION

The specimen is dumbbell shaped about 2 in long with cylindrical cross section . The test is conducted by mounting both the ends of the dumbbell shaped specimen in the testing machine . The specimen is rotated between to spindles and stress in the form of tension and compression is applied. The specimen is subjected to the no. of stress specified.

SURFACE RELATED MECHANICAL PROPERTY

Surface mechanical property based on surface test and it is measure change the dimension of the surface of change weight with respect to original specimen weight. It is classified in to four basic type on the basis of surface test for e.g.1. Friction - ASTMD -18942. Abrasion - ASTMD- 1044

3.Hardness - ASTMD- 785, 2240, 25834 FRICTION ASTMD -1894

The relative resisting force with the surface of one material will slide over an adjoining surface of itself or another material.

Static coefficient of friction is the measured force required to begin movement Kinetic coefficient of friction is related to the measured force required to sustain the movement.

TEAR RESISTANCE

To determine the force necessary to propagate a tear in plastic sheets

Significanceactual end application Standard : - ASTMD 1004, 1922, 1938 Factor: temp, RH ,speed & specimen preparation, MWD Creep Resistance : - To determine deformation under load Stress Relaxation : - to determine gradual decrease in stress with time

under constant deformation Permanent Deformation : -Ratio between creep &stress relaxation Significance :- High performance &extreme reliable applications Standard : - ASTMD -2990 Factors : - temp. RH, speed & specimen preparation , MWD To determine the repeated cycling loading Significance:- High performance &extreme reliable applications Standard ASTMD - 671 Factors : - Temp, RH, speed & specimen preparation ,MWD

ABRASION RESISTANCE

To determine the material loss through frictional force, load , true contact

Significance : - High performance &extreme reliable applications Standard : - ASTMD -1242, 1044

Factors : - Temp, RH ,Wheel of Abrader , MWD HARDNESS Hardness : - Resistance of material to deformation Type of Hardness : - Rockwell Hardness Durometer Hardness Barcol Hardness Significance : - High performance &extreme reliable applications Standard : - ASTMD -785,2240,2583 Factors : - Temp, RH ,Surface Condition , MWD & Additives Determination of Sliding Friction of Plastics. Significance : - High performance &extreme reliable applications

Standard : - ASTMD -3028 Factors : - Temp, RH ,Surface Condition , MWD & Additives

(THIRD WEEK IN CIPET)

CAD / CAM DESIGN

The design department with CAD has latest software for Imparting effective training on product and mould design. The department provides following services to the plastic Industries:

3- Dimensional solid moulding

Product design and mould validation of Injection Moulding

Compression Moulding and Transfer Moulding process

Process simulation and mould design validation of Blow moulding

Extrusion Die Design : Pipe Die , Sheet Die & Co -Extrusion Dies

3-D & 2-D Digitising

A-A plotting services using inkjet/laser plotters

Generation of CNC part programming

Scanning of Drawing/ Profiles

Short term training program for skill upgradation

(FOURTH WEEK IN CIPET)

TOOL ROOM

CIPET-TOOL ROOM at Lucknow has excellent CNC machining facilities for taking up commercial job assignment for mould fabrication , high precision machining andmanufacturing of standard mould bases. The facilities of tool room are given below:

CNC MACHINES

Universal Milling and Boring Machines with SUSCAM SoftwareUME 600-MIKRON SWITZERLAND

Die Sinking-EDM ROBOFORM 40 -CHARMILLS SWITZERLAND

Universal Lathe with Hydrobar feeder TORNADO 300COLCHESTER,ENGLAND U.K

High Precision Surface and Profile Grinder ELBSCHILFF-PERFECT FUTUREGERMANY

INSPECTION FACILITIES

Co-ordinator measuring machine ACCURATE -INDIAProfile Project -EPOLP10-JAPANUltra Sonic Flaw Detector USK5-GERMANYSurf Test -3Mitutoyo-JAPAN

SPECIAL PURPOSE MACHINES

Jig Boring Machine with DRO B3-DR-HAUSER SWITZERLAND

Coordinator Drilling & Boring Machine with DRO AD40-DRO ACCUMAXINDIARigid Die Sinking MachineKA200-RORSCHACH SWITZERLANDCenter Lathe with Hydro Copying Attachment H22-HMT-INDIARotary Surface GrindingRUSSIACylindrical GrinderK130U-HMY-INDIAOptical Profile Grinding MachineGLS 80A WASINO JAPAN

CNC(Computerized Numerical Control)MACHINE

CNC MILLING MACHINEUME-600 , MIKRON (SWISS) MACHINE

SPECIFICATIONS

Controller :Heidenhain TNC-415-BTravel : 600 X 500 X 45Resolution : 0.001Spindle rpm : 600 rpmNC Rotary Table dia : 600 mmUniversal Table : 750 X 425Turning/Tilting : 360 degSwilling angle : 45 deg

Features : 2D,3D,Profile milling ,pocket milling, slot milling, drilling, boring ,mirroring, scaling, datum shifting,etc.

CNC-SPARK EROSION MACHINEROBOFORM-40CHARMILLES(SWISS) EDM MACHINE

SPECIFICATIONS:Table : 700 X 500 mmTravel : 500 X 400 mmMax. part dim : 370 X 700 X 1000 mmMax. part weight : 1000 kgMax Electrode weight : 100 kg

CNC- LATHE MACHINETORNADO-300, COLCHESTER (U K ) MACHINE

SPECIFICATIONS:

Controller Fanuc OTCMax. Spindle speed : 300 rpmTravel : 240 X 500 mmNumber of Tools on turret : 12Spindle bore : 90 mmFeatures : Turning, Facing, Profile turning , Threading , Boring

MILLING MACHINE

A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. The cutter rotates at a high speed and because of the multiple cutting edges it removes metal at very fast rate. The machine can also hold one or more number of cutter at a time .this is why a milling machine finds wide application in production work. This is superior to other machine as regards accuracy and better surface finish, and is designed for machining a variety of tool room work.

TYPES OF MILLING MACHINE1. COLOUMN AND KNEE TYPE Hand milling machine Plain milling machine Universal milling machine Omniversal milling machine Vertical milling machine

2. MANUFACTURING OF FIXED BED TYPE Simplex milling machine Duplex milling machine Triplex milling machine

3. PLANAR TYPE

4.SPECIAL TYPE

Rotatory table milling machine Drum milling machine Planatory milling machine Pantograph, profiling and tracer controlled milling machine

BORING MACHINE

The boring machine is one of the most versatile machine tools used to bore holes in large and heavy parts such as engine, frames etc. which are practically impossible to hold and rotate in an engine lathe or drilling machine. Boring machines have therefore, been developed primarily to do this. In addition to its primary purpose of boring the range of speeds and feeds provided to the various traversing components allow drilling, milling and facing to be performed with equal facility. by the fitting of simple attachments the use machine can be extended still further to include screw cutting turning, planetary grinding, or gear cutting.

TYPES OF BORING MACHINE1) HORIZONTAL BORING MACHINE Table type Floor type Planar type Multiple head type

2) VERTICAL BORING MACHINE

Vertical turret lathe Standard vertical boring machine 3) PRECISION BORING MACHINE

DRILLING MACHINE

The driving machine is one of the most important machine tools in workshop.

As regard its importanceit is second only to lathe.Although it was primarily designed to originate hole ,it can perform a number of similar operations. In a drilling machine holes may be drilled quickly at low cost the hole is generated by rotating edge of cutting tool known as the drill which exerts large force on the work clamped on the table.

TYPES OF DRILLING MACHINE:

1.Portable drilling machine2.Sensitive drilling machine: Bench mounting Floor mounting3. Upright drilling machine: Round column section Box column4. Radial drilling machine: Plain Semi Universal Universal5.Gang drilling machine6.Multiple spindle drilling machine7. Automatic drilling machine

THE LATHE

The lathe is one of the oldest machine tools and come into existence from the early tree lathe which was then a novel device for rotating and machining a piece of work held between two adjacent trees. A rope wound round the work with its one end attached to flexible branch of a tree and other been pulled by a man caused the job to rotate intermittently hand tools were then used . With its further development a strip wood called lathe was used to support the rope and that is how the machine came to be known as lathe. This device continued to developed through centuries and in the year 1797 Henry Maudslay , an Englishman . designed the first screw cutting lathe which is for runner of the present day high speed, heavy duty production lathe, a machine tool which ha

practically given shape to our present day civilization by building machine and industries.

FUNCTION OF LATHE

The main function of a lathe is to remove metal from a piece of work to give it the required shape and size this is accomplished by holding the work securely and rigidly on the machine and then turning it against cutting to which will remove from the work in the form of chips . to cut the material properly the toll should be harder than the material of the work piece should be rigidly held on the machine and should be fed or progressed in definite way relative to the work .

TYPE OF THE LATHE:-

1.SPEED LATHE wood working cantering polishing . spinning2: ENGINE LATHE/CENTRE LATHE:

belt drve Individual motor drive

gear head lathe

3:- BENCH LATHE

4:TOOL ROOM LATHE

5: CAPSTAN AND TURRET LATHE

6:SPECIAL PURPOSE: wheel lathe gap bed lathe T- lathe Duplicating lathe

7: AUTOMATIC LATHE

GRINDING MAACHINES

Grinding is metal cutting operation performed by means of a rotating abrasive wheel that act as a tool . This is used to finish work pieces which must show a

high surface quality, accuracy of shape and dimension. Mostly grinding is the finishing operation because it removes comparatively little metal,025, to 0.50 mm in most operations and the accuracy in dimensions in the order of 0.000025 mm. Grinding is also done to machine materials which are to hard for other machining methods that use cutting tools.

Kinds of grinding:1.Rough or non-precision grinding2. Precision grinding

ROUGH GRINDING: The common forms of rough grinding are snagging and off hand grinding where the work is held in the operators hand .The work is pressed hard against the wheel . The accuracy andsurface finish obtained are of secondary importance. Snagging is done where a considerable amount of metal is removed without regard to the accuracy of the finished surface.

PRECISION GRINDING: This is connected with producing good surface finish and high degree of accuracy .The wheel or work both are guided in precise paths.

Grinding in accordance with the type of surface to be ground isclassified as

1.External cylindrical grinding2.Surface grinding3.Internal cylindrical grinding4.Form grinding

External cylindrical grinding produces a straight or tapered surface on a work piece .the work piece must be rotated about its own axis between centres as it passes length wise across the face of a revolving grinding wheel .

Internal cylindrical grinding produces internal cylindrical holes and tapers the work pieces are chucked by precisely rotated about their own axes the grinding wheel or in the case of small bore holes the cylinder wheels rotates against the sense of rotation of the work piece .

Surface grinding produces flat surface the work may be ground either by the

periphery or by the end face of the grinding wheel the work piece is reciprocated at a constant speed below or on the end face of grinding wheel.

Form grinding is done with specially shaped grinding wheels that grind the formed surfaces as in grinding gear teeth , threads , splined shaft, holes and spheres etc.

MARKETING STRATEGIES

The performance of the CIPET during the last decade, though spectacular, has not been altogether smooth. The euphoric developments in the first few deregulation years were cut short when deceleration set in from the autumn of 1997. The external global environment worsened progressively under pressure from a series of financial meltdowns in various parts of the world while our domestic economy also stagnated. Prices started falling continuously even as the world plastic industry strained under conditions of extreme oversupply and cut-throat competition. The domestic market also dwindled on the back of slow growth in construction and other forms of capital formation/investment. At the present juncture, one can say that the industry has successfully made the transition from a controlled to a market-driven economic environment.

There is a paradigm swift in plastic markets from controlled regime to deregulation. The ambience has opened up the aggression of the international players and allowed plastic Industry the access to international markets. The Marketing Department in CIPET sustained the cyclic the world under the dynamic leadership of its Management. The growths in sales in leaps and bounds in Marketing Department have been achieved in volatile, dynamic and highly competitive business environment. The structure of the Department, its operations in Domestic as well as International Markets, the quality of operations and services to the customers, Marketing techniques adopted for image building are no less than the best in the class.

Finance & Accounts Functions centre round arranging the Finances, facilitating and accounting the operations and compliance with various statutes. Finance function is general discipline having universal application. As such, it has its role in all forms and types of business i.e. from a sole trader to the joint Stock companies, whether it is Indian or Multi-National Company. The function encompasses broadly, Finance, Accounting, MIS, and Audit and taxation areas. Function covers the areas of rising of Finances viz., Capital, loans, working capital and servicing thereof. Finance also covers areas of controls viz., Budgetary Control and Cost Control.

Accounting deals with recording of daily transactions, compilation of Annual Accounts and their audit by various agencies, via, Statutory Auditors appointed under the companies Act, Audit by Comptroller & Auditor General of India in case of Government Companies, Internal Audit and special Audits.

Taxation includes tax planning and complying with provisions of various tax laws such as sales Tax, Central Excise, Income Tax Act, Wealth Tax Act, Service Tax etc.

Though Finance & Accounts function is a general function having universal application, it becomes necessary to modulate it to suit the requirements of the specific industry it serves and accordingly formulate suitable systems and procedures. For instance, in the area of costing, appropriate costing system is required to be laid down keeping in view the manufacturing process. Accordingly, the costing system in VSP is based on process costing. Similarly, Budgeting is done department wise. Various products manufactured by VSP are sold through its all India Branch network. For this purpose, materials are moved from the plant to various branches. This calls for proper documentation for dispatches, receipt of stocks, issue of stocks and stock balancing apart from handling of money on sales, monitoring of outstanding debtors for credit sales, payment of Excise Duty while clearing the material from the plant.

This report is basically an overview of the operations done at CIPET, Lucknow. The study of various machines, testing equipment, tools and designing items would be of great help for purpose of increasing ones knowledge of plastic industry.

Related study of petrochemicals, polymers and plastics should be done for complete understanding of the industry and its functioning.

This report is flexible enough to accommodate any changes, corrections of error and suggestions in the near future.

The development and growth of plastics processing industry is dependent upon the availability of skilled & technically trained manpower. With a rapid development in the field of plastic processing using modern machines, there has been increased demand of manpower for designing, tool making, plastic processing and quality assurance (Total Quality Management - TQM) to meet the diverse requirement of industries.

Hence, the manpower demand will also increase as the polymer material consumption increases in the coming years. Since, CIPET is the only institute of its kind in South Asia having state-of-art facilities and excellent infrastructure in the field of Plastic Engineering &Technology, necessity of CIPET services in terms of development of trained manpower for the plastic industry & technical support in different technologies areas will be more relevant and synonymous with future growth of plastics and allied industries.

CIPET services would be more congruous for the plastic and allied industries in the years to come in terms of specialized training man power support technology support, quality and productivity improvement, developmental activities to newer technologies etc.

During the period of my training I felt that I am not a student doing training but an employee working in CIPET by doing training here I was exposed to the environment of an organization and felt It practically.I came to know how to work in organization? and what an organization wants from an engineer?

I enriched my knowledge and interpersonal skills during conduct of my training and gained deep understanding of various systems of an organization.The experience of my training in CIPET is a great experience of my life and it will prove to be a stepping stone of success in my professional career.

The Book referred for this report are :

>Elements of workshop technology by : H.Chowdhary

>Industrial engineering and management by : O.P. Khanna

Internet was the main source of getting various ideas, information, pictures and designs

>www.cipetindia.com

>www.google.com

>http://chemical.nic.in/petcipet.htm

Above all the intelligent and guidance of the officers of the CIPET,Lucknow was involved. They have given me full support in making of this report.

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