SPECTACLES

Presented by :

FARHAN P.P

EMMANUEL MECHERY

SHYAM KRISHNAN M.K

NIVIN.G

SREEJISH P.K

AMRUTH LAL. AK
 INTRODUCTION
Tool engineering is one of the most important aspects of
Production engineering which enables industries to produce
standard plastic and metal items economically. Stamped and
molded components have found ultimate market in industries
like Automobile, Electrical and Electronics etc.

Design of an engineering product is made with the

intention of manufacturing economically. And also tolerances
are taken in consideration to effectively function and assemble .
 OBJECTIVES
 To involve in the activity of the project undertaken and to
understand various processes involved in DIE CASTING and
INJECTION MOULDING from designing to manufacturing.

 To get practical exposure and understand the does and don’ts to

be followed in design

 To check for the manufacturing feasibility and understand the

benefits of standardization.
 SCOPE OF THE PROJECT
To learn about MOULD DESIGNING and DIE CASTING
DESIGNS.
To study about different TROUBLE SHOOTING involved.
To get a good experience on ESTIMATION AND COSTING.
To learn the importance of TEAM WORK.
To complete our work in the way which we planed.
 PLANNING AND SCHEDULING

 In design, planning plays it relevant role as organizing

the decision to simplify and systemize design
procedures.
 It begins right from the orders confirmation of the
product.
 Planning work according to a schedule makes work
distribution easy and work move faster.
 Scheduling is arranging event such that they achieved
the planned purpose.
 INTRODUCTION TO PRODUCT
As our academic project from our institute. We
received SPECATACLES as our project.
PARTS OF THE PRODUCT

 1 Spectacles frame 3 1
(ALUMINIUM LM 24
Die casting)

 2 Legs (PLASTIC
Injection molding)
4
2
 3 Nose pad ( SILICONE Hand
Injection molding)

 4 Hinge insert (ALUMINIUM

LM 24 Die casting)
 PART : SPECTACLES FRAME
 Frame is used in spectacles to fix lenses
vision purpose.
I has properties :
like stiffness
non-allergic properties to skin

 The material used here is LM24 because

of its properties like

1. Fluidity (internal structure).

2. High accuracy precision components can
be made.
3. Very thin slandered parts can be casted.
4. Can be used under high pressure.
PART : SPECTACLES FRAME
 MATERIAL : LM24(GREY/SILVER)

 NO. OF CAVITY : 1

SHRINKAGE : 0.5 - 0.7%

CONSIDERING AS 0.6%

 WEIGTH OF PART :0.5g

 DENSITY : 2.79g/cc
 PART : FRAME LEG
 Leg is used in spectacles to join it with frame thus provides a
hold to spectacles.
It has properties like
Less weight
Feasibility
Flexibility
Non –allergic properties
 The material used here is
ZYL (zylonite ,cellulose acetate) (BLACK)
Shrinkage : 0.2% -0.5%
Density : 1.28gms/cc
Injection pressure : 600- 1400 kg/cc
Mould temperature : 50º c - 80º c
Weight : .25g
 PART : NOSEPAD
Nose pad
is used in spectacles to keep the spectacles firmly to
head for holding purpose.
It has properties like :
Less weight
Flexibility
Non-allergenic
Easily moldable and cheep
 The material used here is silicone, (TRANSPARENT)
Shrinkage : 0.2% -0.5%
Density : 2.32gms/cc
Injection pressure : 600- 1300 kg/cc
Mould temperature : 30º c - 60º c
Weight : .64g
 AS FOR OUR PROJECT PRESENTATION WE
ARE PRESENTING : SPECTACLES FRAME

CUSTOMER : GTTI
COMPONENT : SPECTACLES FRAME
COLOR : SILVER
MATERIAL : ALUMINIUM ALLOY (LM24)
VOLUME : 8.715 cm³
MACHINE : DC 80
TYPE OF GATE : FAN GATE
EJECTION TYPE : HYDRAULIC
COOLING : WATER / OIL
COMPONENT MATERIAL DATA
(LM 24)
COLOR = Grey to Silver
SHRINKAGE = 0.6%
DENSITY = 2.79 g/cm²
INJECTION PRESSURE = 600 – 1400 kg/cm²
DIE TEMPERATURE = 50º c - 80º c
MELT TEMPERATURE = 520º c - 580º
EJECTION TEMPERATURE= 80º c
SPECIFIC HEAT0.30 = 0.42 cal/ º c/gm
PRODUCT VOLUME = 8.715 cm³
THERMAL CONDUCTIVITY (K) = 96.3W/mK
 SPECTACLES FRAME : DESIGN
CALCULATION
LOCKING TONNAGE : 68.52 TON
PLUNGER DIAMETER : DIA 45
PLUNGER VELOCITY : 21.55 cm/sec
FILLING TIME : 1.83 sec
FILLING WEIGHT : 4.24 g
FLOW RATE : 2.31 cm/sec
FILLING VOLUME : 1.54 cm²
VENTILLATION CROSS SECTION : 18.85mm²
SHOT WEIGHT : 14.09g
 LOCKING TONNAGE

Locking force required = (A x P)/1000 TON

A = Projected area of casting including runner and over
flows in cm
P = Cavity pressure (400-600 kg/ cm²) for AL.

A = 137.04 cm²
P = 500
Therefore = (137.04×500)/1000
= 68.52 TON
 PLUNGERVELOCITY
V = (4Q)/ ∏d²
d = plunger dia in cm
v = cavity filling rate in cm/sec
Q = Volume of casting / cavity filling time

Plunger dia
(DC-180) = Ø40 or Ø50 or Ø 35
V = (4Q)/ ∏d²
Q = volume of casting / cavity filling time
= 35.197cm³/0.13 sec
= 270.75
Therefore

V = (4×270.75)/3.14× (4)²
= 1083/50.24
= 21.55 cm/sec
 FILLING TIME
KT (ti  t f  SZ )
t
t f  td
ti = Metal injection temperature ( º c )
tf = Minimum flow temperature ( º c)
td= Temperature of cavity
(º c )
S = Percent solidification factor allowable in the metal at the end
of the filling
Z = Unit conversion factor
(º c / %)
T = Average part thickness
K= Derived constant (sec/mm)
 KT (ti  t f  SZ )
t
t f  td
t = 0.0346 x 2 (650 - 570) + 15 x 3
570 – 340
= 0.0692 (3600)
230
= 1.83 sec
 FILLING WEIGHT

The Filling weight is the total weight of the

casting including runner and overflow.

Flow weight = Part weight +overflow X no. of

CVT
= 3.59g + 0.70g X 1
= 4.24 g
 FLOW RATE
The flow rate Q is the amount of
material conveyed by the plunger per second.

Flow rate (Q) = Filling weight

Filling time
= 4.24
1.83
= 2.31 cm/sec
 FILLING VOLUME
& SHOT WEIGHT
Filling volume = Filling weight
Density of metal
= 4.24
2.74
= 1.54 cm²

Shot weight = part weight + feed system weight

+Overflow
= 3.59 g + 8.75 g + 1.75 g
= 14.09 g
VENTILATION CROSS SECTION
Air vents are provided for the purpose of making
air escape to prevent the defects.

VCS = flow rate X 1000

200 m/s
= 3770
200
= 18. 85 mm²
 SPECTACLES FRAME : RUNNER
CALCULATION
MININUM DATE DEPTH :0.36 mm
MAXIMUM DATE DEPTH :1.44 mm
GATE CROSS SECTION : 21.55 cm/sec
RUNNER CROSS SECTION : 1.05 mm²
BISCUIT VOLUME : 628 mm²

MAIN
RUNNER

BISCUIT
SUB
FAN
RUNNER
GATE
 MACHINE SELECTION
MAIN FACTORS :
 METAL  DIE
 Alloy composition  Die temperature
 Metal temperature  Filling rate
MACHINE


 Shot weight Accumulator pressure

  flow rate
 Injection pressure
 Solidification
 Plunger diameter
 Locking force
 Mode of injection
 Stages
 Lubrication
 MACHINE DATA FOR DC 80
PLATEN SIZE = 530 x 530
SHOT CAPACITY = 705gms
PLUNGER DIAMETER = 40 mm
MAXIMUM DIE HEIGHT = 400 mm
MINIMUM DIE HEIGHT = 150 mm
DIE OPENING STROKE = 350 mm
EJECTOR SYSTEM = Hydraulic
SLEEVE = fitting Dia 70 X 10
TONNAGE = 80T
TEMPERATURE CONTROL= Water/Oil/Circulation
MOTOR CAPACITY = 18.5 kW
 DIE CASTING MOULD BASE :
35 -35 DME STANDARD
ELEMENTS
 BOTTOM PLATE REST BUTTON

 HEEL BLOCK  PUSH BACK PIN
 EJECTOR PLATE  CORE INSERT
 EJECTOR BACK PLATE  CAVITY INSERT
 PLUNGER BUSH  SPREADER
 CORE HOLDER  SUPPORT LEG
 CAVITY HOLDER  GUIDE RAIL
 PLUNGER SLEEVE
 SUPPORT PILLAR
 SIDE CORE
 TIE BAR
 EJECTOR GUIDE PILLAR
 GUIDE PILLAR
 EJECTOR GUIDE BUSH
 GUIDE BUSH
 COOLING NIPPLE
 DIE CASTING DIE DESIGN
DRAWING

TO BE PRESENTED IN AUTOCAD

AND PRO E
 DIE CASTING DIE
PARTS
DIE CASTING DIE : BOTTOM HALF
 DIE CASTING DIE
PARTS
DIE CASTING DIE : TOP HALF
 HEAT TREATMENT
Heat treatment is defined as an operation
or combination of operations involving heating
and cooling of a metal/alloy in solid state to
obtain desirable conditions and their properties .

HEAT TREATMENT PROCESS

 Annealing
 Hardening
 Tempering
PURPOSE OF HEAT-TREATMENT
PROCESS
It Causes relief of internal stresses
developed during cold working, welding,
casting, forging etc.
Harden and strengthen metals and it improves
machine ability. Soften metals for further
working and to change grain size. Improve
ductility, toughness, electrical and magnetic
properties. Increase heat, wear and corrosion
resistance of materials.
 ESTIMATION AND COSTING
 COSTING
Costing is the determination
of the actual cost of the product
after it has been manufactured.
 ESTIMATION
Methods of costing are,
Estimation is the
calculation of the cost of
a product before it is 1. Assumption according to the
actually manufactured. value of production steps.
2. Educated guessing,
3. Traditional cost accounting and
4. Activity based costing.
 GENERAL ESTIMATION AND
COSTING
ESTIMATION OF TOTAL
COST INCLUDE MACHINE HOUR RATE
 CHECKING AND MILLING MACHINE 75
CORRECTING THE POWER SAW 15
DESIGN. ENGINE LATHE MACHINE 30
 SELECTING COORDINATE DRILLING 75
PROCESS(MATERIAL ORDINARY DRILLING 15
DESCRIBED IN
DESIGN). SURFACE GRINDING 80
 SELECTING MACHINE. CYLINDRICAL GRINDING 100
 FIXING COST OF EDM SINKING 80
MATERIAL AND EDM WIRE 250
MACHINING AS PER CNC MILLING 300
CHART.
CNC LATHE 180
 DIE CASTING DEFECTS CAUSE
AND REMEDIES
These are some of the die casting defects which
may occur in die casting of frame:
 LAMINATIONS
 DIE EROSION
 FLASH
 DEFORMATION FROM EJECTOR PINS
 DRAGS
 LAMINATIONS
Layers of metal inside or outside of
casting

 Cause: Most common is poor metal

flow control, though there are other
causes.
 Remedies:
1. Gating: good flow patterns – no long
flow distance and mixing far from gate.
2. Good die temperature: should be
consistent over the trouble area best if
on the high side.
3. Intensifier action proper and consistent.
 DIE EROSION
Die erosion, cavitations, and burn out.
Die is worn spots causing raised spots on
the casting; can be small deep cavities or
larger erosion areas at the gate area.
 Cause: High metal velocity, bubbles in
incoming metal, high oxide or silicon
content in metal.
 Remedies:
1. Check gate velocities.
2. Check metal temperature should not be
high.
3. Check dies temperature in the gate area,
reduce with spray if possible.
 FLASH
Excessive cast material often
accompanied by dimensional
deviation.
 Cause: High metal temperature and
either poor die fit or poor machine
locking when high pressure is
applied.
 Remedies:
1. Die fit
2. Machine locking conditions
3. Die opening force centered on
machine
 DRAGS
 Cause:
Deformation of the casting by
undercuts encountered during ejection.
Undercuts may be caused buildup on
the die or by die erosion of solder.
 Remedies:
1. See corrections for build-up and check
draft angle.
2. Make sure die surface is smooth,
machining marks have been
completely polished out.
3. Reduce the temperature of the steel
that has the drag-this can be done with
spray or with high heat transfer die
materials.
 DEFORMATION FROM EJECTOR
PINS
 Cause: Caused when the casting is still soft
and sticks in the die; consequently the
ejector pins bend the casting trying to eject.
 Remedies:
1. Casting stays in the die too long or too short
(hold or dwell time not correct for casting).
2. Short dwell time means the casting may be
too soft at ejector pin location and may
deform.
3. Machine ejection system is “jerky”’ with
high impact on the casting. solid state to
obtain desirable conditions and their
properties.
TECHNOLOGICAL IMPROVEMENTS IN
DIE CASTING

THIS IS ONE OF THE IMPROVEMENTS WHICH CAN BE

DONE FOR GETTING BETTER OUTPUTS IN DIE
CASTING PROCESS.

LOST CORE METHOD

 LOST CORE
LOST CORE DIE CASTING IS THE
PROCESS IN WHICH SALT IS USED FOR CORE
AND THAT CORE IS USED FOR CASTING THE
DIE CASTINGS.
PROCESS
SALT CORE
SALT CORE REMOVAL
 BENEFITS

1. COST IS REDUCED BY REDUCEING THE

ASSEMBLING ,MACHINING AND SEALING
SYSTEM.
2. EXPANDING THE GEOMETRIC CONSTRAINS
OF HPDC PARTS.
3. MORE EASY TO REMOVE SALT CORES THAN
ANY OTHER CORE.
 CONCLUSION
We feel great pleasure and satisfaction in
involving in our injection mould and Die casting
project. The most important aspect of this project
was that, they were designed to the industrial
standards. This project has been an opportunity to
enhance our knowledge and designing capabilities.

We ultimately attained our goal of

designing our project. with the required standard
and talking into account of various manufacturing
factors.
THANK YOU