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1.

INTRODUCTION
There is a difference between a product and a project. What we have tried to come up with in this project is a concept of a product which has a true marketing potential. This may not be the most ambitious project ever attempted in this college but it sure is one of the most original and practical projects ever undertaken A) DEFINING THE PROBLEM Rubber components form an integral part of most of the things we use daily, be it automobiles, machines, household appliances (e.g. fans, mixer grinders etc.) or show pieces. This is because rubber has some unique properties which are not found in any other material. Rubber components are indispensable wherever seals, washers or damping is required. Thus thousands of different rubber components have to be manufactured. There are many different processes for manufacturing rubber components, but due to some unique properties of rubber which include low temperature required to bring rubber to plastic stage and curing of rubber required to give it adequate strength have made molding of rubber the most common type of manufacturing process. A study of different compression moulding machines at different industries showed that most are fully manual, flywheel operated machines with low output rates. Most owners want to upgrade to hydraulically operated automatic machines but the cost of these machines is prohibitive. Our project for Pneumatically Actuated Rubber Compression Moulding Machine is a project to prove the viability of pneumatic power for the

operation of such machines. Pneumatic power is cheaper than hydraulic power because of the following reasons :1. The equipment for pneumatic power is cheaper than a corresponding hydraulic system . 2. A single air compressor can power multiple machines but hydraulic machines require individual hydraulic power packs. 3. The expense of oil required for a hydraulic systems can be saved as air is free. 4. Many workshops, puncture repair shops etc, have air compressors, which are usually under utilized and so would require very little investment to install such pneumatically actuated machines.

B) SCOPE OF THE PROJECT Our project group visited two industries :1) M/s Vikamshi Fabrics Ltd., Khamgaon. 2) M/s Usha Rubber Industries, Amravati. Both of which use rubber compression moulding machines. It was found that these manual, flywheel operated machines require upto 3 operators. Two to operate the flywheel & one to handle the dies. What our project intends to achieve is to eliminate the flywheel & replace it by a pneumatic power source to operate the pressure plate and in the process eliminating the two workers required to operate the flywheel. Pneumatic power was chosen because : 1. The advantages of pneumatics over hydraulics power for the said purpose as stated in the previous page. 2. Because we found that most workshops & puncture repair shops have idle air compressors available. Thus such workshops or puncture repair shops can start a side business requiring just a single operator to manufacture rubber components with very little investment. Especially we found that a puncture repair shop has both the raw material i.e. rubber (from tyres and tubes) which are used to manufacture low cost rubber components and vastly underutilized air compressor. They usually have a single person manning the shop who is mostly idle. Such shops can very easily afford this type of machine and start a side business giving high profits that too with very little investment and also utilize their idle time.

2. SOME ASPECTS OF RUBBER


(A) RUBBER AS A MATERIAL Rubber belongs to the class of substances termed as polymers with high molecular weight compounds which are predominantly organic, consisting of long chain molecules made up of repeating units usually on a backbone of carbon atoms. These high molecular weight polymers have a lower temperature limit to their plastic state. . Types of Rubber :a) Natural Rubber a) Natural Rubber i) ii) Ribbed smoked sheet Pale crepe b) Synthetic Rubber

b) Synthetic Rubber i) ii) iii) iv) v) Styrene Butadiene Rubber (S.B.R.) Butadiene acrylonitrile Poly chloroprene Poly isoprene Poly butadiene

Physical properties of Rubber a) Viscosity (stokes) b) Ultimate tensile strength ( kg/cm2 ) c) Ultimate elongation Percentage d) Modulus Chemical Requirement of Rubber Specification 1) Dirt content 2) Volatile matter 3) Total ash content 4) Copper 5) Manganese 6) Nitrogen Percentage by weight 0.05 1.00 0.75 8.00 10.00 0.70 Max. 73 200 1200 96 Min. 14 160 800 25

(B) PROCESSING OF RUBBER i) Rubber compounding:Rubber is compounded with various additives to improve properties like mechanical, physical along with cost reduction.

Additives used for rubber compounding


Sr.N o. 1. Additives Fillers Type of material Carbon black, Activated silica, Activated magnesium carbonate, 2. 3. 4. 5. Pigments Accelerator Activator Antioxidant Saw dust, calcium silicate Red iron oxide , Titan white, ultra marine blue, yellow iron oxide Mercapto benzthiazole, dibenzthiazyl disulphide Zinc oxide, stearic Acid Substituted phenyl group of pphenylene 6. 7. 8. 9. 10. Plasticizer Blowing agent Stabilizer Vulcanizing Dusting agent Dioctyl pthalate Di-Iso octyl pthalate Azo compounds foaming-N N-Nitroso compound White lead Sulphur Zinc stearate Purpose Provides Reinforcements Reduction in cost Coloring Accelerates the vulcanization rate Activates the accelerator Provide moderate oxidant production with min discoloration Aids the processing operation of mixing. Provides foam like structure Prevents degration of rubber during processing Provides cross linking Avoids sticking of material.

Sequence of additives used during compounding :Rubber + Peptizer (Renasin) Pigment + Tackifier (Rosin) Small chemicals :1) Accelerator ( Mercapto benzthiazole ) 2) Activator ( Stearic Acid, Zinc oxide ) Fillers :1) Processing aids ( white oil ) 2) Special purpose agents 3) Sulphur ( Vulcanization )

Additives Used for General Rubber Product Sr.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Ingredients Natural Rubber ( Basic Raw Material ) HAF Block (filler) SRF black (colour) Paraffin wax ( lubricating agent ) Zinc Oxide (Activator) Stearic acid (Activator) Sulphur Vulcanizing agent Mercapto Benzthiazole (MTB) ( Accelerator ) Mercapto di Benzthiozyl di Sulphide % in weight 31.7 20 28.5 5 6 1.6 2.5 0.8 1.4 2.5

( Accelerator ) (MBTS) 10. Dioctyl pthalate - ( Plasticizer ) ii) Vulcanization :-

One of the overriding and predominant technologies in the industry, particularly with the emphasis on higher production rates and new techniques is the control of chemical reactions leading to cross linking & bonding to metals , fabrics and rubber break down. The final step in the manufacturing sequence is the vulcanization or curing of the formed product. Basically, the process is that of applying heat at a certain

temperature for a certain time. Vulcanization is most often combined with forming. It is the process in which rubber is transferred from plastic state to elastic state by promoting a certain degree of cross linking between chains. This involves heating with sulphur and developing crosslinks. chemical changes involved in vulcanization have been given the name Curing. Vulcanization process leads to the improvement of the following characteristics :Property Raw Rubber Vulcanized Rubber

The

1) Tensile strength (kg/cm2) 2) Percentage elongation 3) Water absorption capacity 4) Tackiness 5) Working temp 6) Chemical Resistance 7) Elasticity 8) Resistance to oxidation abrasion wear and tear

200 1200 Good More 10 600C Very poor Very much lower Very much lower

2000 800 Very good Very small - 40 to 1000C Excellent much higher much higher

3. RUBBER MOULDING
The manufacture of moulded rubber articles from compounded rubber sheet involves one or other of the sequence of operations shown in fig below. COMPOUND SHEET CALENDER EXTRUDED

CUTTING

HAND BUILDING

MOULDING

TRIMMING Block diagram for Sequence of operations for Rubber Moulding

The project Pneumatically operated Rubber Compression Moulding Machine deals with the Moulding aspect of the sequence & on a later stage may also include some aspects of cutting.

A) BLANK PREPARATION In some of the large factories & most of the smaller ones moulding blanks were prepared in a separate section, devoted exclusively to this work. In some factories however, blanks were cut by the press operatives. A great variety of different cutting methods were employed ; the particular one chosen for a given blank being determined mainly by the machines available, the no. required and the type of blank.

Classification of the different methods used is given below:1. Manual : This category includes hand cutting with scissors & knives, hand punching & manually operated guillotines. 2. Punching Presses : Range from simple hand operated presses to large power presses. Usually cutters are held in the press & rubber sheets moved beneath it. 3. Circular Knives : These are exclusively used for cutting extrusions. The knives are usually water cooled & larger than 1 inch dia. 4. Power Gulliotines : These are usually of three types : a. Firstly with the gulliotines mounted at the end of belt conveyor to cut off set length.

b. c.

Secondly with fixed bed machines with wide blades 2-3 feet wide. Thirdly - big enough to cut normal size sheets. The positioning is usually done manually with the help of stops.

d.

Finally : There are moving bed gulliotines, again with wide set blades where rubber can be fed automatically or manual set blades where rubber can be fed automatically or manually by means of a feed screw.

5. Volumetric Cutter : - These are large capacity machines where hot rubber strips are fed to the machines. Here it is cut to size, compressed to required thickness and then cut by a punch to required shape. The blanks are then dropped into a container & the waste strip returns to the mill.

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B) METHODS OF MOULDING Introduction : Moulding of plastics comprises forming an article to the desired shape by application of heat and pressure to the moulding compound in a suitable mould and hardening the material in the mould. Selection of moulding process is largely determined by the moulding material selected, to provide the desired physical properties in the finished moulded pieces. Process determination is sometimes complex because there are two types of moulding materials in general use, i.e. thermosetting and thermoplastic. There are four basic moulding methods : 1. Compression 2. Transfer 3. Injection 4. Extrusion Moulding Moulding Moulding Moulding Thermosetting materials are generally processed by compression and transfer moulding. For thermoplastic materials injection and extrusion processes are used. 1. Compression Moulding : In compression and transfer moulding monomers are partially polymerised in a separate operation and the polymerisation reaction is completed in the mould. The partially polymerised material is prepared as pallets. It is placed in heated mould. After the compound is softened and becomes plastic, the upper part of the die

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moves downwards, compressing the materials to the required shape and density. Continuous heat and pressure produces the chemical reactions. The mould remains closed until the curing is complete. There are four basic types of processes for compression moulding a. Flash Type b. Positive Type c. Landed Positive Type d. Semi-positive Type (a) Flash Type : As the mould closes, the excess material escapes over the land where it forms a very thin. The fin hardens first, preventing the escapement of the mould charge. Flash type moulds may be loaded by volume since excess material is permitted to escape. (b)Positive Type : The characteristics of positive type mould are deep cavity and a plunger that compresses the compound at the bottom of the mould. As there is very little escapement of material, it is necessary to weigh the charge accurately if the size of the part is to be controlled. (c) Landed Positive Type : This type of mould is similar to the positive mould except that lands are incorporated in the design to stop the travel of the plunger at a predetermined point. The density may vary depending upon the charge. (d)Semi positive Type : This is combination of flash type and landed positive type mould. In addition to the flash ridges, land is incorporated to restrict the travel of the plunger while some of the pressure is taken up by the land.

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2. Transfer Moulding : The thermosetting moulding powder is prepared by mixing filler with resin which is only partly condensed and make it capable of being softened on reheating. In transfer moulding, charge of moulding powder is forced from a cylinder through a relatively restricted opening into the main mould. Thus due to flow through restricted passage, the moulding powder becomes heated much more rapidly and uniformly than by conduction from the walls of mould. 3. Injection Moulding : The granular moulding material is loaded into a hopper. The injection ram pushes the material in to the heating cylinder and in doing so pushes a small amount of heated material out of the other end of cylinder through the nozzle and mould is then opened and piece is ejected out. 4. Extrusion Moulding : The material in granular form is placed into a feed hopper which feeds the cylinder of the extruding machine. The hopper portion is kept cool by circulating water. A rotating screw is used for carrying and mixing of material through cylinder and forcing it through a die of required shape. The extruded shape coming from the die is carried through a cooling medium by a conveyor and when it has been cool sufficiently to retain shape, it is cut into lengths or coils.

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C) BASIS FOR SELECTION OF FLASH TYPE COMPRESSION MOULDING OVER OTHER METHODS
This machine is made for low cost and small production runs with minimum investment. The following methods are rejected due to the given reasons. 1) Rubber Injection Moulding :- The equipment is very expensive & viable only for high production runs & is also plagued by many technical problems which limits its use in the field of rubber moulding. 2) Extrusion : It is suitable only for the manufacture of pipes, tubes & solid sections 3) Transfer Moulding :- It requires very high pressure and moulding cost is very high. 4) Positive and Landed Positive Type :- Both these methods are suitable only for bulky material & deep drawing parts. Thus flash type compression moulding is the most suitable for small inexpensive products with small production runs. Thus we select this process.

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D) ADVANTAGES OF COMPRESSION MOLDING 1. Wastage of material in the form of sprue, runner, and transfer-cull loss is avoided, and there is no problem of gate erosion. 2. Internal stress in the molded article is minimized by the shorter and multidirectional flow of the material under pressure in the mold cavity. In the case of high impact types with reinforcing fibers, maximum impact strength is gained. This results because reinforcing fibers are not broken up as they are when forced through runners and gates in transfer and injection molding, and because fibers are more randomly positioned, as compared to the more oriented fibers resulting from flow into transfer or injection molds. 3. A maximum number of cavities can be used in a gives mold base without regard to demands of a sprue and runner system. 4. Compression molding is readily adaptable to automatic loading of material and automatic removal of molded articles. Automatic molding is widely used for small items such as wiring device parts and closures. 5. This technique is useful for thin walled parts that must not warp and must retain dimensions. 6. For parts weighing more than 3 pounds, compression molding is recommended because transfer or screw injection equipment would be more expensive for larger parts.

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7. For high-impact, fluffy materials, compression molding normally is recommended because of the difficulty in feeding the molding compound from a hopper to the press or performer. In general, compression moulds usually are less expensive to build than transfer or injection types.

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4. PRINCIPLE & WORKING OF MACHINE


This m/c is sturdy & compact one for manufacturing small moulded rubber products. The operation is so simple that even an unskilled worker can operate the m/c and no special requirement other than pneumatic power, electricity and raw material is desired. PROCEDURE FOR COMPRESSION MOLDING The sequence of operations constituting the molding cycle is as follows. 1. Open the mold. 2. Eject the molded article(s). 3. Remove all foreign matter and flash from the mold, usually by air blast. 4. Place inserts or other loose mold parts, if any. 5. Load molding compound (powder or performs, cold or preheated). 6. Plate the die on the heating chamber. 7. Actually pneumatic cylinder to apply pressure on die to close the mould. 8. Mold under temp & pressure until curing is complete 9. Retract the pressure plate & remove die.

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5. DESIGN CONSIDERATIONS FOR THE PROJECT


This project is a based on the concept of using pneumatic power for the actuation of pressure plate of rubber moulding presses. The basic concept is to prove the feasibility of pneumatic power for such machine. The size of such machines is specified in two ways :(i) the maximum force that the pressure plate can apply on the die (ii) the maximum size of the die which can be accommodated . As the main aim of this project is to prove the feasibility of pneumatic power we chose to design a small m/c using a single die. Large machines which can accommodate multiple dies would prove to be too expensive for the purpose. The various assumptions & design considerations for the project are as follows :1. The max pressure from the available air compressor was found to be 9 kg/cm2. 2. With the main criterion cost in mind, the size of the pneumatic cylinder was chosen first { but one that could apply a min force of 150 kg }. The specifications arrived at were as follows :3. 50 mm dia 4. 100 mm stroke 5. double acting 6. flange mounting 7. cushion ended

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iii). Once the specifications for the pneumatic cylinder had been chosen and fixed, next the max size of the rubber component that could be manufactured was calculated, and the size of the die for such a mould was determined. Based on the S P I Plastic Engg Hand book, the pressure required for

moulding low pressure, thermoplastic phenolics & rubbers was found to be 350 psi (24 kg/cm2) for mouldings upto a max depth of 1.90 cm.

iv) Once the size of the die had been determined, it was fairly simple to determine the maximum size of the heating chamber and the distance of the supporting pillars. The size of the heating chamber should be at least equal to the size of the die, to heat the die uniformly and the supporting pillars should be far enough not to hamper inserting & removal of the die.

Based on the above consideration the following was determined. 1. Max force from the pneumatic cylinder = area of piston x max pressure from

compressor =

71 52 9 = 176kg 180kg 4

2. The size of the die considering provision for latent heat was determined as 100mm x 100mm. 3. Size of the heating chamber was chosen as 200 mm x 200 mm to accommodate larger dies in future.

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4. The distance between the supporting pillars was fixed at - 350mm & 250mm respectively for easy removal of larger dies. 5. Similarly the stroke of the pressure plate was chosen as 100 mm for easy removal of dies from the heating chamber and to allow for parts with greater moulding depth & thus thicker dies.

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6. DESIGN OF MACHINE
A. PROPERTIES OF MATERIAL USED FOR THE PROJECT a) The grade of steel selected for use in the project is Fe 310 general purpose engg steel. Characteristics of Fe 310 :i) ultimate tensile strength ii) yield point stress iii) modulus of elasticity/youngs modulus iv) shear stress v) crushing stress 310 N/mm2 180 N/mm2 2.0 to 2.2 10 kg /cm2 400 kgf/cm2 900 kgf/cm2

B. STANDARD DATA FOR THE PROJECT a) value of Factor of Safety The type of load is assumed to be shock load as it is applied suddenly at the end of the downward stroke of the pressure plate & also suddenly removed. For shock loads the standard value of factor of safety is (F.S.) = 12 b) design/working stress (tensile) Ft = yield point stress/F.S. = 15 N/mm2 c) maximum pressure that the compressor can provide = 9 kgf/cm2 d) maximum force that pneumatic cylinder can provide (cylinder of dia 50 mm) = area of piston max. pressure of compressor = 180 kgf = 1764 N

The further design of the m/c is based on this data. 21

C. CALCULATIONS FOR THE DIMENSIONS OF THE SUPPORT PILLARS. a) Max shear occurs where the diameter of the pillar is minimum i.e. At the core of the threaded part (dc). b) For design to be safe working stress area of C/S. of core No. of pillar = max load 15 /4 dc2 4 = 1764 N dc = 6.1 mm Therefore core diameter of bolt (dcb) = 6.11 mm c) From Design Dimensions of Screw Threads, Bolts & Nuts, According to IS:4218 (part IV). 1987 :Taking next higher value of core diameter of nut from standard table, core diameter of bolt (dcb) = 6.647 mm Core dia 6.647 mm represents nut & bolt size M 8. d) Design features of standard nuts & bolts of size M 10 (all dimensions in mm) :1. Pitch 1.25 2. Major or nominal diameter, nut & bolt (d=D) 8 3. Effective or pitch diameter, nut & bolt (dp) 7.188 4. Minor or core diameter of bolt, (dcb) 6.466 5. Minor or core diameter of nut (dcn) 6.647 6. Depth of thread of bolt 0.767 7. Shear area-58.3

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e) Calculations for bolt :i) initial tension while tightening bolt = Pn = 1420 d = 14200 N ii) checking for failure in shear :A) design or working shear stress ( Fsd) =Ultimate shear stress / F.S. = 400/12 = 33.33 kgf/cm2 B) calculated value of shear stress across threads (bolt) :Fs = P / .dcb.b.n = 1.91 N/ mm = 19.5 kgf/cm2 Wheredcb = core diameter of bolt b = width of thread at root = pitch n = no. of threads engaged Therefore Fs = 1764/4 Fs = 19.5 kgf/cm2 As the calculated value of shear stress across threads( Fs= 19.5 kgf/cm2) is lower than the design stress (Fsd = 33.33 kgf/cm2) , the design is safe. iii) Calculation for shear stress across threads of nut:Fsd = P/4..d.b.n. = 15.9 kgf/cm2 is less than the working shear stress Fsd = 33.33 kgf/cm 2, the design is safe. f) For reasons of structural rigidity & to accommodate the drilling & tapping operations the size of the support pillars is chosen as 20 mm diameter.

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D. DESIGN OF TOP PLATE a) dimension of top plate = 400 mm 300 mm 8mm b) 4 holes of diameter 8mm at 4 corners at a distance of 25mm from each edge c) design for shearAs the plates rest on the support pillars & are fixed to them using M8 size bolts & washers of internal diameter 8mm & external diameter 15mm, shear force on plate = P/ 4..D1.t < = design shear stress (3.266 N/mm2) therefore t = 2.149 mm d) design for bending :as the guide rods cannot be allowed to deflect or bend , therefore assuming that there is zero deflection of guide rod. The max deflection of plate allowable = 0.05 cm Dimension of plates are 400 300 t Therefore, bending will occur on the largest supported span is 400mm. As the bending load is applied by pneumatic cylinder, at the center of the plate and at the end of forward stroke. Therefore, bending force = 180 kgf = 1764 N Max deflection due to a point load at the middle of a body with both ends fixed Therefore y = + FL3/ 193 EI 0.05 = 1/192 180 383 / 2.2 106 I I = 0.467 24

As

I = bt3/12 = 0.467 t = 5.8 mm As the value is larger than the value of shear, therefore minimum acceptable

value = 5.8 mm. We take the plate of the thickness 8mm for added safety, rigidity and higher factor of safety. Thus, thickness of 8mm if more than sufficient for a safe design of the top plate. E. DESIGN OF BOTTOM PLATE For added stability & lower centre of gravity of the machine , a heavy base plate is used of dimensions 400mm 300mm 20mm (All other design parameters and considerations for base plate is the same as the Top Plate.) F. DESIGN OF HEATING CHAMBER The heating chamber has to take the same stresses as the top plate & thus is made from 10mm M.S. plate. The size of the heating chamber is 300mm 200mm with a height of 60mm & one side open.

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7. DESIGN OF PNEUMATIC SYSTEM


a) PNEUMATIC CIRCUIT For the actuation of the pressure plate, a simple pneumatic circuit, utilizing a single 4 way, 3 position, spring return , manually operated valve is used in conjunction with the pneumatic cylinder. The circuit diagram for the circuit is shown in fig

Pneumatic Cylinder 1 2

4/3 DCV A c B

From cylinder

FRL unit

To operate the pr plate the operator first shifts the manually operated lever of the 4/3 DCV to position A.

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By doing this air flows from the compressor, through the FRL (Filter regulator & lubricating) unit, into port 1 of the pneumatic cylinder causing forward stroke of the cylinder. The cylinder initially moves at a fast rate but as it is cushion ended , towards the end it slows down & makes a soft contact with the top of the die. When the cylinder has moved forward to the max limit ( i.e. when the two halves of the die are closed), the operator switches the lever to position C and thus holds the pressure on the die. When the curing process has been completed the lever is switched to position B causing the cylinder to retract speedily. A 3 position value is used instead of a 2 position value so that the operator can stop the ram at any position he wants. This is especially helpful when dies with low heights do not require the ram to be retracted fully.

b) MOUNTING AND COUPLING OF PNEUMATIC CYLINDER :-

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The pneumatic cylinder is of flange mounting type with the flange having dimensions 65 mm x 100 mm x 12 mm The flange was provided with four holes at four corners having a dia of 12 mm and length wise and width wise centre distance between the holes at 90 mm and 45 mm. The shaft of the pneumatic cylinder was of 20 mm diameter with a standard thread of designation of M 18. 1) Mounting the cylinder To mount the cylinder four holes were drilled in the top plate with centre distances of 45 mm (width wise) and 90 mm lengthwise and with a dia of 12 mm. The pneumatic cylinder was then mounted on the top plate with the help of four nuts and bolts of designation M 10 ( Major/nominal dia of 10 mm ) 2) Coupling of Pneumatic Cylinder shaft to Pressure Plate :As M.S. bar of 30 mm diameter and 20 mm length was welded on to the pressure plate. A hole of 17 mm diameter was drilled and then a hand tapping tool for internal threads of designation M 18 ( major dia 18 mm) was used to tap the hole. The shaft of the pneumatic cylinder was then attached to the pressure plate using the above mentioned threaded fastening and a corresponding locking nut.

8. DESIGN OF ELECTRICAL CIRCUIT


The curing of rubber requires both heat and pressure

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The provision for heating is provided by means of a heating coil fitted in an insulated fixture and placed under the heating chamber For proper curing of rubber, a temperature between 1400 C and 1600 is usually required to control the temp within this range a thermostat is connected in series with the coil and directly mounted on the side of the heating chamber. It is properly calibrated using a thermometer of break the circuit when the temp reaches a given specified point between 1400 C and 1600 C under steady state operating condition. When the top plate of the heating chamber reaches the specified temperature the bimetallic strip in the thermostat bends, causing the circuit to break.

Heating Coil + Frame for 1500 watt.

Thermostat

230 9. ASPECTS OF DIE DESIGN. V a.c. supply

a) Die design theory :-

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Moulds are made of a variety of materials depending on the use and conditions of moulding. Cast iron and steel are very common materials. In the moulding process, it must be remembered that shaping and curing are being done at the same time. It is essential that the rubber must flow and take shape of the mould before actual vulcanization starts. This is extremely important in precision moulding, since any structure developed before moulding pressure is applied will cause a variation in shrinkage after the product is removed from the mould. There must be sufficient stock in the mould to fill it, otherwise the cured article will be light in the corners, i.e. corners will be round, when they should be sharp and rubber product may show porosity both externally and internally. Some moulds are provided with sprue rings to take small amount of overflow, to accommodate the amount of rubber that must overflow. Even then if

excessive rubber is put in mould, the two halves will not close properly. In intricate mould designs, such as treads of pneumatic tyres, it is necessary to cut little holes or vents right through the mould to get rid of trapped air. Unless very precise products are required, it is not necessary to consider tolerances for expansion and ejection. b) Design of Die :1. Maximum force available from the pneumatic cylinder = 180 kgf. 2. Based on data from S P I Plastic Engg Hand Book, the pressure required for moulding low pressure phenolics and rubber = 350 psi = 24 kg/cm2 upto depth of 1.9 cm

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3. The maximum size of rubber component that can be moulded = 180/24 = 7.5 cm2 i.e. with surface area upto 7.5 cm2 and depth or thickness upto 1.9 cm. 4. It was decided to make a mould for the manufacture of rubber washers because the design of the mould is simple. 5. Size of the rubber washer planned for manufacture has dimensions of 15 mm internal dia 30 mm external dia and thickness of 4 mm 6. The surface area of the mould is = 2 (D d 2 ) = 5.3 cm 2 4

and is therefore acceptable. 7. The size of the die was chosen as 100 mm x 100 mm to be able to store sufficient latent heat and also, if needed, to be converted into a multiple die in future. 8. Two handles were welded to the bottom half of the die for easy removal of die from inside machine.

CHART NO : 01 Name of the Part : Top Plate Raw Material M.S. Plate. 1 No. 31

M.S.Plate Size: 400 x 300 x 8 mm S r.No . 1. Filing Operation Standard machine Used Description of Tool used operation Edge preparation surface 2. Drilling Drilling m/c Rough & Tri-square & Smooth finish File 20 min. Gauge use Operation Time 30 min.

for the plate Drilling of 4 10mm holes at corner, drill as per specification Drilling of

3.

Drilling

Drilling m/c

40mm -

10 min.

centre hole of drill tool. 4. Drilling Drilling m/c 40mm in plate Drilling of 12 12 mm (4nos.) mounting pneumatic cylinder holes drill for of mm 15 min.

CHART NO : 02 Name of the Part : Basic Plate Raw Material M.S. Plate. 1 No. M.S.Plate Size: 400 x 300 x 15 mm

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S r.No . 1.

Operation

Standard machine

Description of Tool used operation

Gauge use

Operation Time

Filling

Used -

To obtain better Rough & Tri-Square 30 min. surface finish Smooth mm 20 min.

2.

Drilling

Drilling m/c

file Drilling of 4 8 holes at corners Drill as specification per

CHART NO : 03 Name of the Part : Heating Chamber Raw Material M.S. Plate and angle M.S.Plate Size: 200 x 200 x 6 mm 1 No. Angle Size : 200 x 45 x 45 2 Nos. 150 x 45 x 45 1 Nos. 33

S r.No . 1. 2.

Operation

Standard machine

Description of Tool used operation To obtain better File surface finish First weld the 3 angles to plate & then this

Gauge use

Operation Time

Filling Welding

Used Welding m/c

Tri-square

20 min. 30 min.

welded part is welded to base plate

CHART NO : 04 Name of the Part : Pillar Raw Material M.S. Bar 4 Nos. M.S.Bar Size: 25 mm x 230 mm

S r.No .

Operation

Standard machine Used

Description of Tool used operation

Gauge use

Operation Time

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1.

a) Facing b) Turning

Lathe

Face & turn the Single bar required upto point cutting

Vernier Calliper

90 min.

2.

Drilling & Lathe Boring

specification tool Drilling of 8 6 holes as per Drill,

mm -

90 min.

specification. Boring 3. Tapping followed. To form thread up is

Boring

the Hand to Tape

80 min.

specification

CHART NO : 05 Name of the Part : [Flange] Pressure Plate. Raw Material qty : 1 M.S.Plate Size: 90 mm dia x 10 mm M.S.bar 30 mm dia x 15 mm height S r.No . 1. Welding Operation Standard machine Used ArcWelding 2. Facing & Lathe Description of Tool used operation Welding M.S. bar M.S. Plate Turning of to of Single Vernier 45 min. 35 Gauge use Operation Time 10 min.

Turning

M.S. Facing

bar

& point & cutting of tool

Calliper

Turning

M.S. plate on 3. Drilling Drilling m/c both side Drilling up to Drill & 5 mm depth 4. Drilling Drilling m/c (1 hole) Drilling up to Drill 10 mm depth (3 holes) on circular M.S.Plate Vernier Calliper 30 mm 15 mm

CHART NO : 06 Name of the Part : Die Raw Material M.S. Plate. M.S.Plate Size: Two pan

S r.No . 1.

Operation

Standard machine

Description of Tool used operation

Gauge use

Operation Time

facing

used lathe jaw

four Facing on both Single top & bottom point halves of die. cutting tool

Vernier

45 min.

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Grooving

Lathe jaw

four Grooving

on Form tool

Vernier, Height gauge

40 min

the face of the die

11. BILL OF MATERIALS


Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Particulars Base plate Support Pillars Angles Top plate of heating chamber Pressure plate ( flange ) M.S. Bar Top plate Die (top half) Die (bottom half) Pneumatic cylinder Flange Nuts & bolts Heating coil Coil frame Thermostat Wires Plug Connector Asbestos sheets Quantity 1 4 3 1 1 1 1 1 1 1 1 8 1 1 1 1 1 2 Specification 400 x 300 x15 20 45 x 45 x 5 200 x 200 x 8 90 mm 30 mm 400x300x8 100x100x10 100 x100x15 50(piston size) 110x65x12 M-8 1000W 200x200 Length _ 225 200 _ 10mm (thickness) 20 mm 100 (length of stroke) 25 6000 -

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20 21 22

Thermostat cover Insulating sleeves Nuts & bolts

1 4

1 M12

500 30

12. ESTIMATION FOR THE PROJECT


Sr.No. Particulars 1 Estimates for procurement of raw material : i. ii. iii. iv. Base plate : { Dim-400x300x15} @ 25/kg Upper plate :{ Dim-400x300x8) @ 25/kg Supports :{Dim-20x225} Heating chamber (4 Nos)a) Top plate { Dim-20x200x8} b) Angles { Dim-45x45x5}{Length 200} 2 3 Estimate for die Estimate for machining charges i) ii) iii) iv) 4 Top plate Base plate Guides Heating chamber 83 68 375 180 125 480 235 115 1785 820 110 176 365 117 Amount ( Rs.) 390 193 212

v) Pressure plate (Flange) Estimates for pneumatic system i) ii) Pneumatic cylinder 4/3 Direction control valve

iii) Pneumatic plumbing & connectors Estimate for heating system i) ii) iii) Heating coil + holder Thermostat +control +casing Electrical accessories ( Wires, connector, asbestos

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6 7

sheet, sleeves , etc.) Painting Misc. expenses Final total estimate

163 223 6215

13. ESTIMATION FOR RUNNING COST OF MACHINE


The running cost of the machine is made up of two components a) Cost of electricity to run the heating system :The heating coil is of 1500 watts. As during a steady state operation the heating system is in use for approximately 75 % of the time. Therefore cost of electricity per operation ( assuming a average 20 operations per hour and rate of electricity Rs. 5 per unit). = { 0.7 x (1500/1000) x 5 } 20 = Rs. 0.26 = 26 paisa. b) Cost of operating pneumatic cylinder :The pneumatic cylinder can give satisfactory service bet 5 and 7 kg / cm2 pressure. Time taken to raise compressor pressure from 5 to 7 kg/cm2 = 10 No. of operations possible between this pressure range = 20 Therefore cost of operation of pneumatic cylinder per stroke (0.75 Hp motor) = 0.75 x 0.746x 5 x 10 20 x 60 = Rs 0.02 = 2 paisa. Therefore, total running cost of machine per operation = 0.02 + 0.26 = Rs. 0.28 = 28 p. 39

14. ADVANTAGES OF THE MACHINE


a) b) This machine is much cheaper than any other hydraulically operated automatic m/c. The no. of operator required is one and thus it eliminates one to two workers as compared to manual machines. c) d) e) f) Operator fatigue is much lower than manual machine . The pressure applied is much more consistent leading to better quality products. Productivity is increases greatly. Its operating costs are at par with or lower than other machines. ( Both manual and automatic). g) Due to only single moving part maintenance costs are very low.

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Source : SPI Plastic Engineering Handbook.

MOULDING DEPTH & PRESSURES FOR LOW PRESSURE, THERMOPLASTIC PHENOLICS. Sr. No. 1 2 3 4 5 6 7 8 9 10 Mould Depth (inches) inch 1 inch 1 inch 1 inch 1 inch 2 inch 2 inch 2 inch 2 inch 3 inch Pressure (psi) 350 450 550 650 750 850 950 1050 1150 1250

Add 100 psi for every inch increase in moulding depth.

Design Dimensions of screw threads, bolts and nuts according to IS : 4218 1978.

(Part IV)

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Designation

Pitch mm

(1)
Coarse series

(2) 0.1 0.15 0.2 0.25 0.25 0.3 0.35 0.35 0.4 0.45 0.45 0.5 0.6 0.7 0.75 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5

Major or nominal diameter Nut and Bolt (dD) mm (3) 0.400 0.600 0.800 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.500 3.000 3.500 4.000 4.500 5.000 6.000 7.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 22.000 24.000 27.000 30.000

Effective or pitch diameter Nut and Bolt (dp) mm (4) 0.335 0.503 0.670 0.838 1.038 1.205 1.373 1.573 1.740 1.908 2.208 2.675 3.110 3.545 4.013 4.480 5.350 6.350 7.188 9.026 10.863 12.701 14.701 16.376 18.376 20.376 22.051 25.051 27.727

Minor or Core Diameter (de) mm Bolt Nut (5) 0.277 0.416 0.555 0.693 0.893 1.032 1.171 1.371 1.509 1.648 1.948 2.387 2.764 3.141 3.580 4.019 4.773 5.773 6.466 8.160 9.858 11.546 13.546 14.933 16.933 18.933 20.320 23.320 25.706 (6) 0.202 0.438 0.584 0.729 0.929 1.075 1.221 1.421 1.567 1.713 2.013 2.459 2.850 3.242 3.688 4.134 4.918 5.918 6.647 8.876 10.106 11.835 13.835 15.294 17.294 19.294 20.752 23.752 26.211

Depth of thread (bolt) mm (7) 0.061 0.092 0.123 0.153 0.158 0.184 0.215 0.215 0.245 0.276 0.276 0.307 0.368 0.429 0.460 0.491 0.613 0.613 0.767 0.920 1.074 1.227 1.227 1.534 1.534 1.534 1.840 1.840 2.147

Stress area mm2

(8) 0.074 0.166 0.295 0.460 0.732 0.983 1.27 1.70 2.07 2.48 3.30 5.03 6.78 8.78 11.3 14.2 20.1 28.9 36.6 58.3 84.0 115 157 192 245 303 353 459 561

M 0-4 M 0-6 M 0-8 M1 M 1-2 M 1-4 M 1-6 M 1-8 M2 M 2.2 M 2.6 M3 M 3.5 M4 M 4.5 M5 M6 M7 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30

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15. CONCLUSION
The concept of this project was truly original and the advantages of this machine over other comparable machines is not an exaggeration. This machine has a true market potential if marketed properly. With indispensable help from our professors and workshop staff and sincere effort on the part of both our guide Prof. C.V. Deshmukh and the member of this team we have been able to convert a concept into a reality. Now it remains to be seen if someone has the initiative to market this product properly. Thank You.

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BIBLIOGRAPHY
1. Machine Design By : R.S. Khurmi 2. Production Technology By : R.K. Jain 3. S.P.I. Plastic Engg. Hand book 4. Rubber technology By : C.M. Blow 5. Rubber Chem Review ( Feb. 2001 issue )

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