UNIVERSITI TEKNIKAL MALAYSIA MELAKA
A Precision Assembly in Plastic Injection Mould
Thesis submitted in accordance with the requirements of the Universiti Teknikal
Malaysia Melaka for the Degree of Bachelor of Engineering (Honours)
Manufacturing (Process)
By
Husaini Bin Abdullah
Faculty of Manufacturing Engineering
April 2008
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:
A Precision Assembly in Plastic Injection Mould
SESI PENGAJIAN: Semester 2 2007/2008
Saya Husaini Bin Abdullah
mengaku membenarkan laporan PSM / tesis (Sarjana/Doktor Falsafah) ini disimpan
di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1.
2.
3.
4.
Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
*Sila tandakan (√)
SULIT
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA
RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan oleh
organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
(TANDATANGAN PENULIS)
Alamat Tetap:
4, Persiaran Mayang Pasir,
(TANDATANGAN PENYELIA)
Tarikh: 25 Mach 2008
Tarikh: _______________________
Cop Rasmi:
11900 Bayan Lepas,
Pulau Pinang.
* Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414
Email : fkp@kutkm.edu.my
FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) :
Rujukan Tuan (Your Ref):
15 Mei 2008
Pustakawan
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM)
Taman Tasik Utama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD
- LAPORAN PSM SARJANA MUDA KEJURUTERAAN PEMBUATAN (PROSES):
Husaini Bin Abdullah
TAJUK: A Precision Assembly in Plastic Injection Mould
Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk “A
Precision Assembly in Plastic Injection Mould” mohon dikelaskan sebagai
terhad untuk tempoh lima (5) tahun dari tarikh surat ini memandangkan ia
mempunyai nilai dan potensi untuk dikomersialkan di masa hadapan.
Sekian dimaklumkan. Terima kasih.
“BERKHIDMAT UNTUK NEGARA KERANA ALLAH”
Yang benar,
……………………………………………………..
MOHD AMRAN BIN ALI
Pensyarah,
Fakulti Kejuruteraan Pembuatan
DECLARATION
I hereby declare that this report entitled “A Precision Assembly in Plastic Injection
Mould” is the result of my own research except as cited in the references.
Signature
:
Author’s Name
:
Husaini Bin Abdullah
Date
:
25 Mach 2008
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Process). The members of the supervisory committee are as follow:
Mohd Amran Bin Ali
(PSM Supervisor)
25 Mach 2008
ABSTRACT
This project describe the method that was used to assemble plastic injection moulding.
This project was done in the Manufacturing Workshop in Universiti Teknikal Malaysia
Melaka (UTeM) that located at Fasa B. The material that been used in this mould project
was Acrylic. This acrylic material was choose because of the characteristic that are
transparent. The purpose of this project is to assemble plates that been provided to be
one completed plastic injection moulding. The problem has been investigate such as
machining with wrong dimension, off set, over cut, not enough cut, standard part cannot
fit into plate and sharp edges. As a result, the plate must be remachining to get an actual
dimension according to the drawing that been provided. Type of machining that been
use in this project such as, milling machine, lathe machine, Computer Numerical Control
(CNC) machine and Electrical Discharge Machine (EDM) wirecut. This project started
from checking all plates to find out any defect or machining error or out of dimension in
plastic injection mould. Every plate will be using quality measurement tool. It will be
remachine if any defects found at mould plate. Various machines will be use such as
milling machine, EDM machine, CNC, chamfering machine, drilling machine and lathe
machine. During this project, all of learning outcome will be implement in every aspect
of work. In order to get accurate result in measurement, various equipment have been
used including vernier calliper, micrometer, high gauge, and Coordinate Measuring
Machine (CMM). In this project also use a quality measurement equipment to get an
accurate dimension. The equipment that involve in this project such as vernier caliper,
micrometer, height gauge and Coordinate Measuring Machine (CMM). As a result, the
measuring plate have been easier assembled with various mould component and finally
one completed mould set was produce.
ABSTRAK
Projek ini akan memperihalkan tentang cara untuk menggabungkan acuan suntikan.
Secara amnya, projek ini akan dijalankan di bengkel pembuatan Universtiti Teknikal
Malaysia Melaka (UTeM) yang terletak di kompleks Fasa B. Dalam projek ini, bahan
yang digunakan untuk membuat acuan ialah acrylic. Acrylic adalah bahan yang
diperbuat daripada plastik. Bahan ini dipilih kerana sifatnya yang lutsinar. Tujuan projek
ini dijalankan ialah untuk menyambung plat-plat yang dibekalkan menjadi satu acuan
yang lengkap. Ini kerana plat-plat yang dibekalkan mempunyai masalah seperti dimensi
yang salah, terpotong lebih, tidak cukup potong dan sebagainya. Maka plat-plat tersebut
perlu di mesin semula untuk mendapatkan ukuran sebenar mengikut lukisan yang
disediakan. Jenis mesin yang terlibat di dalam projek ini adalah mesin pengisar mesin
pengejat, mesin pengawalan berangka komputer dan mesin penyahcas elektrik Projek ini
dimulakan dengan menyemak kesemua plat untuk mengetahui kerosakan, kesilapan
memesin, dan terkeluar daripada dimensi yang ditetapkan. Setiap plate akan
menggunakan alat pengukuran yang berkualiti. Ianya akan dimesin semula jika terdapat
kerosakan. Pelbagai mesin digunakan seperti mesin pengisar mesin pengejat, mesin
pengawalan berangka komputer dan mesin penyahcas elektrik. Sepanjang projek ini,
segala hasil pembelajaran akan digunakan dalam setiap aspek kerja. Untuk mendapatkan
pengukuran yang tepat, pelbagai peralatan mengukur digunakan termasuk angkup
venier, tolok skru mikrometer, tolok tinggi dan mesin pengukur koordinasi. Hasilnya,
plat yang telah diukur, mudah untuk dicantumkan dengan pelbagai komponen acuan dan
akhirnya satu set acuan lengkap telah dihasilkan.
ACKNOWLEDGEMENTS
Assalamualaikum w.b.t. and warm greeting,
First of all, thank to ALLAH SWT for His blessings and for the strength given to me to
finish this Projek Sarjana Muda.
I would like to extend my heartfelt gratitude to all that have been contributed to the
success of this Projek Sarjana Muda. I wish to acknowledge and express my gratitude
and appreciation to my supervisor, Mr. Mohd Amran b. Md Ali for his supervision,
encouragement, suggestion and assistance through the research, technician and my
parent whose constant encouragement, faith and confidence besides continuously moral
support.
I also would like to convey my biggest thanks to Universiti Teknikal Malaysia Melaka
(UTeM) and Fakulti Kejuruteraan Pembuatan (FKP) especially Professor Dr. Mohd
Razali b. Muhamad, Dean of Faculty of Manufacturing Engineering, my PSM panel and
all the lectures in the faculty.
It is a pleasure for me to express huge gratitude to all technician especially Mohd
Farihan Bin Mohammad Sabtu and Muhammad Azwan bin Abdul Kadir who construct
and guide through completing this research while conducting the machining process in
manufacturing workshop as their kindness and willing really regards me with pleasure. I
could offer here only an inadequate gesture of my appreciation and all of your good
deeds will always be in my mind.
TABLE OF CONTENTS
Abstract…………………………………………………………………………...
i
Abstrak……………………………………………………………………………
ii
Acknowledgement………………………………………………………………..
iii
Table of Contents………………………………………………………………...
iv
List of Tables……………………………………………………………………..
viii
List of Figures…………………………………………………………………….
ix
List of Abbreviations……………………………………………………………..
xv
1. INTRODUCTION……………………………………………………………
1
1.1 Background……..……………………….………………………………..
1
1.2 Objective of project……………………………………………………….
3
1.3 Problem Statement……….…..……………………………………………
1.4 Scope of the project……………………………………………………….
1.5 Project Overview….……….…..………………………………………….
3
4
4
2. LITERATURE REVIEW………………………….………………………...
5
2.1 Mould……………………………………………………………………...
5
2.1.1 Two Plate Mould……………………………………………………..
5
2.1.2 Three Plate Mould……………………………………………………
8
2.2 Characteristic of Injection Moulding………………………………….…..
10
2.2.1 Impression…………………………..………………………………..
10
2.2.2 Runner.………………………...……………………………………..
10
2.2.3 Gate…………………………………………………………………..
11
2.2.4 Air Vent………………………………………………………………
12
2.3 Acrylic…………………………………………………………………….
13
2.3.1 Properties of Acrylic………………………………………………....
14
2.3.2 Advantages of Acrylic………………………………………………..
16
2.4 Conventional Machine…………………………………………………….
16
2.4.1 Milling Machine………………………………………………...........
16
2.4.1.1 Type of Milling Machine……………………………………..
17
2.4.1.2 Vertical Milling Machine……………………………………..
18
2.4.2 Clasification of Milling.......................................................................
19
2.4.2.1 Peripheral Milling……………………………………………
19
2.4.2.2 Face Milling………………………………………………….
19
2.4.2.3 End Milling……………………………………………..........
20
2.5 Lathe Machine…………………………………………………………….
20
2.5.1 Component of Lathe Machine..........................................................
21
2.5.1.1 Bed and Ways..........................................................................
21
2.5.1.2 Head Stock...............................................................................
22
2.5.1.3 Tail Stock.................................................................................
22
2.5.1.4 Carriage....................................................................................
23
2.5.1.5 Feed Rod..................................................................................
23
2.5.1.6 Lead Screw...............................................................................
24
2.5.1.7 Crossfeed slide.........................................................................
24
2.5.1.8 Accessories and Attachments...................................................
24
2.5.1.9 Lathe Chuck.............................................................................
25
2.6 Advance Machining……………………………………………………….
26
2.6.1 Computer Numerical Control (CNC)………………………………..
27
2.6.1.1 Movements..............................................................................
28
2.6.1.2 Tool Changes...........................................................................
29
2.6.1.3 Drilling.....................................................................................
30
2.6.1.4 Drilling Cycle………………………………………………..
30
2.6.1.5 Parametric Programming…………………………………….
31
2.6.2 Electrical Discharge Machining (EDM)……………………………...
32
2.6.2.1 Wire EDM Cutting..................................................................
34
2.6.2.2 Possible Shapes.......................................................................
35
2.6.2.3 Advantages of Wire EDM cutting...........................................
35
2.7 Measuring Equipment....................................................................................
36
2.7.1 Vernier caliper......................................................................................
36
2.7.2 Coordinate Measuring Machine (CMM)..............................................
38
2.7.2.1 Machine Body...........................................................................
39
2.7.2.2 Machine Probe………………………………………………..
40
2.7.2.3 Physical Principle………………………………………….....
42
2.7.3 Height Gauge………………………………………………………...
42
2.7.4 Micrometer…………………………………………………………..
45
2.7.4.1 Types…………………………………………………….......
45
2.7.4.2 Reading an Inch System Micrometer……………………......
46
2.7.4.3 Reading a Metric Micrometer……………………………......
47
3. METHODOLOGY……………………………………………………...……
48
3.1 Introduction………………………………………………………………...
48
3.2 Flow Chart of Mould Assembly……………………………………………
49
3.3 Selection of Component……………………………………………………
51
3.4 Assemble Moveable Half…………………………………………………..
51
3.5 Checking……………………………………………………………………
52
3.6 Machining……………………………………………………………..........
52
3.7 Assemble Stationary Half……………………………………………..........
53
3.8 Checking……………………………………………………………………
54
3.9 Assemble…………………………………………………………………...
54
4. PROBLEM ANALYSIS AND MOULD ASSEMBLY……………………..
55
4.1 Introduction…………………………………………………………………
55
4.2 Assembly drawing…………………………………………………………..
55
4.3 Problem Analysis …………………………………………………………...
59
4.3.1 Sprue Bush…………………………………………………………….
59
4.3.1. Measurement method…………………………………………
60
4.3.1.2 Machining Method………………………………………….
62
4.3.2 Shoulder Guide Bush Over Than Plate and Offset…………………..
64
4.3.2.1 Procedures…………………………………………………..
66
4.3.3 Core Plate…………………………………………………………….
74
4.3.3.1 Method……………………………………………………...
75
4.3.4 Sprue Bush Loose…………………………………………………….
76
4.3.4.1 Measurement method……………………………………...
77
4.3.4.2 Machining Procedures…………………………………….
78
4.3.5. Cavity plate 2 ……………………………………………………….
80
4.3.5.1 Measurement Procedure…………………………………….
81
4.3.5.2 Machining Procedure………………………………………...
82
4.3.6 Socket Head Cap screw M6 x 25……………………………………
84
4.3.6.1 Procedure……………………………………………………
84
4.3.7 Socket Head Cap Screw M8 x 15…………………………………..
87
4.3.7.1 Procedure…………………………………………………...
87
4.3.8 Thread……………………………………………………………….
89
4.3.8.1 Procedure…………………………………………………..
89
4.3.9. Sharp Edge………………………………………………………….
91
4.3.9.1 Procedure…………………………………………………..
92
4.3.9.2 Result………………………………………………………
93
4.3.10 Oil, Scratch and Mark……………………………………………...
94
4.3.10.1 Procedure…………………………………………………
95
4.4 Mould Assembly……………………………………………………………
97
4.4.1 Moveable Half……………………………………………………….
97
4.4.1.1 Procedure…………………………………………………..
100
4.4.2 Fix Half…………………………………………………………….. 113
4.4.2.1 Procedure…………………………………………………
115
4.4.3 Align Moveable Half and Stationary Half………………………… 124
5. DISCUSSION………………………………………………………………… 125
5.1 Introduction………………………………………………………………..
125
5.2 Machining Error…………………………………………………………...
126
5.3 Standard Part………………………………………………………………
128
5.4 Scratches ………………………………………………………………….. 128
5.5 Overcut or not enough cut…………………………………………………
129
5.6 Chamfering………………………………………………………………...
130
6. CONCLUSION & RECOMMENDATION………………………………...
130
6.1 Conclusion…………………………………………………………………
130
6.2 Recommendation…………………………………………………………..
131
References……………………………………………………………………….
132
Appendix A Garnt Chart of PSM 1..…………………………………………..
134
Appendix B Garnt Chart of PSM 2……………………………………………
135
LIST OF TABLES
2.1.1.1 Acrylic Properties
15
LIST OF FIGURES
2.1.1.1 Clamping Unit
5
2.2.2.1 Two Plate Injection Moulding
6
2.3.2.1 Cooling System
7
2.4
Water Cooling Located Inside the Mould
8
2.5
Three Plate Mould
8
2.6
Concept of 3 Plate Mould
9
2.7
Impression
10
2.8
Sprue and Runner
11
2.9
Gate
12
2.10
Air Vent
12
2.11
Acrylic Material
14
2.12
Vertical Milling Machine
18
2.13
Face Milling
19
2.14
Lathe Machine Component
21
2.15
CNC machine
26
2.16
CNC spindle
28
2.17
CNC magazine
29
2.18
Drilling Process
30
2.19
EDM machine
32
2.20
EDM wire cut
34
2.21
Product from EDM Process
35
2.22
Vernier Caliper Parts
37
2.23
Coordinate Measurement Machine (CMM)
38
2.24
CMM probe
41
2.25
Height Gauge
42
2.26
Scriber
44
2.27
Micrometer
46
3.1
Process Flow chart
49
3.2
Selected Acrylic Plate
51
3.3
Moveable Half Mould
51
3.4
CMM
52
3.5
EDM
53
3.6
Stationary Half Mould
53
3.7
Marking Mould
54
3.8
Complete Mould
54
4.1
Assembly Drawing
55
4.2
Bill of Material
56
4.3
Guide Piller and Shoulder Guide Bush
56
4.4
Ejector Pin, Locating Ring and Sprue Bush
57
4.5
Straight Guide Bush
57
4.6
Product Dimension
58
4.7
Sprue Bush Area
59
4.8
Sprue Bush
59
4.9
CMM Control Panel
60
4.10
Point to Measure
60
4.11
Initial Point
61
4.12
End Point
61
4.13
Result
62
4.14
Parting Tool
62
4.15
3 Jaw Lathe Machine
63
4.16
After Cutting Process
64
4.17
Shoulder Guide Bush Location
64
4.18
Guide Bush Shoulder
65
4.19
Guide Bush not enough cut hole
65
4.20
Parallel Bar
66
4.21
Workpiece on parallel bar
66
4.22
Edge finder
67
4.23
Clamp in milling chuck
67
4.24
Display of DRO
68
4.25 X-axis button
68
4.26 zero button
69
4.27
Enter Button
69
4.28
Y-axis button
70
4.29
All X,Y, Z-axis set zero
70
4.30
X-axis 2mm
71
4.31
Y-axis 2mm
71
4.32
4 Fluid End Mill
72
4.33
Tool Position
72
4.34
Machining Process
73
4.35
Shoulder Guide Bush Fit into the Hole
73
4.36
Radius Area
74
4.37
File Area
75
4.38
core insert fit into core plate
75
4.39
Loose sprue bush
76
4.40
mild steel
76
4.41
Washer Area
77
4.42
Result
77
4.43
Facing Process
78
4.44
Parting process
78
4.45
washer
79
4.46
Cavity Insert Location
80
4.47
Measure Cavity Insert
81
4.48
Measure cavity plate 2
81
4.49
Result
82
4.50
Dial Gauge
82
4.51
Boring process
83
4.52
Cavity insert fix into cavity hole
83
4.53
M6 x 25 locations
84
4.54
Socket Head Cap screw M6 x 25
84
4.55
Cutting Process
85
4.56
M6 screw that been cut
85
4.57
Cut off area
86
4.58
Ejector pin Socket Head cap screw M8 x 15 location
87
4.59
Cutting Process
87
4.60
Result
88
4.61
All M8 x 15 fit into hole
88
4.62
Damage Thread
89
4.63
Threading Tool
89
4.64
Tappering process
90
4.65
Result
90
4.66
Sharp edge
91
4.67
Chamfering machine
91
4.68
Chamfering Process
92
4.69
Repeating Process
92
4.70
Before chamfering
93
4.71
After Chamfering
93
4.72
Oil, scratch and mark
94
4.73
Denurated alcohol 95%
94
4.74
Workpiece
95
4.75
Cleaning Process
95
4.76
Clean Plate
96
4.77
Moveable Half Flow Chart
97
4.78
Ejector Base Plate
100
4.79
Socket head cap screw M6 x 25
100
4.80
Ejector Pin
101
4.81
Ejector Pin with Ejector Plate
101
4.82
Ejector Base Plate with Ejector Plate
102
4.83
Core insert
102
4.84
Core plate
103
4.85
Core insert with core plate
103
4.86
Stripper plate
104
4.87
Stripper plate with core plate
104
4.88
Backup plate
105
4.89
Guide piller
105
4.90
Backup, Core Plate and Stripper Plate with Guide Piller
106
4.91
Ejector plate with backup, core plate, stripper plate
106
4.92
Spacer Block
107
4.93
Join spacer block
107
4.94
Bottom Clamping Plate
108
4.95
Socket head cap screw M10 x 100
108
4.96
Joint bottom clamping plate
109
4.97
Guide bush
109
4.98
Guide bush location
110
4.99
Set screw m6 x 10
110
4.100 Set screw M6 x 10 location
111
4.101 Socket head cap screw M6 x 25
111
4.102 Joint Socket head cap screw M6 x 25 with ejector pin
112
4.103 Complete movable half
112
4.104 Fix Half Flow Chart
114
4.105 Guide bush shoulder
115
4.106 Cavity plate
115
4.107 Guide bush shoulder with Cavity plate
116
4.108 Cavity inserts 1
116
4.109 Cavity insert 1 with cavity plate 2
117
4.110 Cavity inserts 2
117
4.111 Cavity Plate 1
118
4.112 Cavity Inserts 2 with Cavity Plate 1
118
4.113 Cavity plate 1 with cavity plate 2
119
4.114 Top clamping plate
119
4.115 Socket head cap screw M6 x 25
120
4.116 Socket head cap screw M6 x 25 with top clamping plate
120
4.117 Sprue bush
121
4.118 Sprue bush in the locating ring
121
4.119 Locating ring
122
4.120 Counter sunk cap screw M4 x 8
122
4.121 Counter sunk cap screw M4 x 8 location
123
4.122 Complete fix half
123
4.123 Align fix half and stationary half
124
4.124 Complete set of mould
124
5.1
Datum and reference point
125
5.2
Digital Readout (DRO)
126
5.3
Clamping Area
127
5.4
Radius in core insert
127
5.5
Silicon area
128
LIST OF ABBREVIATIONS
CMM
-
Coordinate Measurement Machine
EDM
-
Electric Discharge Machine
CAD
-
Computer Aided Design
CAM
-
Computer Aided Machining
CNC
-
Computer Numerical Control
NC
-
Numerical Control
DRO
-
Digital Read Out
CHAPTER 1
INTRODUCTION
1.1
Background
Injection moulding is a process in which a polymer is heated to a highly plastic state and
forced to flow under high pressure into a mold cavity, where it solidifies. The moulded
part, called a moulding, is then removed from the cavity. The process produces discrete
components that are almost always net shape. The production cycle time is typically in
the range 10 to 30 seconds, although cycles of one minute or longer are not uncommon.
Mould consists of various type of component. Such as locating ring, sprue bush, guide
bushes and guide pillar, ejector system, sprue puller, return pin and ejector rod. Mould is
devided into two parts. moveble half dan stationary half. Moveable half consist of
several component that which are core plate, support plate, space block, top ejector
plate, bottom ejector plate and bottom clamping plate, meanwhile stationary half is
consist of top clamping plate and cavity plate. There are two type of mould, firstly two
plate mould, and three plate mould.
In this project, the 2 plate mould was chosen in order to produce a cup mould. The
purpose is to assemble the cup mould and define any defect on the mould and proceed to
remachine the mould back if any defect is found. Mould are usually made from pre
hardener metal, but in this project, acrylic material was used as a mould. Acrylic is a
useful, clear plastic that resembles glass, but has properties that make it superior to glass
in many ways. Common brands of high-grade acrylic include Polycast, Lucite and
Plexiglass. There are two basic types of acrylic, extruded and cell cast. Extruded or
"continuous cast" acrylic is made by a less expensive process, is softer, can scratch
easier and may contain impurities. Cell cast acrylic is a higher quality acrylic and it has
been use for jet and airplane glass. The advantages using acrylic mould in this project,
the mould is transparent and clear. This mean every process in injection mould can be
see clearly.
Conventional machine has been used in this project. Variety machine such as milling
and lathe were use to remachine the defect area. The machining process that are learn at
the last semester such as drilling, boring, facing, surfacing and others are practiced in
this project.
Measurement equipment such as verniar caliper, high gauge, dial indicator and
Coordinate Measurement Machine (CMM) has been implemented in this project. This is
to ensure the accuracy of each plate. Accuracy is very important in injection moulding, it
is because it will influent the size of product.
1.2
Objectives
The main objective of this project is to assemble the plastic injection mould. To achieve
this project there are five objectives:
1. To find out any defect, machining error, out of dimension in plastic
injection mould.
2. To fix all mould plates at movable half and stationary half.
3. To align all the guide pin and guide bush between moveable half and
stationary half.
4. To fix all mould components and inserts to the reference follow the
assembly drawing.
5. To assemble all plates, component and insert for producing one set of
mould.
1.3
Problems Statement
After machining, all plates of injection mould need to be assemble into one mould.
However, there are some plates and components cannot assembly in one mould. Due to
that, procedure of mould assembly should be prepared for industrial guide.
There are many sources, why plastic injection mould cannot assembly. Firstly the
method to assemble between moveable half and stationary half is not documented. The
wrong method to assemble the mould was use. To solve this problem, procedure of
assembling mould should be documented.
Secondly, some plate may be machine with wrong dimension. For example offset, over
cut, not enough cut and etc. To ensure that all plate were machine accurately, all plate
should be checked using measurement tool such as vernier caliper, micrometer, and
CMM.