plastic-knowledge-kanyakumari

Tool Design - AutoCAD Application in the area of MOLD DESIGN / PRODUCT DESIGN - PART:-2

2013-04-29T03:28:00.001-07:00

UTILITY COMMANDS USED IN THE MOLD DESIGN BY USING CAD

The following is an alphabetical list of commands used in development of the standard mold base and design of molds.

S.No.	COMMAND	DESCRIPTION	REMARKS
1	ARC	Draws an arc of any size. The default method is by specifying two ends points and a point along the arc, but several other methods are available.	This command is effectively used in the product development.
2	AREA	Computes the area of a polygon, polyline, or circle.	Used in the calculation of core and cavity development and clamp-force factors.
3	ARRAY	Makes multiple copies of selected objects in a rectangular or circular plan.	Polar circular array and rectangular array is used in core and cavity layout plan.
4	ATTDEF	Creates an Attribute definition entity for textual information to be associated with a Block Definition.	Preparation of database for standard mold parts.
5	ATTEDIT	Permits editing of Attributes.	Used in preparation of database.
6	AXIS	Displays a “ruler line” on the graphics monitor.	Gives on-line element locations.
7	BLOCK	Forms a compound object from a group of entitles.	Development of database for mold parts e.g. guide pillar, screws, guide bush, locating ring etc.
8	CHAMFER	Creates a chamfer at the intersection of two lines.	Used in detailed designs and drafting.
9	CHPROP	Modifies properties of selection objects.	Used in the editing during the mold drafting to alter the part positioning.
10	CIRCLE	draws a circle of any size. The default method is by centre point and radius, but other methods are available.
11	COLOR	Establishes the color for subsequently drawn objects.	To differentiate the important parts like core and cavity in the assembly different colours may be used.
12	COPY	Draws a copy of selected objects.	Used in cavity and runner layout design for multi-impression molds.
13	DELAY	Delays execution of the next command for and for a specified time. Used with command scripts.
14	DIM	Invokes dimensioning mode, permitting many dimension notations to be added to a drawing.	Used in dimensioning of the mold parts.
15	DIM 1	Allows one dimension notation to be added to a drawing then returns to normal command mode.	Used in dimensioning of the mold parts.
16	DIST	Finds distance between two points.	Used to check the exact position of cavity and runner positions.
17	DIVIDE	Places markers along a selected object, dividing it into a specified number of equal parts.	Used to divide core and cavity into required number of parts for the analysis purpose.
18	DOUGHNUT or DONUT	Draws rings with specified inside and outside diameters.	Used to highlight the impression or molding.
19	DTEXT	Draws text items dynamically.	Preparation of title blocks, bill of materials.
20	DVIEW	Defines parallel or visual perspective views dynamically.	To view the core and cavity assembly in different angles.
21	ELEV	Sets elevation and extrusion thickness for subsequently drawn entities. Used in 3D visualizations.	Modifying thickness of mold core and mold plates.
22	ELLIPSE	Draws ellipses using any of several specifications.
23	END	Exits the drawing editor after saving the updated
24	ERASE	Erases entities from the drawing	Used for editing the existing drawings.
25	FILL	Controls whether solids, Traces, and wide Polylines are automatically filled on the screen and the plot output.	Cavity development.
26	FILLET	Constructs an arc of specified radius between two lines, arcs, or circles.	Detailed drawing works.
27	GRID	Displays a grid of dots, at desired spacing, on the screen.	This feature helps to get a sense of the sizes of drawing entities and this relationship. The grid is not considered part of the drawing, it is for visual reference only and is never plotted.
28	HATCH	Perform crosshatching and pattern filling.	Hatching generates line entities for the chosen pattern and adds them to the drawing. Since a pattern may contain many lines, CAD normally groups there lines into an internally generated block.
29	‘HELP or ‘?	Displays a list of valid commands and data entry options or obtains help for a specific command.	Displays a list of valid commands and data entry options or obtains help for a specific command.
30	HIDS	Regenerates a 3D visualization with “hidden” lines removed.	Regenerated a 3D visualization with “hidden” lines removed.
31	LAYER	Creates names drawing layers and assigns color and linetype properties to those layers.
32	LIMITS	Changes the drawing boundaries and controls checking of those boundaries.
33	LINE	Draws a straight lines of any length.
34	LINETYPE	Defines linetypes (sequences of alternating line segments and spaces), loads them from libraries, and sets the linetype for Subsequently drawn objects
35	LIST	Lists database information for selected objects.
36	LTSCALE	Sets scale factor to be applied to all linetypes within drawing.
37	MEASURE	Places markers at specified intervals along a selected object.
38	MIRROR	Reflects designed entities about a user specified axis.
39	MOVE	Moves designated entities to another location.
40	MULTIPLE	Causes the next command to repeat until canceled.
41	ORTHO	Constrains drawing so that only lines aligned with the grid can be entered.
42	PLAN	Puts the display in PLAN view (V POINT 0, 0, 1) relative to either the current UCS, a specified UCS, or the World Coordinate System.
43	PLOT	Plots a drawing on a pen plotter.
44	POLYGON	Draws regular polygons with the specified number of side.
45	QUIT	Exists the Drawing Editor and returns to AUTOCAD’S Main Menu, discarding any changes to the drawing.
46	SAVE	Updates the current drawing file without exiting the Drawing Editor.
47	SCALE	Alters the size of existing objects.
48	SHAPE	Draws pre-defined shapes.
49	SKETCH	Permits free-hand sketching.
50	SOLID	Draws filled in polygons
51	STATUS	Displays drawing statistics & modes.
52	STRETCH	Allows you to move a portion of a drawing while retaining connections to other parts of the drawing.
53	STYLE	Creates named text styles, with user selected combinations of font, mirroring, obliquing, and horizontal scaling.
54	TEXT	Draws text characters of any size, with selected styles.
55	TIME	Displays drawing creation and update times, and permits control of an elapsed timer.
56	UNITS	Selects coordinate and angled display formats and precision.
57	VIEWPORTS OR VPORTS	Divide AUTOCAD’S graphics display into multiple viewports, each of which may contain a different view of the current drawing.
58	VPOINT	Selects the viewpoint for a 3D visualization.
59	3D FACE	Draws three-dimensional plane sections.
60	3D MESH	Defines a three dimensional polygon mesh by specifying its size (in terms of M and N) and the location of each vertex in the mesh.
61	3DPOLY	Creates a three-dimensional polyline.

DIMENSIONING COMMANDS

COMMAND

DESCRIPTION

ALIGNED

ANGULAR

BASELINE

CENTRE

CONTINUE

DIAMETER

EXIT

HOMETEXT

HORIZONTAL

LEADER

NEWTEXT

RADIUS

REDRAW

RPTATED

STATUS

STYLE

UNDO

UPDATE

VERTICAL

Generates a linear dimension with the dimension line parallel to the specified extension line origin points. This permits you to align the dimensioning notation with the object.

Generates an arc to show the angle between two nonparallel lines.

Continues a linear dimension from the baseline (first extension line) of the previous dimension.

Draws a Circle/Arc centre mark or centre lines.

Continues a linear dimension from the second extension line of the previous dimension. In effect, this breaks one long dimension into shorter segments that add up to the total measurement.

Dimensions the diameter of a circle or arc.

Returns to the normal Drawing Editor command mode.

Restores the text of an associative Dimensions.

Generates a linear dimension with a horizontal dimension line.

Draws a line or sequence of lines (similar to the normal LINE command) for controlled placement of dimension text. Useful mostly for radius and diameter dimensioning.

Changes the text of existing associative Dimensions.

Dimensions the radius of a circle or arc, with an optional centre mark or centre lines.

Redraws the entire display, erasing any marker “blips” that were present (just like the normal REDRAW command).

Generates a linear dimension with the dimension line drawn at a specified angle.

Displays all dimensioning variables and their current values.

Switches to a new text style.

Erases the annotations produced by the most recent dimensioning command.

Updates existing associative Dimension entities to use the current settings of the dimension variables, the current UNITS settings.

Generates a linear dimension with a vertical dimension line.

OBJECT SELECTION :

OBJECT SELECTION OPTION

MEANING

POINT

MULTIPLE

LAST

WINDOW

CROSSING

BOX

AUTO

ADD

REMOVE

UNDO

SINGLE

Selects one object that crosses the small “pick box”. If no object crosses the pick box and Auto mode has been selected, this designated point is taken as the first corner of a Crossing or window box.

allows selection of multiple objects using a single search of the drawing. the search is not performed until you give a null response to the “select objects” prompt.

selects the most recently drawn object that is currently visible.

Selects all objects that lie entirely within a window.

Selects all objects that lie within or cross a window.

Prompts for two points. If the second point is to the right of the first point, selects all objects inside box (like “Window”). Otherwise, selects all objects within or crossing the box (like “crossing”).

Accepts a point, which can select an object using the small “pick box”. If the point you pick is in an empty area, it is taken as the first corner of a “Box” (see above).

Selects the previous selection set.

Establishes “add” mode to add following objects to the selection-set.

Sets “remove” mode to remove following objects from the selection-set.

Undo (remove objects last added).

Sets “single” selection mode. As soon as one object or one group of objects via Window/Crossing box) is selected, the selection-set is considered complete and the editing command uses it without further user interaction.

for want to see the previous PART-1

Tool Design - AutoCAD Application in the area of MOLD DESIGN / PRODUCT DESIGN - PART:-1

2013-03-18T02:50:00.000-07:00

BASICS OF CAD (FOR MOLD DESIGN)

Computer-Aided Design (CAD) is a computer-aided technique for improving the efficiency of design engineering and manufacturing activities. The term CAD was originally used to mean computer-aided design and is still sometimes used in this sense in that it is the use of computer in conceptual design/engineering design part of the process and includes analysis and simulation rather than drafting. The term CAD has also nevertheless been used to mean computer-aided drafting. Some CAD applications in the Design Engineering are as listed

(1) Preparation of quotations

(2) Conceptual design

(3) Styling

(4) Finite-element analysis

(5) Simulation

(6) Engineering designs

(7) Detailed design

(8) Part listing

(9) Quality assurance

COMPUTER-AIDED DESIGN

With the help of computer technology, the designer has the capability of managing the enormous number of design, material, and process applications available when designing with plastics. IN the past, the designer more often than not had to limit the material, process, and design choices to those that were familiar. However, the computer now provides a means of developing a number of design concepts, quickly evaluating them against established functional and performance criteria in a wide range of materials and processes, and making the necessary design modifications.

The approach provides finished drawings and specifications that can be furnished with increased accuracy and confidence, usually in less time than before. In addition, the computer provides many other advantages. IF one dimension is changed that effects many others, all the dimensions will be changed automatically by the computer a the same time the initial change is made.

It is of course possible that entering the initial three-dimensional geometry for various design concepts into a computer can be more time consuming than developing concept sketches with conventional long-hand methods. However, subsequent revisions and analyses of that geometry can be performed many times faster on computer than manually.

BENEFITS OF CAD:

(1) Direct cost saving

(2) Direct time saving

(3) Improvement in product quality

(4) Increase in volume of business

Benefits of using can be explained taking case in which, by manual techniques, design and drafting of a part takes two people 15 days each or total of 30 man-days.

As a direct cost saving, for example, terminate the employment of one of the people, thus making a saving in salary costs (this is a fairly unusual solution, since it implies stagnation of the company’s business, and most companies look to CAD/CAM to promote growth);

As a direct time saving, for example by only spending 15 days on design and drafting of this part, the overall design engineering cycle time will be reduced. Hopefully, the part can be therefore be produced and sold earlier than would have been possible without CAD/CAM. Since both people are retained by the company, the 15 days “saved” can be used to design another part, which can also be produced and sold earlier than would otherwise have been possible.

As an improvement in product quality: continue to spend 30 days on design and drafting of the part, but investigate more than design alternatives and carry out more through checks of the design;

As an increase of volume of business: spending the required 15 days on the part, but spending the 15 days “saved” on preparation a proposal and quotation to compete for a tender that would otherwise have been ignored.

INTRODUCTION TO AUTOCAD:

The AUTOCAD design package is a general purpose Computer Aided Design/drafting application software for the computers. CAD applications are tremendously powerful tools. The speed and ease with which a drawing can be prepared and modified using a computer offers a phenomenal advantage over “hand” preparation.

There is virtually no limit to kinds of the drawings you can prepare using AUTOCAD. IF a drawing can be created by hand, it can be generated by AUTOCAD.

The application for which AUTOCAD is being used today.

* Work flow charts and organizational diagrams.

* Proposals and presentations.

* Graphs of all kinds.

* Drawings for electronic, chemical, civil, mechanical, automotive, and aerospace engineering applications.

* Plots and other representations of mathematical and scientific functions.

* technical illustrations and assembly diagrams.

* Company logos.

AUTOCAD remembers the locations, sizes, and colors of the objects you draw,

maintaining them in a database for subsequent retrieval, analysis and manipulations.

No technical knowledge is required to use AUTOCAD effectively; practice and a

thorough understanding of its features are key to proficiency.

THE AUTOCAD DRAWING :

An AUTOCAD drawing is a file that describes a graphic image. AUTOCAD uses this

description to produce the image on the screen or the plotter paper.

CREATING THE DRAWINGS:

The following concepts and terms introduce the main elements of an AUTOCAD

drawing.

(1) WORLD CO-ORDINATE SYSTEM:

AUTOCAD uses a fixed cartesian co-ordinte system, to locate point in your drawings. A point is expressed as an (x,y,z) co-ordinate pair. the origin is where the values of x and y,z are zero. We’ll call this system the world co-ordinate system.

(2) USER CO-ORDINATE SYSTEM:

The world co-ordinate system is fixed and cannot be altered in AUTOCAD. However, you can define an arbitrary coordinate system, called user co-ordinate system (UCS), within this UCS.

(3) CO-ORDINATE SYSTEM ICON:

To help your bearings among different co-ordinate systems in drawings, you can refer to the co-ordinate system icon.

(4) RIGHT HAND RULE :

AUTOCAD uses the right hand rule, to define all coordinate system.

(5) DRAWINGS UNITS & SCALING :

The distance between two co-ordinate is measured in drawing units.

(6) DRAWING LIMITS AND EXTENTS :

AUTOCAD assumes that you are drawing in a rectangular area. The drawing limits are the borders of this rectangle, expressed in X,Y drawing co-ordinates. You can select whatever limits make sense for your drawing.

(7) DRAWING ENTITIES :

Much of the “drawing” you do with AUTOCAD consists of positioning entities at co-ordinate locations. An entity is predefined element that you place in a drawing by means of a single command. Lines, arcs, and circles use entities you will use frequently.

(8) COLOURS AND LINETYPES :

You can assign and a linetypes to each entity. the colour is a number from 1 to 255 that selects the actual colour in which items are drawn on the graphics monitor. A lintype is a specific sequence of alternating line segments and spaces using these properties, you can draw attention to important details in your drawing, highlight recent changes, or depict the relationships among entities.

(9) LAYERS :

You can assign portions of your drawing to different layers, and you can define as many layers as you like. The layering concept is similar to the transparent overlap used in many drafting applications. Layering allows you to view and plot related aspects of a drawing separately or in any combination.

(10) DRAWING INSERTION :

You can treat an existing AUTOCAD drawing (stored on disk) as a block and merge it into the drawing that you are currently creating.

(11) FREE HAND SKETCHING :

AUTOCAD has a facility for sketching. You can draw short, connected lines freehand with a pointing device allowing you to trace map, or add your signature to a drawing.

VIEWING THE DRAWING

AUTOCAD offers many ways for you to view your drawing in progress and after it is completed.

(i) Zooming and Panning.

(ii) Display Extents.

(iii) Plan view and 3D views.

(iv) Viewports.

(v) Resolution.

(vi) Editing the drawing.

PRODUCT DESIGN MAKING IN AUTO CAD (example)

In the next part we will see about the commands which are mainly used for making mould design and product design...

Tool Design - Sprue bush & locating ring

2013-02-09T01:58:00.000-08:00

SPRUE BUSH and LOCATING RING

when you choose sprue bush, make sure you was know the diameter ball nozzle of plastics injection (SR) is less than diameter ball (SR - at picture below indicate by R)

if diameter R of Sprue bush to little than nozzle SR diameter, that will not good match or touching, if injection machine working plastic flash will out between nozzle and sprue

LOCATING RING
some mold designer usually use Locating ring to prevent unmatching nozzle of injection machine, before choose inside diameter of locating ring, we must know the outer diameter of nozzle that will touch with locating ring, at the picture below written in purple

Red color indicating flow of plastic material, from this picture we can take a conclusion that the picture is 2plate type of mold, look at picture there is no runner plate, and the gate type is side gate

Z pin Ejector
is used to make the runner ( RED COLOR) still adhere in core side when mold open and take the product, then Z pin will push the runner together with other ejectors

Tool Design - BASICs of PLASTIC MOLD..(Feed System)Part-3

2012-12-04T23:43:00.000-08:00

Runner system, flowing part of plastic injection

After material injected by nozzle, runner systems will convey the molten material from the sprue to the gate. basic runner system consist of sprue, main runner, sub runner, cold slug, and gate. since the design of the runner system has large effect on molding quality, molding efficiency, cycle time, cooling time and other factor, it is important key when design of mold.

Runner System Construction

Sprue
sprue will contact first time with melt plastic, at the injection process, sprue always contact with nozzle from the injection machine, so consider when design the sprue consider the ball radius of nozzle, make sure it isn't make undercut on sprue.The dimensions of the sprue depend primarily on the dimensions of the molded part in particular the wall thickness, too little sprue will make sprue cold faster and make insufficient flow.

Main Runner
First time when design runner system, determine number of cavities, shape and gate types, then arrange the cavity layout,at the multi cavity of mold balancing of runner is important, balancing ensures virtually equal flow of plastic trough each gate.
To achieve balancing runner layout must be though,

Sub Runner
this part will continues flow from main runner until the gate, the dimension of sub runner and how much sub runner system will be, is very depending on how much cavity of the mold, and how the layout, what the layout use herring bone, H type, or star type. at the picture above use H type runner layout.

Cold Slug
when runner layout bent, clod slug may be required to continue plastic flow of better quality to the cavities.The cold slug well helps the flow of material through the runner system by stopping colder, higher viscosity material moving at the forefront of the molten mass entering into the cavity.The length of the well is usually equal to or greater about 1,5-2 time than the runner diameter.

Gate
Basic purpose of the gate is to limit the flow of the melted plastic, but it must allow that melted plastic flow and fill the cavity easily.
considering the fluidity of the material, gate should be made near the center of gravity of molding or the line to make flow uniform and melted material even, then make the gate thick but still considering melted plastic material, becouse thin part will cooled easily and faster.
the gate type is very various depend on part shape, mold layout, mold system, etc, here some explanation about design those gate type:
1. Direct gate
2. Side, edge gate
3. Tab gate
4. film gate
5. fan gate
6. Disc gate

Runner geometry
they are various geometry that we can use in runner, such us
1. full round
2. half round
3. trapezoid
use full round and trapezoid shape is recommended in various mold. Half round runners are not recommended because of their low volume to surface ratio
here some area calculation of cross section of runner (source : http://www.dsm.com)

Runner dimensions
The diameter of a runner depends on its length in addition to the part volume, part flow length, injection machine capacity, and gate size, Generally runner must never be smaller than the largest wall thickness of the product, it's usually make from 3 mm until 15 mm. picture below shown relation between runner diameter and maximum runner length (source : http://www.dsm.com)

The runner should be large enough to minimize pressure loss, yet small enough to maintain satisfactory cycle time, Large runners are not economical because of the amount of energy that goes into forming, and then regrinding the material that solidifies within them.

Runner layout
In general they are three type of runner layout
1. "H" bridge (branching) runner system
2. Standard (herringbone) runner system (conventional runner)
3. Radial (star) runner system
look at picture below shown standard runner and H bridge type runner.

and below is star layout runner system (both bottom picture)

Balancing the runner system ensures that all mold cavities fill at the same rate and pressure, if the product have not similar product geometry, it is recommended to use mold analysis software like mold flow or C-Mold.

Kanyakumari - Beauty of Kanyakumari at SunSet & Moon Rise..

2012-11-15T03:04:00.001-08:00

FOR MORE DETAILS ABOUT KANYAKUMARI TOURIST PLACES and TOUR EXPERIENCE
VISIT THE BEAUTIFUL full fledged Kanyakumari website which is shown below:- Clicking that link take you to that Beautiful page :-
http://heartin-kanyakumari.blogspot.in

In the Above website you get the details of
1.) Train , Bus , Flight timings to reach kanyakumari
2.) Beautiful photos with details of all tourist places.
3.) Route map of all tourist places in there
4.) Personal Journey Experience Review of all tourist places.
5.) Videos of that particular tour place.

Kanyakumari is famous for its spectacular sunrises and sunsets, especially on full moon days. It is at its best during Chitra Pournami (full moon day in April) when the sun and moon are face to face at the same horizon. but other full moon days are also special when you can see the sun set and the moon rise almost simultaneously, as if by prior arrangement.The beach itself is a beautiful sight with multi-coloured sand. Palmleaf articles of Kanniyakumari are very much world famous.

Chitra Poornima is the name of Full Moon on Tamil month of Chitra.This occurs when our Sun is in its Exalted state of Aries (close to the Earth), and Moon is full and aligned with the bright star called Chitra in the constellation of Libra

Kanyakumari Distance Chart

Thanjavur – 400KM Trichy – 384KM | Trivandrum – 87KM | Velankanni – 489KM

Kanyakumari –Little known Facts

· Main Kanyakumari temple is dedicated to Devi Kumari (Kumari Amman Temple) and it is over 3000 years old.
· During peak season, the ferry service to Vivekananda rock memorial is used by over 10,000 tourists per day!
· Sunrise is visible throughout the year in Kanyakumari, but sunset is visible only from October 15 to March 15.
· From the hillock called Murugan Kundram (3KM from Kanyakumari), both sunset and sunrise is visible throughout the year.
· Full moon day of April is the best day to visit Kanyakumari (Chithra Pournami).
· Swami Vivekanandan attained enlightenment while meditating on the Kanyakumari rock in 1892.
· Vivekananda memorial was constructed in 1970 and it took 650 men and 2000+ days to complete construction.
· Mahatma Gandhi visited Kanyakumari in 1925 and 1937. There is a Gandhi memorial on the beach side.

EARLY MORNING SUNRISE from the SEA LEVEL

SUNRISE little bit above.....

SUNRISE little bit above.....and given Sexy orange eye catching view ....

SUNRISE little bit above.....and then Clouds trying to hide SUN ....

SUN with Full bright ...eye catching view ....

No SUN and Rainy effect in mid-day ....

SUNSET at evening ... eye catching view ....

SUN become dim and beautiful rays spread on ....

Last moments of SUNSET ....within few minutes it will go and MOON rise soon..

MOON RISE little bit above.....and given Mind touching peaceful golden eye catching view ....

MOON above the 133 Feet tall statue....at 9pm

MOON from long shot and in background of vivekananda rock & thiruvalluvar statue at night 12pm ....

MOON SET at early morning, eye catching view .... at 3am

MOON SET at early morning, eye catching view .... at 5am

Early morning, eye catching view .... with Rainy Clouds and calm waves...

We cant explain our personal feelings and beautiful moments only through Photo's ..its possible u come and feel it in your own way and touch... don't miss the chance in your life, at least once come to this place and enjoy the pleasure..its up to u...

Tool Design - BASICs of PLASTIC MOLD..Part-2

2012-11-14T03:04:00.000-08:00

Classification or types of mold injection very depend on what we need to make the plastic parts, because every parts have specific and unique design. when design molds we must see what the influencing factor like geometry, number of cavities, ejection principle, plastic material and shape of parts.

The basic classification of mold based on construction shown on picture below

1. Standard Molds
the standard mold is the most simple design, basically the standard molds is same as two plate molds construction, they divided in two side : cavity side and core side, cavity side is the side that construct to flowing plastic material from nozzle to cavity parts, basically they consist of sprue, runner.

core side construct to make shape for core, demolding system and ejection system, at this side we design ejection system.
standard mold have one parting line, and have one opening direction. this type of mold use in all kinds of plastic parts that doesn't have undercut, inner and outer screw.
Light brown color little and straight in ejection system is shown ejector pin.

2. Slide mold or Split mould
development from this mold type is the used slider parts in various molds types, basic slide mold is transfer horizontal movement of mold to vertical movement, this types of molds is used to make parts with undercut, you should see more at the post when we need slider for learn more.

3. Three plate molds
basically three plate molds has two parting line, and floating plate, floating plate support by support pin, Since the mold has two parting planes, the runner system can be located on one side of floating plate or make special plate that attach in floating plate, we called runner plate, see post about runner plate. Three plate molds are used because of their flexibility in gating location. this types of molds is flexible even use in multiple cavity.

note : floating plate also called cavity plate or plate number 3, to know more the different between two plate mold and three plate mold see the posting about Basic and Types Molds Construction

4. Split Cavity Mold
basically the split cavity is same as 2 plate standard mold, but the cavity have split block to make undercut product or external threads.

this type of mold use when the slider is not enough to make the undercut or the threads. the disadvantages of this mold is when use for little parts, the construction will difficult.

5. Mold With Screw Device
this mold special to make thread forming, the core can be rotate when demolding process, both internal or external threads can be forming by this type mold.

from those picture we can see that they have gear device, the gear will rotate when form thread.

6. Stripper Ejector Mold
this type of mold have special purpose to make a cup shape without undercut, stripper ejector will make ejection more easy, same movement and power at the product and without a lot of marks in product

Molds with complex and difficult design can be integrated or combined one to the others mold type.

Tool Design - BASICs of PLASTIC MOLD..Part-I

2012-11-14T02:59:00.000-08:00

A mold plate is any plate required to built a complete mold, in all plate use for molds have the main requirements, they are :
1. Good corrosion resistant
2. Good Machinability.
3. Easy to clean
3. Good heat transfer.
4. Homogeneity of steel.
5. Easy ability.
6. Low Cost.

at picture below you can see 3 plate mold base type with closed position, basically 3 plate type and 2 plate type has some main plate, see explanation about mold construction type to understand more, in next post or PART-2

explanation below based on number at those picture
1. Fixed Clamping Plate or Top Plate
Holds The fixed side of the mold to attached at the fixed platen of the injection machine. at this plate will attach locating ring, eye bolt, and sprue bush.
2. Runner Stripper Plate
this plate only used in 3 plate molds type, the function is to cut resin from nozzle in top of sprue bush, and pull the runner by runner locking pin.
3. Fixed Mold Plate or Cavity plate.
use to hold cavity side of product, leader pin, support pin, Puller bolts, and Angular pin when slider attached.
4. Movable Cavity Plate or Cavity plate
it used to attach core side of product, return pin, leader bush and slider core if needed.
5. Back up Plate or Support plate
used to support cavity plate, attach the hole for return pin's spring, and cooling channel when in cavity plate can not make it.
6. Spacer Block
Mounted between the movable clamping plate (bottom plate) and the movable cavity plate to give space and allow the ejector plate to move when ejecting the
part. the required length of spacer block depend on ejector stroke that needed to eject product.
7.Ejector retainer plate
to hold the ejector, Z pin, shoulder bolts,and give space to ejector leader pin and support pillar.
8. Ejector Plate
Pushes the ejector pins and return pins, connected with ejector rods.
9. Movable Clamping Plate or Bottom plate
Holds The movable side of the mold like spacer block, support plate, cavity plate and ejector mechanism to the movable platen of the injection machine.

and look at picture below, shown 3 plate molds type in opening position, but at picture below, Bottom plate or movable clamping plate is number 7, number 8 is ejector retainer plate, and number 9 is ejector plate.

G.K - Government Research Institutes All over india (STATE wise List) PART-II

2012-10-01T23:37:00.000-07:00

Ahmedabad

Allahabad

Harish Chandra Research Institute

Bangalore

Barrackpore (W. B.)

Central Inland Capture Fisheries Research Institute

Bhopal

Central Institute of Agricultural Engineering

Bhubaneswar

Calcutta

Chandigarh

Post Graduate Institute of Medical Education and Research

Chennai (Madras)

National Centre for Ultrafast Processes

National Institute of Ocean Technology

SPIC Science Foundation

Structural Engineering Research Centre

Delhi

Directorate of Wheat Research

Dehradun

Hyderabad

Indore

Center for Advanced Technology

Jammu

Regional Research Laboratory

Jhansi (U. P)

National Research Centre for Agroforestry

Jodhpur (Rajasthan)

Central Arid Zone Research Institute

Kanpur

Kasaragod

Central Plantation Crops Research Institute

Kharagpur

Indian Institute of Technology

Kochi

Central Marine Fisheries Research Institute

Lucknow

Mathura

Central Institute for Research on Goats

Mumbai (Bombay)

Palakkad

Fluid Control Research Institute

Palampur (H.P.)

Institute of Himalayan Bioresource Technology

Peechi

Kerala Forest Research Institute

Pilani

Puttur (Karnataka)

National Research Centre on Cashew

Pune

Roorkie (U. P.)

Central Building Research Institute

Trivandrum (Thiruvananthapuram)

Varanasi (U. P.)

Indian Institute of Vegetable Research

G.K - CENTRAL GOVERNMENT INSTITUTES and COLLEGES - PART-1

2012-09-03T04:22:00.000-07:00

National Institutes of India

SEE NEXT POSTS or PART for all other institutes in INDIA or ABROAD...

G.K - Public Sector Companies in INDIA for a government JOB

2012-08-31T03:06:00.010-07:00

	Bharat Coking Coal Limited (BCCL) Bharat Coking Coal Limited (BCCL) is a Public Sector Undertaking engaged in mining of coal and allied activities. It occupies an important place in as much as it produces bulk of the coking coal mined in the country. BCCL meets almost5 50% of teh total prime coking coal requirement of the intregrated steel sector. It also supplies substantial quantity of coal to the pig iron sector and bulk of the coal requirement of the power station in the Northern region. web site url: http://www.bccl.nic.in/
	Bharat Dynamics Ltd BDL was established in July 1970 under the control of Ministry of Defence with the prime objective of establishing a production base for guided missiles in India. It is now one amongst a few strategic industries of the world having the capability to produce the most advanced guided missile systems for Armed Forces. web site url: http://bdl.ap.nic.in/
	Bharat Earth Movers Ltd Bharat Earth Movers Limited is a premier ISO 9001-2000 Company in India and the second largest manufacturer of earthmoving equipment in Asia. A four- decade-old multi-locational and multi-product company, BEML has vital applications in diverse sectors of economy such as coal, mining, steel, cement, power, irrigation, construction, road building and railway. It has expanded its product range to cover high-quality hydraulics, heavy-duty diesel engines, Welding robots and undertaking of heavy fabrication jobs. web site url: http://www.bemlindia.com/
	Bharat Heavy Electricals Limited (BHEL) BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Telecommunication, Renewable Energy, etc. The wide network of BHEL's 14 manufacturing divisions, four Power Sector regional centers, over 100 project sites, eight service centers and 18 regional offices, enables the Company to promptly serve its customers and provide them with suitable products, systems and services - efficiently and at competitive prices. web site url: http://www.bhel.com/
	Bharat Refractories limited Bharat Refractories limited, a public sector company under administrative control of ministry of steels, Govt. of India came into existence in 1974. Since inception, the company has crossed major milestones to become one of the largest refractory producers in India. The company is world renowned for its quality and has been successfully catering to the requirement of the steel industry and other users. web site url: http://www.bharatref.com/
	Bharat Sanchar Nigam Limited(BSNL). On October 1, 2000 the Department of Telecom Operations, Government of India became a corporation and was christened Bharat Sanchar Nigam Limited(BSNL). Today, BSNL is the No. 1 Telecommunications Company and the largest Public Sector Undertaking of India with authorized share capital of $ 3600 million and networth of $ 13.85 billion. It has a network of over 45 million lines covering 5000 towns with over 35 million telephone connections. web site url: http://www.bsnl.co.in/
	Bongaigaon Refinery & Petrochemicals Ltd Bongaigaon Refinery & Petrochemicals Limited (BRPL) was incorporated as Government of India Undertaking under the administrative control of the Ministry of Petroleum and Natural Gas on 20th February 1974. The company became a subsidiary of IndianOil on 29th of March 2001 after disinvestments of share by Govt of India. web site url: http://www.brplindia.com/
	Cement Corporation of India Limited (CCI) Cement Corporation of India Limited (CCI) was incorporated as a Company wholly owned by Government of India on 18th January 1965 with the principal objective of achieving self sufficiency in cement production. The authorised and paid-up capital of the company as on 31.3.2003 was Rs. 700 crores and Rs. 428.28 crores respectively. web site url: http://business.vsnl.com/cci/
	Centre For Railway Information Systems Centre For Railway Information Systems is entrusted with the task of design, development and implementation of the Freight Operations Information Systems(FOIS), alongwith its associated communications infrastructure. The Centre started functioning from July,1987. It is a registered society having an autonomous status and headed by Managing Director . CRIS is mainly a project oriented organisation engaged in development of major computer systems on the Railways. web site url: http://www.cris.org.in/
	Coal India Ltd The company is incorporated under the Companies Act, 1956 and is wholly owned by the Government of India (GOI). Company's objective is to promote the development and utilisation of the coal reserves in the country for meeting the present and likely future requirement of the nation with due regard to need for conservation of non-renewable resources and safety of mine workers. web site url: http://coalindia.nic.in/
	Engineers India Ltd Engineers India Limited was established in 1965 to provide engineering and related technical services for petroleum refineries and other industrial projects.In addition to petroleum refineries, with which EIL started initially, it has diversified into and excelled in other fields such as pipelines, petrochemicals, oil and gas processing, offshore structures and platforms, fertilizers, metallurgy and power. web site url: http://www.engineersindia.com/
	Erstwhile Gas Authority of India Limited(GAIL) GAIL (India) Ltd, (Erstwhile Gas Authority of India Limited) was set up by the Indian Government in August 1984 to create gas sector infrastructure for sustained development of the gas market in India. Primarily a natural gas company, it deals with all aspects of the gas-value chain, including exploration, production, transmission, extraction, processing, distribution and marketing of natural gas and its related process, products and services. web site url: http://www.gailonline.com/
	Food Corporation of India The Food Corporation of India was setup under the Food Corporations Act 1964, in order to fulfil objectives of the Food policy. Effective price support operations for safeguarding the interests of the farmers. Distribution of foodgrains throughout the country for Public Distribution System; and Maintaining satisfactory level of operational and buffer stocks of foodgrains to ensure National Food Security. web site url: http://fciweb.nic.in/
	Heavy Water Board Heavy Water Board (HWB), a constituent unit under Department of Atomic Energy, is primarily responsible for production of Heavy Water (D2O) which is used as a 'moderator' and 'Coolant' in the nuclear power as well as research reactors. HWB is successfully operating six Heavy Water Plants in the country. web site url: http://www.heavywaterboard.org/
	Hindustan Aircraft Limited HAL's supplies / services are mainly to Indian Defence Services, Coast Guard and Border Security Force. Transport aircraft and Helicopters have also been supplied to Airlines as well as State Governments of India. The Company has also achieved a foothold in export in more than 30 countries, having demonstrated its quality and price competitiveness. web site url: http://www.hal-india.com/
	Hindustan Insecticides Limited (HIL) HIL, a Government of India Enterprise under the Ministry of Chemicals and Fertilizers, Deptt. Of Chemicals & Petrochemicals, Government of India, was incorporated Programme launched by the Government of India. Subsequently the Company diversified into agro pesticides to meet the requirements of agriculture sector, and has grown manifold, with a turnover of 1148 million rupees in 2001-02. Company has also entered into the field of safe and eco-friendly botanical and bio-pesticides for public health and plant protection. web site url: http://www.hil-india.com/
	Hindusthan Aeronautics Ltd The history of the Indian Aircraft Industry can be traced to the founding of Hindustan Aircraft Limited at Bangalore in December 1940 in association with the erstwhile princely State of Mysore and late Shri Seth Walchand Hirachand, an Industrialist of extra -ordinary vision. Govt. of India became one of its shareholders in March 1941 and took over the management in 1942. Hindustan Aircraft Limited was merged with Aeronautics India Limited and Aircraft Manufacturing Depot, Kanpur to form Hindustan Aeronautics Limited (HAL) on 01st October 1964. web site url: http://www.hal-india.com/
	Indian Oil Corporation Indian Oil Corporation Limited (IndianOil) is the country's largest commercial enterprise, with a sales turnover of Rs. 1,30,203 crore.IndianOil is India's No.1 Company in Fortune's prestigious listing of the world's 500 largest corporations, ranked 189 for the year 2004 based on fiscal 2003 performance. It is also the 19th largest petroleum company in the world. web site url: http://www.indianoilcorp.com/
	India Trade Promotion Organisation (ITPO) India Trade Promotion Organisation (ITPO)is the nodal agency of the Government of India for promoting the country's external trade. ITPO, during its existence of nearly three decades, in the form of Trade Fair Authority of India and Trade Development Authority, has played a proactive role in catalysing trade, investment and technology transfer processes. Its promotional tools include organizing of fairs and exhibitions in India and abroad, Buyer-Seller Meets, Contact Promotion Programmes, Product Promotion Programmes, Promotion through Overseas Department Stores, Market Surveys and Information Dissemination. web site url: http://www.indiatradepromotion.org/
	Kudremukh Iron Ore Company Limited Kudremukh Iron Ore Company Limited, a wholly owned Government of India Enterprise, was established in 1976 to develop the mine and plant facilities to produce 7.5 million tonnes of concentrate per year. The mine and plant facilities were commissioned in 1980 and the first shipment of concentrate was made in October 1981. A pelletisation plant with a capacity of 3 million tonnes per year was commissioned in 1987 for production of high quality blast furnace and direct reduction grade pellets for export web site url: http://www.kudremukhore.com/
	National Fertilizers Ltd NFL was incorporated on 23rd August, 1974 with two manufacturing Units at Bathinda and Panipat. Subsequently, on the reorganization of Fertilizer group of Companies in 1978, the Nangal Unit of Fertilizer Corporation of India came under the NFL fold. The Company expanded its installed capacity in 1984 by installing and commissioning of its Vijaipur gas based Plant in Madhya Pradesh. web site url: http://www.nationalfertilizers.com/
	National Scheduled Tribes Finance and Development Corporation (NSTFDC) NSTFDC is the Apex organisation for providing financial assistance for scheme(s)/project(s) for the economic development of Scheduled Tribes. The objectives of NSTFDC are Identification of economic activities of importance to the Scheduled Tribes so as to generate employment and raise their level of income.Upgradation of skills and processes used by the Scheduled Tribes through providing both institutional and on the job training etc. web site url: http://nstfdc.nic.in/
	National Small Industries Corporation Ltd. The National Small Industries Corporation Ltd., an ISO 9001:2000 Company, was established in 1955 by the Government of India with a view to promote, aid and foster the growth of Small Industries in the country. NSIC continues to remain at the forefront of industrial development throughout the country, with it's various programs and projects, to assist the small scale sector in the country. web site url: http://www.nsicindia.com/
	Neyveli Lignite Corporation NLC Limited is an integrated project complex owned by Govt.of India. Liginite excavation and power generation are the core activities of NLC. It has three opencast liginite mines. web site url: http://www.nlcindia.co.in
	Nuclear Power Corporation of India Limited (NPCIL) Nuclear Power Corporation of India Limited (NPCIL) is a wholly owned Enterprise of the Government of India under the administrative control of the Department of Atomic Energy (DAE), Government of India. It has been incorporated in September 1987 as a Public Limited Company under the Companies Act, 1956 with the objective of undertaking the design, construction, operation and maintenance of the atomic power stations for generation of electricity in pursuance of the schemes and programmes of the Government of India under the provision of the Atomic Energy Act, 1962. web site url: http://www.npcil.org/
	Oil and Natural Gas Corporation Limited (ONGC) A modest entity in the serene Himalayan settings - Oil and Natural Gas Corporation Limited (ONGC) was set up as a Commission on August 14, 1956. The company became a corporate on June 23, 1993, which has now grown into a full-fledged horizontally integrated petroleum company. Today, ONGC is a flagship public sector enterprise and India's highest profit making corporate, achieving the record of being the first Indian corporate to register a five digit profit figure of Rs. 10,529 Crore in the year 2002-03. web site url: http://www.ongcindia.com/
	Shipping Corporation of India The Shipping Corporation of India was established on 2nd October 1961 by the amalgamation of Eastern Shipping Corporation and Western Shipping Corporation. Starting out as a marginal Liner shipping company with just 19 vessels, the SCI today has metamorphosed into a giant conglomerate having 83 ships of 4.6 million DWT with substantial interests in 10 different segments of the shipping trade. web site url: http://www.shipindia.com
	Steel Authority of India Limited (SAIL) Steel Authority of India Limited (SAIL) is the leading steel making company in India. It is a fully integrated iron and steel maker, producing both basic and special steels for domestic construction, engineering, power, railway, automotive and defence industries and for sale in export markets. web site url: http://www.sail.co.in
	Steel Authority of India Steel Authority of India Limited (SAIL) is the leading steel-making company in India. It is a fully integrated iron and steel maker, producing both basic and special steels for domestic construction, engineering, power, railway, automotive and defence industries and for sale in export markets. web site url: http://www.sail.co.in/
	The Nuclear Fuel Complex (NFC) The Nuclear Fuel Complex (NFC), established in the year 1971 is a major industrial unit of Department of Atomic Energy, Government of India. The complex is responsible for the supply of nuclear fuel bundles and reactor core components for all the nuclear power reactors operating in India. It is a unique facility where natural and enriched uranium fuel, zirconium alloy cladding and reactor core components are manufactured under one roof starting from the raw materials. web site url: http://www.nucfuel.gov.in/default.htm
	Uranium Corporation Ltd Incorporated on 4th October 1967, Uranium Corporation of India ltd, a public sector Enterprise under the Department of Atomic Energy, is at the forefront of the Nuclear Power Cycle. Fulfilling the requirement of Uranium for pressurised Heavy Water Reactors, UCIL plays a very siginificant role in India's Nuclear Power Generation Programme. web site url: http://www.ucilindia.com/
	Airports Authority of India (AAI) Airports Authority of India (AAI) was constituted by an Act of Parliament and came into being on 1st April 1995 by merging erstwhile National Airports Authority and International Airports Authority of India. The merger brought into existence a single Organization entrusted with the responsibility of creating, upgrading, maintaining and managing civil aviation infrastructure both on the ground and air space in the country. web site url: http://www.aai.aero/
	Bharatiya Nabhikiya Vidyut Nigam Limited The Nuclear Energy Programme in India has been visualized to grow in three phases. Phase – I consisting of natural uranium fuelled Pressurized Heavy Water Reactors (PHWR) which can sustain a capacity of 12 GWe for about 30 years with proven reserves of 50,000 t of natural uranium in the country. web site url: http://www.bhavini.nic.in
	Bird Group of Companies (BGC) The Bird Group of Companies (BGC), under administrative control of the Ministry of Steel, Government of India was part of erstwhile Bird & Company Ltd, which was nationalized by the Government of India by virtue of The Bird & Company Ltd ( Acquisition and Transfer of Undertakings and other properties ) Act, 1980 ( Act No. 67 of 1980). web site url: http://birdgroup.gov.in
	Broadcasting Engineering Corporation of India Limited BECIL, a Govt of India enterprise is a profit making PSE under Ministry of Information and Broadcasting, established on 24th March,1995.BECIL works as consultancy agency,as a system integrator and as a turnkey solution provider in the fields of Broadcast Engineering and Information Technology. web site url: http://www.becil.com/
	Central Mine Planning & Design Institute Limited CMPDI (Central Mine Planning & Design Institute Limited), an ISO-9001 company, holds the pre-eminent position as the India's largest consultancy organisation and the market leader in an expanding earth resource sector. web site url: http://www.cmpdi.co.in
	The Cotton Corporation Of India Ltd CCI was established on 31st July 1970 as a Government Company registered under the Companies Act 1956. In the initial period of setting up, as an Agency in Public Sector, Corporation was charged with the responsibility of equitable distribution of cotton among the different constituents of the industry and to serve as a vehicle for the canalization of imports of cotton. web site url: http://cotcorp.gov.in
	Educational Consultants India Limited (EDCIL) EdCIL( India) Limited is a Government of India enterprise offering consultancy services in all areas of education and human resource development, in India and beyond national boundaries with special focus on developing countries of Asia and Africa. web site url: http://edcilindia.co.in
	Export Credit Guarantee Corporation of India Limited Export Credit Guarantee Corporation of India Limited, was established in the year 1957 by the Government of India to strengthen the export promotion drive by covering the risk of exporting on credit.Being essentially an export promotion organization, it functions under the administrative control of the Ministry of Commerce & Industry, Department of Commerce, Government of India. web site url: http://www.ecgc.in/Portal/index.aspx
	Ferro Scrap Nigam Limited Ferro Scrap Nigam Limited is a joint sector company, incorporated on 28-3-1979. Presently it is "Mini Ratna II PSU"(IMS Certified) a Government of India company under Ministery of Steel. It is a wholly owend subsidiary of MSTC Limited and the share capital is INR 200 Million. FSNL undertakes the job of recovery and processing of scrap from slag and refuse generated during iron and steel making at Steel Plants. web site url: http://fsnl.nic.in/
	The Fertilizer Corporation of India Ltd. Incorporated on January 1961, FCIL was re-organised with effect from 1.4.1978.FCIL is a Central Government Undertaking under the administrative control of Ministry of Chemicals & Fertilizers (Department of Fertilizers).Management of FCIL is by a Board of Directors and Principal Executives. web site url: http://fertcorpindia.nic.in
	Goa Shipyard Limited Goa Shipyard Limited (GSL) established in 1957, is a leading ISO 9001-2008 certified shipyard on the West Coast of India, functioning under the administrative control of Ministry of Defence, Govt. of India.GSL is strategically located on the banks of river Zuari in Goa, a major international tourist destination well connected by its international airport and major port enroute all important shipping lines. web site url: http://www.goashipyard.co.in
	Heavy Engineering Corp. Ltd HEC was established in the year 1958 as one of the largest Integrated Engineering Complex in India. It manufactures and supplies capital equipments & machineries and renders project execution required for core sector industries. It has complete manufacturing set up starting from casting & forging, fabrication, machining, assembly and testing - all at one location backed by a strong design - engineering and technology team. web site url: http://www.hecltd.com/
	Hindustan Copper Limited (HCL) Hindustan Copper Limited (HCL), a public sector undertaking under the administrative control of the Ministry of Mines, was incorporated on 9th November 1967. It has the distinction of being the nation’s only vertically integrated copper producing company as it manufactures copper right from the stage of mining to beneficiation, smelting, refining and casting of refined copper metal into downstream saleable products. web site url: http://www.hindustancopper.com
	HLL Lifecare Limited HLL Lifecare Limited (HLL) commenced its journey to serve the Nation in the area of healthcare, on 1st March 1966, with its incorporation as a corporate entity under the Ministry of Health and Family Welfare, Government of India. HLL was set up in the natural rubber rich state of Kerala, for the production of male contraceptive sheaths for the National Family Welfare Programme. web site url: http://www.lifecarehll.com
	Hindustan Prefab Limited (HPL) Hindustan Prefab Limited (HPL) was incorporated in 1953.HPL thus became a fully integrated company with modern prefabrication facilities and a railway siding of its own in the heart of Delhi to undertake faster and challenging jobs in the country. web site url: http://www.hindprefab.org List of Maharatna, Navratna and Miniratna CPSEs As per available information (as on May, 2012) Maharatna CPSEs Coal India Limited Indian Oil Corporation Limited NTPC Limited Oil & Natural Gas Corporation Limited Steel Authority of India Limited Navratna CPSEs Bharat Electronics Limited Bharat Heavy Electrical Limited Bharat Petroleum Corporation Limited GAIL (India) Limited Hindustan Aeronautics Limited Hindustan Petroleum Corporation Limited Mahanagar Telephone Nigam Limited National Aluminium Company Limited NMDC Limited Neyveli Lignite Corporation Limited Oil India Limited Power Finance Corporation Limited Power Grid Corporation of India Limited Rashtriya Ispat Nigam Limited Rural Electrification Corporation Limited Shipping Corporation of India Limited Miniratna Category - I CPSEs Airports Authority of India Antrix Corporation Limited Balmer Lawrie & Co. Limited Bharat Dynamics Limited BEML Limited Bharat Sanchar Nigam Limited Bridge & Roof Company (India) Limited Central Warehousing Corporation Central Coalfields Limited Chennai Petroleum Corporation Limited Cochin Shipyard Limited Container Corporation of India Limited Dredging Corporation of India Limited Engineers India Limited Ennore Port Limited Garden Reach Shipbuilders & Engineers Limited Goa Shipyard Limited Hindustan Copper Limited HLL Lifecare Limited Hindustan Newsprint Limited Hindustan Paper Corporation Limited Housing & Urban Development Corporation Limited India Tourism Development Corporation Limited Indian Railway Catering & Tourism Corporation Limited IRCON International Limited KIOCL Limited Mazagaon Dock Limited Mahanadi Coalfields Limited Manganese Ore (India) Limited Mangalore Refinery & Petrochemical Limited Mishra Dhatu Nigam Limited MMTC Limited MSTC Limited National Fertilizers Limited National Seeds Corporation Limited NHPC Limited Northern Coalfields Limited Numaligarh Refinery Limited ONGC Videsh Limited Pawan Hans Helicopters Limited Projects & Development India Limited Railtel Corporation of India Limited Rashtriya Chemicals & Fertilizers Limited RITES Limited SJVN Limited Security Printing and Minting Corporation of India Limited South Eastern Coalfields Limited State Trading Corporation of India Limited Telecommunications Consultants India Limited THDC India Limited Western Coalfields Limited WAPCOS Limited Miniratna Category-II CPSEs Bharat Pumps & Compressors Limited Broadcast Engineering Consultants (I) Limited Central Mine Planning & Design Institute Limited Ed.CIL (India) Limited Engineering Projects (India) Limited FCI Aravali Gypsum & Minerals India Limited Ferro Scrap Nigam Limited HMT (International) Limited HSCC (India) Limited India Trade Promotion Organisation Indian Medicines & Pharmaceuticals Corporation Limited M E C O N Limited National Film Development Corporation Limited National Small Industries Corporation Limited P E C Limited Rajasthan Electronics & Instruments Limited

Tool Design - A Perfect Mold Design-Metal to plastic-2012 Award for Single component molding..

2012-07-02T02:43:00.002-07:00

Brand Owner: Nissan

Designer: MPC, Inc.

Machinery Manufacturer:Demag Plastic Group

Materials: Solvay Specialty Polymers

Molder: MPC, Inc.

Moldmaker: Industrial Molds

Product Description:

This Water Outlet Assembly was a metal to plastic conversion which integrated two components into one assembly. The thermoplastic replacement is a single molded product, delivering greater than 25% cost savings and a 450 gram weight reduction. This assembly is made possible through the development of a complex injection mold, incorporating multiple sequential valve gates to prevent material over-pack and gas entrapment. The ten male ports are created without a parting line usually required with conventional injection molding. Seamless hose joints are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex product in one-piece. Scientific molding was used to activate the valve gates and monitor product quality. The molding process was combined with a robot to monitor and remove non-conforming product. The plastic product eliminates the need for 18 machining operations and eliminates two leak paths. This plastic product achieves machined metal tolerances right out of the mold without any secondary machining processes. The injection mold tooling will last the life of the five year program, with annual volumes of approximately 800,000 pieces. Traditional cast aluminum tooling needs replacement after approximately 100,000 cycles, which adds to the cost savings.

Why is the product innovative?

This Water Outlet Assembly was a metal to plastic conversion which integrated two components into one assembly. The thermoplastic replacement is a single molded product, delivering greater than 25% cost savings and a 450 gram weight reduction. The plastic product eliminated the need for 18 machining operations and eliminated two leak paths. This plastic product achieves machined metal tolerances right out of the mold without any secondary machining processes. The injection mold tooling will last the life of the five year program, with annual volumes of approximately 800,000 pieces. Traditional cast aluminum tooling needs replacement after approximately 100,000 cycles, which adds to the cost savings.

The main function of the water outlet is to act as a manifold for the cooling system. The water outlet features ten seamless barb ports that feed coolant to and from the transmission cooler, throttle cooler, heater core, oil cooler, and provides coolant to the radiator. The outlet also includes a press-in place seal, sealed threaded insert, a wire harness bracket, an oil drip rail, and houses the thermostat. The ten male ports are created without a parting line usually required with conventional injection molding. Seamless barb joints are made possible through precision timing of multiple valve gates and multiple slide actions to properly form this complex product in one-piece.

To successfully mold this water outlet requires precisely timed hydraulics and mechanical mechanisms, along with the study of the flow of plastic into the mold to optimize the filling of the cavity. After the mold is closed the valve gate in location one is activated. The molten plastic then passes over the transducer and the temperature sensor, which closes valve gate location one. Valve gate location two activates, allowing the molten plastic to pass over the second transducer, which then closes valve gate location two. During this time the part is allowed to cure for a period of time. During the same time the mold is closed the slide pull sequencing begins. Three custom cylinders are sequenced to pull past under cuts. During this sequence six ports are released. While the mold opens a mechanical slide action releases two additional ports. The final two ports are released by a two stage Aside action. A hydraulic slide action holds the part into place to allow for the remaining port cavities to be pulled. The part is ejected into a robotic arm. The valve gate hot runner system was paired with a complex hot oil cooling system.

The valve gate sequencing prevents any material from over packing and any gas entrapment. The precise timing of the two valve gates and multiple slide actions allow for the part to properly form. Scientific molding process was used to precisely activate the valve gates and monitor product quality. The molding process monitoring was combined with the press robot to monitor and deliver a defect free product.

The combination of sequencing, precision timing, multi slide actions, scientific molding process, and robotics resulted in a world class product.

This Tool is a Very Big Challenge for the tool designer.CIPETIANs please note it out...

Product Design -Folding Bike with a Built-in Briefcase...BIKE With A BAG...

2012-07-02T02:00:00.001-07:00

BIKOFF is a folding bike with a built-in briefcase designed by Marcos Madia. The Bikoff was a finalist in the Seoul Cycle Design competition, but is currently just a concept. The designer made the fancy carbon fiber briefcase an essential element of his Bikoff bike concept’s structure, adding stiffness to what would otherwise be a very flexible frame design. You don’t have to carry any bags, because this folding bike has the briefcase.

Tool Making - Certifications for Manufacturing Engineers...

2012-06-25T03:36:00.000-07:00

Society of Manufacturing Engineers (SME) provides certifications to manufacturing engineers, which is well respected and recognized among the manufacturing industry. SME provides four certifications, viz... Certified Manufacturing Technologist (CMfgT), Certified Manufacturing Engineering (CMfgE), Lean Certification and Six Sigma Certification. In this blog i will cover CMfgT and CMfgE.

Certified Manufacturing Technologist (CMfgT): This certification tests the competencies in the fundamentals of manufacturing. Certification is useful for beginners in the manufacturing industry. To apply for this certification one should have minimum of 4 years of combined manufacturing experience and education. Topics covered in the certification exam include basic maths, applied science, manufacturing process, manufacturing management, quality control, manufacturing economics, materials, design, computer applications and automation.

Certified Manufacturing Engineering (CMfgE): This certification showcase the knowledge in advance manufacturing and demonstrates that certified personnel has the comprehensive knowledge of manufacturing process and practices. To apply for this certification one should have minimum of 8 years of experience or 7 years of experience with CMfgT certification. For test candidate can select any one of the area - Integration & Control, Process, Support Operations and Management.

http://www.sme.org/certified-manufacturing-technologist-certification.aspx

http://www.sme.org/certified-manufacturing-engineering-certification.aspx

http://www.sme.org/engineering-manager-professional-certification.aspx

this links help you to get certificate as a manufacturing expert.CIPETIANS please visit and enrich your values..

Product Design - New Product Development Professional (NPDP) Certification for product development professionals

2012-06-25T03:19:00.000-07:00

NDPD is one of the recognized certification for engineers/professionals working in the product design and development industry. NDPD certification is provided by Product Development and Management Association (PDMA), which is a premier global advocate for product development and management professionals.

Why NDPD certification ?

Covers business aspects along with new product development process.
Covers product design, product management and product marketing.
Learning best practices in product development process.
Credibility associated with PDMA and the certification.

Eligibility requirements for NDPD certification:

Education: Bachelor’s or higher university degree (or an equivalent degree) from an accredited institution, Or High school diploma or equivalent.
Experience: At least TWO years of professional-level experience working in new product development ( For bachelor degree holders) Or at least FIVE years of professional-level experience working in new product development ( For High school diploma holders)
Exam: Passing score on the NPDP Certification Exam

Topics Covered in the NDPD certification:

Portfolio Management, Strategy
New Products Process
Market Research, Tools and Metrics
Teams, People, and Organizational Issues

Certification Test:

It's a 3 1/2 hours exam with 200-questions.

Results will be provided immediately upon completion.

The passing requirement is 75% score

Exam Fee $200

CIPETIANS please note this and visit the website
http://www.pdma.org and register you as a PRODUCT DESIGNER...

Product Design - 5 Important points for Development of a NEW Product...

2012-06-25T02:48:00.000-07:00

Product design and development starts with indentifying the needs of a customer in terms of specification and requirements of a product. There are various qualities of product to be considered before taking up the design and development. Products which are introduced into the market without considering the following 5 important factors / qualities are doomed to fail in the market place given the high level of competition.

Convenience: Competitive world made most people to use products and services which provide lot of convenience. People look for products that are simple, understandable, easy to use, and available when and where customers wish to use them.

Productivity: One of the most important factors in a product customer looks for is productivity. Customers obtain direct and indirect savings from the superior quality, accuracy, and reliability of the products or services i.e. by a productive product.

Product choice: Customization is the new phrase used by industry in offering product choices. Customers should be offered a wider range of products levels which increase variety and flexibility.

Low Price: Customer always looks for products with high quality low priced products! Customers enjoy direct savings as the upfront cost of purchase or ongoing costs of a product use are low.

Feel Good Factor: No one can agree more! Believe it or not “feel good factor” is the one which determines how your customer think (or promote) about the product. Customers should feel better for making the purchase because of enhanced prestige, perceived excellence, or uniqueness. Product offered by you should be enjoyable or entertaining to use, or is made for ethical reasons.

Overall companies and product designers should think about creating value to the customers by building quality products. Companies which have seen high level product success before taking up development of a product each time questions themselves how product quality can be improved. Let us know what other important factors / qualities to be considered for development of a product.

Plastic Injection Moulding - SECRETS OF SUCCESSFUL THIN-WALL MOLDING

2012-06-15T23:28:00.000-07:00

SECRETS OF SUCCESSFUL THIN-WALL MOLDING

Demands to create smaller, lighter parts have made thin-wall molding one of the most sought after capabilities for an injection molder. These days, "thin-wall" is generally defined by portable electronics parts having a wall thickness less than 1 mm. For large automotive parts, "thin" may mean 2 mm. In any case, thinner wall sections bring changes in processing requirements: higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. These process changes have in turn prompted new considerations in mold, machinery, and part design.

Machinery considerations

Standard molding machinery can be used for many thin-wall applications. Capabilities built into newer standard machines go well beyond those of 10 years ago. Advances in materials, gating technology, and design further expand the capabilities of a standard machine to fill thinner parts.

But as wall thicknesses continue to shrink, a more specialized press with higher speed and pressure capabilities may be required. For example, with a portable electronics part less than 1 mm thick, fill times of less than 0.5 sec and injection pressures greater than 30,000 psi are not uncommon. Hydraulic machines designed for thin-wall molding frequently have accumulators driving both injection and clamping cycles. All-electric and hybrid electric/hydraulic models with high speed and pressure capabilities are starting to appear as well.

To stand up to the high pressures involved, clamp force should be a minimum of 5-7 tons/sq in. of projected area. In addition, extra-heavy platens help to reduce flexure as wall thicknesses drop and injection pressures rise. Thin-wall machines commonly have a 2:1 or lower ratio of tiebar distance to platen thickness. Also, with thinner walls, closed-loop control of injection speed, transfer pressure, and other process variables can help to control filling and packing at high speeds and pressures.

When it comes to shot capacity, large barrels tend to be too large. We suggest you aim for a shot size of 40% to 70% of barrel capacity. The greatly reduced total cycle time seen in thin-wall applications may make it possible to reduce the minimum shot size to 20%-30% of barrel capacity, but only if the parts are thoroughly tested for property loss due to possible material degradation. Users must be careful, as small shot sizes can mean longer barrel residence times for the material, resulting in property degradation.

Molds: make 'em rugged

Speed is one of the key attributes of successful thin-wall molding. Faster filling and higher pressures are required to drive molten thermoplastic material into thinner cavities at a sufficient rate to prevent freeze off. If a standard part is filled in 2 sec, then a reduction in thickness of 25% potentially can require a drop in fill time of 50% to just 1 sec.

One benefit of thin-wall molding is that as wall sections drop, there is less material to cool. Cycle times can drop by 50% with aggressive wall-thickness reduction. Careful management of the melt-delivery system can keep runners and sprues from diminishing that cycle-time advantage. Hot runners and heated sprue bushings are often used in thin-wall molding to help minimize cycle time.

Mold material should be reviewed too. P20 steel is used extensively in conventional applications, but due to the higher pressures of thin-wall molding, molds must be built more robustly. H-13 and other tough steels add an extra degree of safety for thin-wall tools. (If possible, you will also want to select a molding material that doesn't accelerate mold wear when injected into the cavity at high speeds.)

However, robust tools cost money—possibly even 30% to 40% more than a standard mold. Yet the cost is often offset by increased productivity. In fact, the thin-wall approach is frequently used to save money on tooling. A 100% increase in productivity can mean that fewer molds need to be built, thereby saving money over the life of a program.

Here are some more tips on tool design for thin walls:

For aggressive thin-wall applications, use steel harder than P20, especially when high wear and erosion are expected. H-13 and D-2 steels have been successful in gate inserts.

Mold interlocks sometimes can stave off flexing and misalignment.

Cores that telescope into the cavity can help reduce core shifting and breakage.

Use heavier support plates (often 2 to 3 in. thick) with support pillars (typically preloaded 0.005 in.) under the cavities and sprue.

Use more and larger ejector pins than with conventional molds to reduce pin pushing.

Consider strategic placement of sleeve and blade knockouts.

No. 2 diamond polish on cores and ribs can eliminate problems of part sticking. Mold surface treatments, such as nickel-PTFE can also improve part release.

Venting is critical and can be facilitated with vented core pins and ejector pins, as well as venting along up to 30% of the parting line around the part. Vents are typically 0.0008 to 0.0012 in. deep and 0.200 to 0.0400 in. wide. While not usually necessary, some processors have sealed the parting line with an O-ring in order to pull a vacuum on the cavity for quick gas evacuation.

With higher injection speeds, gates larger than the nominal walls help reduce material shear and gate wear and help prevent freeze-off before good packing is achieved.

Gate inserts with a Rockwell (Rc) hardness greater than 55 are typically used to withstand high injection pressures.

When gating directly onto a thin wall with a sprue, pinpoint, or hot-drop, use gate wells to reduce stress at the gate, aid filling, and reduce part damage when degating.

Hot manifolds can help reduce pressure loss in runner systems, but they require at least 0.5-in.-diam. inner passages with no sharp corners or dead zones. Manifolds should have external, not internal, heaters. Valve gates, if used, must be non-restrictive and built to take high pressure.

In addition, cooling of the cores and cavities is more critical and challenging in thin-wall applications. Two important guidelines are:

Non-looping cooling lines should usually be located directly in the core and cavity blocks to help keep the mold surface temperature as consistent as possible.

Instead of decreasing coolant temperature to maintain the desired steel temperature, it is generally better to increase the amount of coolant flow through the tool. As a rule of thumb, the difference in temperature between the delivery coolant and return coolant should be no more than 5° to 10° F.

STANDARD VS. THIN-WALL PROCESSING
Key Factors	Conventional	Thin-Wall
Typical Wall, in.	0.080-0.120	0.050-0.080	<0.050
Machinery	Standard	High-end	Custom
Inject. Pressure, psi	9000-14,000	16,000-20,000	20,000-35,000
Hydraulic System	Standard	Standard	Accumulators on injection & clamp units. Servo valves.
Control System	Standard	Closed-loop on injection speed, hold pressure, decompression speed, screw rpm, backpressure, and all temperatures.	Same as at left, with resolution of 0.40 in. on speed, 14.5 psi on pressure, 0.004 in. on position, 0.01 sec on time, 1 rpm on rotation, 0.10 ton on clamp force, 2° F on temperature.
Processing
Fill Time, sec	>2	1-2	0.1-1
Cycle Time, sec	40-60	20-40	6-20
Tooling	Standard	Better venting, heavier construction, more ejector pins, better polish	Extreme venting, very heavy construction, mold interlocks, precise surface preparation, extensive ejection features, mold costs 30-40% higher than standard.

Tool Making - Where To use Milling m/c or EDM - That Is The Question? Ans for that is...

2012-05-10T02:48:00.000-07:00

Moldmakers are under constant pressure to cut costs and production time. Determining whether high-speed milling or EDM'ing - or perhaps a combination of both - is the best option may be what makes or breaks a job.

The key is deciding which process is right for your project.

The mold and die industry today needs to respond to market demands quicker and with greater flexibility than ever before. To stay competitive, a moldmaking shop must decrease production times and costs while at the same time ensuring that quality meets the customer's expectations. An intelligent combination of high-speed milling (HSM) and electrical discharge machining (EDM) can often become a decisive factor in the race for on-time delivery. The process of choosing the appropriate technology most often depends on the specific manufacturing scenario in a mold and die shop. The goal however should be a continuous feedback of up-to-date information on all the technologies available for die making to the design engineer. This facilitates part design and enables the engineer to choose the most appropriate manufacturing technique with respect to criteria such as accuracy, cost, lifetime, etc. Carriers for this information can be features, i.e., part segments that can be used along the whole CAD/CAM process chain.

Current Situation

The three major products of mold and die making - forging dies, injection and diecasting molds and deep-drawing dies - create different constraints with regard to the application of the available technologies (see Figure 1). The flat structures and typically easy to cut materials of deep-drawing dies are usually best machined by milling. EDM has found widespread use for the production of forging dies, based on the high strengths of the materials used. However, due to the low depth of contours and relatively large concave radii, a complete machining by milling has proven to be industrially feasible and economical.

Figure 1: Characteristics of tools and their machining in tool and die making.

The milling of injection and diecasting molds, on the other hand, is a challenge. Deep slots (e.g., for ribs or webs) and small radii can only be machined using slim and, consequently, chattering tools, reducing process control and stability} (see Figure 2). Additionally, economically viable feeds and speeds are only achieved for high spindle speeds that are usually not available in the standard mold and die shop. It is thus necessary to continuously monitor the development of EDM and milling, redefining their technological and economical barriers, to be able to make an optimum choice for machining.

Figure 2: High-speed machining of an injection mold with slim milling tools.

Besides geometric constraints, other factors such as material, function, surface quality or subsurface damage of a tool influence the technology decision between HSM and EDM(see Figure 3). Especially when these two techniques are used in combination, their respective influence on the mold's surface has to be considered, since varying adhesion for coatings or problems with lacquering of the molded parts may be the result.

Figure 3: Mold requirements and related process planning.

Using Features to Decide Which Technology to Use

The decision for a certain technology is most often based on personal background and not on the actual technological potentials, limits and interdependencies. To convey this information in an objective manner to the design, process planning and manufacturing engineers, a structural approach is needed. Implementation can be achieved through technology features that combine information about part requirements with suitable manufacturing alternatives. We understand technology features to be a group of coherent geometrical primitives that can be associated with a certain method of production or technology. Features in general can be used along the whole product development and production chain - in the design phase, during function analysis and during assembly. In manufacturing, features help with production and technology planning.⁷

If technology features are to be used in mold and die making, each feature has to be coupled to a machining sequence. Adding to the complexity of the task of building up such a sequence, the geometries to be created appear inverted at the tool. Even though CAD/CAM systems are becoming more powerful and versatile, a fully automatic recognition of features, together with the calculation of an optimized machining sequence (taking various technologies into account), could not yet be implemented. Some systems do offer automatic identification of grooves and slopes, but do not include functionality to help with the milling/EDM decision, which would require extensive surface and volume analysis over the whole die. However, for now features can be created interactively and coupled with technology information and may then be used for process planning.

A Practical Example

Looking at the high-speed milling and EDM technologies, a decision has to be made whether a complete machining can be done by either one of the processes or if an intelligent combination will yield an optimum with respect to quality, time and cost. For the example shown in Figure 4 - a detail of a complex injection mold with narrow grooves of different depth and a small draft angle - three manufacturing alternatives as discussed above were compared. A complete machining by milling was impossible due to the grooves' depths; a complete machining by EDM would have been too time-consuming. A combination of high-speed milling down to a groove depth of 30 mm with a subsequent EDM proved to be the most efficient machining alternative.

Figure 4: Feature-based technology planning for a groove.

The data gathered on machining time, cost and feasibility was fed back into a database, along with data of numerous other, similar experiments (see Figure 5). Now, with the selection of a geometry in the CAD/CAM system, e.g., a deep groove, the system suggests a machining sequence, including information on the result to be expected and the relative cost, as well as additional processing constraints that may be of relevance (see Figure 6). For the example shown, the database suggests a technological feasibility limit for milling of l_kr = 20 mm for the length of the milling tool and R = 0.25 D 0.5 mm for its radius (Figure 5).

Figure 5: Technology database with material and geometry information.

Figure 6: Machining alternatives retrieved from the technology database for a certain feature.

The actual use of the CAD/CAM system's suggestion for machining depends on the specific situation of a company concerning workload, scheduling or hourly rates. Also, some restrictions exist with respect to machine availability and their specifications. For milling machines, restrictions can result from speeds, feeds, spindle power, acceleration, stiffness, etc.; for EDM machines, these limiting parameters could be generator power, planetary radius, contour control and others. Of course, the database feeding the CAD/ CAM system with technology information can be tailored to reflect the resources actually available; however, a continuous monitoring of technological development should always be established to make sure that innovations are implemented early to stay on the competitive edge.

An Integrated Milling/EDM Cell

However, using features to come up with optimum process chains is not fully effective in a conventional manufacturing environment. Considering that, even for small molds, sometimes as many as 300 electrodes are needed, an efficient realization of the manufacturing sequence is equally important. An integrated milling/ EDM cell that is being developed at the Fraunhofer Institute for Production Technology IPT jointly with an industrial consortium may turn out to be the most economic approach to addressing the manufacturing, quality and material flow issues. The cell consists of a milling machine, an EDM machine, a workflow management system, computers for NC data generation, a metrology station for intermediate and final quality control and a pallet handling system, with all stations being connected to a central database (see Figure 7 and 8). Typical errors resulting from numerous setups of workpieces and electrodes are avoided by using the palleting system. An additional advantage is that adjustments of workpieces and electrodes are done on stations separate from the EDM and milling machine, decreasing machine down times. Furthermore, the pallet racks and handling system allow for unmanned shifts, increasing the overall economics of the cell. The computer-assisted workflow management facilitates control of the cell and introduces flexibility in case of unforeseen changes or repair work.

Figure 7

Figure 8: Integrated milling/EDM cell.

Conclusion

New developments in machinery, process technology and software help tool and die makers become more efficient through simulation and automation. Using features that retain a company's process know-how during tool design and process planning ensures that optimized manufacturing sequences are laid out. If these are realized within an integrated EDM/ milling cell, a maximum productivity gain can be expected. Still, the technical expertise of the manufacturing engineers and experience gained over many years can not be replaced by such a system and represents the main capital of the mold and die shops.

Kanyakumari - Rare Photos of kanyakumari - Part-2

2012-05-01T04:04:00.000-07:00

Old View Of NAGARAJA Temple in NAGERCOIL...

Old View Of KANYAKUMARI Temple

Old Bus Service in Nagercoil

Old FRONT View Of KANYAKUMARI Temple

Old View Of Suchindrum Temple

Old View Of KANYAKUMARI SEA b4 1960

Old View Of KANYAKUMARI's TWIN ROCK
b4 build VIVEKANANDA ROCK & THIRUVALLUVAR STATUE

FOR MORE DETAILS ABOUT KANYAKUMARI TOURIST PLACES and TOUR EXPERIENCE
VISIT THE BEAUTIFUL full fledged Kanyakumari website which is shown below:- Clicking that link take you to that Beautiful page :-
http://heartin-kanyakumari.blogspot.in

Tool Making - How to Choose the Correct Ejector Pin?

2012-04-24T23:28:00.001-07:00

HOW TO SELECT EJECTOR PIN:-

There are many different kinds of ejector pins in the market nowadays and it is a challenge for users to select the correct ones. In most cases, selecting an inappropriate ejector pin is wasting resources andcreates inefficiency in production.

Many of us understand the importance of material and related hardness when selecting an ejector pin. However, in this article, we will focus on another important factor and that will be the working temperature.

Working Temperature

Working temperature is crucial because it affects the lifetime or durability of an ejector pin. For example, if the working temperature is high and the ejector pin being used is made for a low working temperature environment, then the ejector pins will certainly not last long.

In the market, there are three common types of ejector pins: (1) through hard pins, (2) nitride H13 pins and (3) the newly developed black ejector pins. All of these pins are excellent to use; however, each has its own characteristics and is designed to be used in a specific environment.

Through Hard Pins
The design of the through hard pins involves the same hardness throughout the diameter of the ejector pin. With this characteristic, the ejector pin can last much longer in working temperatures below 200oC. It is mainly suitable for plastic injection molds.

Nitride H13 Pins
If the working temperature goes beyond 200oC, then nitride H13 pins will be a much better fit. The reason is that the surface of these pin has a hardness of HRC 65 to 70, which can lead to a much better life expectancy in high working temperatures. These pins are best for die casting.

Black Ejector Pins
Nitride H13 pins are not suitable for working temperatures that exceed 600oC, so black ejector pins were developed as an option. These pins have a special black surface coating treatment on the entire pin that can sustain working temperatures up to 1,000oC. Also, the special black surface treatment provides additional self lubrication to the ejector pin, making it an excellent fit for automobile injection molding. These pins are suitable for most working temperatures, but the cost of such a pin is higher.

Summary

From the above comparison, it is evident that different types of ejector pins are suitable for different environments, which is why working temperature is a necessary factor to consider before your final selection. This will also apply to ejector sleeve and ejector blade selection.

Product Design - Stunning Product Designs of BIKES-PART-1

2012-04-24T22:08:00.001-07:00

Luxury Tricycle “Enzo Trike ” from Kid Kustoms

Company Kid Kustoms aims to make a tricycle, rather a children’s tricycle, a source of pride, both the child and his parents. This tricycle called “Enzo Trike” comes with a huge list of accessories including a deep aluminum tub fixed to a single axle and custom billet disk wheels, or the matching 52 spoke wheels. Crafted from the finest material available and certain to become a family heirloom, the trike features interchangeable fenders with functioning brake lights, custom pedals, headlights, exhaust tips and grips to make sure no two trikes are alike. The special shape of the wings and frames, headlight, and other design decisions, force these tricycle to look very special. You’ll be able to make your child happy for $950.

Honda’s “Motor Compo”

On exhibition at Tokyo Motor Show 2011 Honda represent “Motor Compo”, a foldable electric scooter, which design hearkens back to the 1980′s “Motocompo”. The Motor Compo’s total length and height are under 1 meter (39”), which makes it super compact. It also features a removable battery specifically designed to be used as an emergency power source in case of disaster.”Looking at the “Motor Compo” now, it’s as if we combined the memories of both the city [line of honda cars] and the [1980's original] motocompo to create an image to represent this new generation.” Take a look!

Futuristic Bike “Detonator” by Daniel Simon

The Cosmic Motors Detonator is an unique concept created by German automotive futurist Daniel Simon for his futuristic vehicle design company, “Cosmic Motors”. Simon calls this futuristic bike a “street cruiser bike built for humanoid droids.” Simon obtained his degree in vehicle design in 2001 at the University of Applied Science in Pforzheim, Germany. After completion, Simon went to Barcelona and designed concept cars for Bugatti and Lamborghini, followed by five years at the VW Group’s Advanced Studio where he is currently designing virtual vehicles for his brand Cosmic Motors. He has published a book, “Comic Motors” and continues to offer his services to premium carmakers while designing his own concepts.

Hybrid Bike Concept “INgSOC”

Today we want to show you very interesting bike concept INgSOC by designers Edward Kim and Benny Cemoli. Unusual combination of aerodynamic shapes of triathlon designs, flexible handling of traditional bikes and advanced hybrid power technology turns ordinary bike into vehicle from fantastic movies. “The frame is constructed from carbon fiber reinforced polymer (CFRP) for its high strength yield to weight ratio. Adaptability comes from mono-direction reinforcing of the frame, directing stiffness by orienting carbon fiber strains along a projected trajectory. The battery which powers the motor, integrated front and rear lights, as well as a charging dock for communication devices, entertainment, or navigation is directly charged from the rider’s own energy output to maximize efficiency.”

Electric Motorcycle “Orphiro”

Orphiro is not just an electric bike, it’s efficient, quiet and an all around a great option for sustainable mobility. This battery-powered cruiser made in the Netherlands. Company founder Alexander Steegh says the slick streamlined exterior covers five lithium-ion batteries putting out 72 volts. Top speed is 75 mph, and recharging the batteries takes six and a half hours. “Sustainable fun, a cool design and comfortable driving. Orphiro combines all ideals when it comes to new motorcycling: fully electric, fast loading and one with nature.”

Voltitude Folding Urban Electric Bike

This compact electric vehicle called Voltitude was presented at the Geneva Motor Show. Red color and cross on the body resemble folding swiss knife. Folded bicycle-scooter has a minimum size. "Even though its size and wheelbase is absolutely comparable to a normal bicycle, the Voltitude bike can be folded in a very small space such as a locker, cupboard or car boot. Basically two Voltitude bikes can be stored in a space similar to a European washing machine."

Kanyakumari - Beauty of Kanyakumari + PHOTO's ONLY (PART-1)

2012-04-24T03:07:00.001-07:00

MAP WITH DIFFERENT COLOUR CODE IDENTIFICATION

MAP WITH PHOTOS WHICH THE PLACE IS FAMOUS FOR...

MAP WITH TRAIN, ROAD , RIVER and ALL HIGHWAY DETAIL

MAP WITH EACH VILLAGE AND ALL MAJOR PLACES of DISTRICT

What 's in KANYAKUMARI - A short GLANCE...

C - KANYAKUMARI...

AT AFTERNOON IN KANYAKUMARI FROM HELICOPTER

AT EVENING IN KANYAKUMARI

AT NIGHT IN KANYAKUMARI

CLOSE-UP SHOT OF VALLUVAR

ON ROAD SIDE...

ON THE ENTRANCE TO KANYAKUMARI FROM CHENNAI...

ON ROAD SIDE...

a SHOT FROM SMALL HILL..

a SHOT OF MATHUR BRIDGE & SURROUNDING SCENERY

a SHOT OF HILLOCK JAIN TEMPLE & SURROUNDING SCENERY

a SHOT OF TIRPARAPPU WATERFALLS & SURROUNDING SCENERY

a SHOT ON THE SIDE OF A RIVER IN KK...

a SHOT OF SEA SHORE's IN KANYAKUMARI

a SHOT OF RUBBER ESTATE IN HILL AREA

a SHOT OF KALIKESAM FOREST

a SHOT NEAR BHOOTHAPANDY SHIVA TEMPLE

This are some of the PHOTO's from kanyakumari District. Remaining PHOTO's YOU CAN VIEW in NEXT POST - PART-2

Tool Making - Six Points You Must Want to Know about High-Feed Milling...

2012-04-11T04:51:00.000-07:00

A look at why the benefits of high-feed milling can significantly outweigh the potential challenges.High-feed milling focuses on removing as much material as possible in the shortest amount of time. It’s a process that’s been around for a while and can open doors to more lucrative business opportunities. Unfortunately, some manufacturers have moved away from the process due to what they consider reliability concerns. And it’s true, if not applied properly, high-feed milling can create some unfavorable results.

                                           For those willing to take the leap, the benefits of high-feed milling can significantly outweigh the potential challenges. The process offers amazing productivity, nearly triple the metal removal rate of conventional methods, and increases tool life. However, there are several things you must know in order to make high-feed milling successfully work for you.

1.   Machine Tools
                                    Rigid, highly capable machine tools are a must because the cutters run at high feeds, which require the machine and the control to keep up with these demands. New equipment is a lot more advantageous when dealing with high-feed milling technology. It’s possible to apply new high-feed mills on older machines, but the process works best with large cutters because the feeds and speeds are not as accelerated.

2.   Inserts
                     Trigon-style inserts provide the lowest possible lead angle over round or square inserts. Low lead angles produce a much thinner chip, which in turn, requires higher feedrates to maintain proper chip thickness for the insert geometry. The lower lead angle also directs the cutting forces in the axial direction, pushing up into the spindle, which is more stable and easier on the machine. Higher lead angles create thicker chips requiring less adjustment in feedrate. They also produce more radial force causing vibration and stress on the spindle bearings.

High-feed cutters that use trigon-style inserts, providing the lowest possible lead angle over round or square inserts to direct cutting forces in the axial direction, which is more stable and easier on the machine

3.   Insert Grade
                              Make sure you have the right insert grade for your job because you don’t want your tool to fail prematurely, especially if you’re performing a lights-out operation. Choosing the correct insert grade for the type of material you are machining can increase tool predictability, resulting in fewer tool changes, less rejects and less reworking.

4.   Machining Application
                                                   Not every machining method is created equal. While high-feed mills with long overhangs are great, for high-speed options for milling processes, you need to remember you can’t run them as fast as you would tools with shorter overhangs without adding specialized vibration dampening toolholders or reducing cutting speed. When a tool with long overhang operates faster than it should, you can experience increased vibrations, causing insert chipping and premature insert failure.

High-feed mills well suited for plunge milling because they are free cutting and provide efficient chip evacuation.

5. Programming
Optimize the cutter path through proper programming, so you don’t put any unrealistic demands on the cutting tool. For example, when you are in a mold and come to a corner, changing directions without using a smooth transition is very hard on a tool because it creates a large angle of engagement. A good rule of thumb is to program an arc that is 50 percent larger than the cutter diameter. If using a 2.0” cutter, program a 3” diameter arc. Programming an arc in pocket corners reduces the angle of engagement and avoids overloading the cutter. Machine tools can also have problems in this area because several calculations are involved in generating an arc. If the machine tool can’t properly calculate the arc, the toolpath can become erratic.

Where drilling would draw too much power on low-power machines, this high-feed mill offers the option of instead creating holes by helical ramping.

6. Engaged Tools
Keep your high-feed mills as engaged as possible across the full diameter or less than half the insert width. One of the reasons these mills work so well is because their cutting forces are directed at the machine spindle in the axial direction to create balance. If you use the same cutter and only engage it 50 or 60 percent of the diameter, you will experience push and increased vibrations because the cut is unbalanced.

Tool Making - Idea for Reduce Production Costs and Maintain Precision..

2012-03-21T01:03:00.000-07:00

One of the greatest challenges facing moldmakers today is reducing production costs while still maintaining high levels of precision. Moldmakers have frequently relied on one of two technologies to help them accomplish this: hot runner systems or mold base quick-change systems. Hot runner systems produce cleaner, more precise parts and eliminate material waste. Mold base quick-change systems reduce the time it takes to swap out molds and enable molders to produce different parts in the same system. Both technologies have distinct advantages, but recent advancements now enable moldmakers to combine all the benefits of mold base quick-change and hot runner technology in one system.

A combined mold base quick-change/hot runner system allows molders to substitute different mold inserts into a mold and produce a variety of parts in the same system with little downtime.

By understanding the potential of this type of system, designers can now engineer the cost-saving features of both products into a mold, and as a result, significantly reduce the cost of part production. This article will focus on the benefits of combining these systems in mold designs, because the more moldmakers know about this technology, the better they will be able to improve their offer to molders.

The Mold Base
The mold base quick-change system approach is based on an unlimited number of companion insert molds that are easily interchanged within a single quick-change frame. The frame remains in the molding machine during mold changeovers, resulting in increased uptime and cost reductions. It works with any standard mold base in any molding machine up to 500-ton capacity.

The frame is installed without modifying the machine. Standard mold bases equipped with companion ear plates are interchanged within this adapter frame. Just one adapter frame accommodates an unlimited number of standard mold bases. While these frames can remain in the machine indefinitely, they are easily transferred to other machines. No other special mounting hardware is required.

This system is based on a unique slide and clamp approach to mold changeovers. Standard mold bases equipped with ear plate sets simply slide in and out of the quick-change adapter frame. Just one adapter frame is needed for each molding machine selected for quick-change operation.

A mold base quick-change system approach uses a frame that remains in the molding machine during production changeovers. The frame is installed without modifying the machine and just one adapter frame accommodates an unlimited number of standard mold bases.

For installation simply clamp the quick-change adapter frame to the platens of the molding machine. Companion ear plates are bolted to the standard mold bases to be interchanged in the machine. Both the machine and the standard mold bases are now ready for production changeovers in less than 10 minutes.

The Hot Runner
Hot runner systems were created out of a need to mold plastic parts better, faster and at a lower cost. When they are selected, installed and working properly, they do just that—delivering better part quality, faster speeds, less scrap, lower labor costs, higher-volume production and increased efficiency. However, achieving the maximum potential requires proper knowledge, planning, design and execution.

One of the primary benefits of hot runner systems is their speed. The cost savings associated with producing products faster is a driving force behind the growing demand for hot runners. Fractions of a second in cycle time add up quickly and can make a large difference to the bottom line.

Mold base quick-change/hot runner systems are particularly well-suited for increasing efficiency in the production of automotive, medical, electronic and small appliance parts, as well as for a variety of other applications.

Hot runners also cut cost by greatly reducing waste. The very nature of the technology eliminates runner waste and any costs necessary to re-grind or dispose of scrap. The technology also enables a variety of increased process efficiencies, as well as the capability for extreme precision. An example of how exact hot runner systems can be is the electric valve gate. This technology uses variable pin positioning in 0.001” increments, giving an ultimate level of control to molders.

The Combination
By using a combined mold base quick-change/hot runner system, a molder is able to quickly swap different mold inserts into a mold and produce a variety of parts in the same system with minimal downtime. The systems are especially well-suited for increasing efficiency in the production of automotive, medical, electronic and small appliance parts, as well as for a variety of other applications.

With a traditional mold base and hot runner setup, a molder needs a new mold and new hot runner for each new part number. But by combining these powerful technologies, one can create an infinite number of different parts with just one hot runner and a quick-change system. For example, instead of using 10 separate mold and hot runner systems to create 10 different parts, a molder can use one hot runner with a mold base quick-change system and create those same 10 parts, saving more than 50 percent on costs.

Additionally, since the system incorporates hot runner technology, it keeps the polymer melt more uniform during the injection molding process. The hot runner precision produces cleaner, more accurate parts, which is especially beneficial for more complex part designs. The hot runners, compatible with any hot runner nozzles, also reduce material waste, cycle times and other costs.

Summary
Mold base quick-change/hot runner systems provide many advantages for moldmakers and molders alike. However, they’re not always the right solution. This is especially true, if the parts being produced aren’t similar in size and shape. The best way for moldmakers and part designers to determine whether these systems are suitable for a specific application is to work closely with a mold supply partner. Through collaboration, planning and implementing this technology, when appropriate, moldmakers and molders can experience all the benefits of both quick change and hot runner—reducing production costs and ensuring the highest levels of precision.

Tool Making - SQUARE Drilling a superb Technology...

2012-02-21T21:30:00.000-08:00

A bit that drills square holes ... it defies common sense. How can a revolving edge cut anything but a circular hole? Not only do such bits exist (as well as bits for pentagonal, hexagonal and octagonal holes), but they derive their shape from a simple geometric construction known as a Reuleaux triangle (after Franz Reuleaux, 1829-1905).
To construct a Reuleaux triangle, start with an equilateral triangle of side s (Figure 1). With a radius equal to s and the center at one of the vertices, draw an arc connecting the other two vertices. Similarly, draw arcs connecting the endpoints of the other two sides. The three arcs form the Reuleaux triangle. One of its properties is that of constant width, meaning the figure could be rotated completely around between two parallel lines separated by distance s.

It was with this property of constant width that the Reuleaux triangle was introduced in a sidebar of our geometry text (Moise and Downs, Teachers' Edition, p. 555). "This figure has constant width," I lectured, "just like a circle." Without thinking, I volunteered, "Imagine it as wheels on a cart." "What sort of cart?" "Why, a math cart, to carry my board compass and protractor," I replied, digging myself in deeper. This was the first of several impulsive misstatements I made about the Reuleaux triangle, only to admit after a little reflection that it wasn't so. Not in twenty years of teaching had my intuition failed me so completely.
The constant width property can be used to transport loads, but not by using Reuleaux triangles as wheels. If several poles had congruent Reuleaux triangles as cross sections, bulky items could ride atop them (Figure 2). Movement would occur as poles were transferred from back to front, providing a moveable base of constant height.

But the Reuleaux triangle cannot be a wheel. The only conceivable point for the axle, at the triangle's centroid, is not the same distance from the Reuleaux triangle's "sides" (Figure 3). If the sides of the equilateral triangle are s, then

2  s           sqrt(3)
(1)       AP = -  - sqrt(3) = ------- s » 0.577s,
               3  2              3

while

sqrt(3)           sqrt(3)
          PB = s - ------- s = s(1 - -------) » 0.423s.
                      3                 3

Even if four Reuleaux triangle wheels were synchronized, the load would rise and fall continuously -- you'd need Dramamine to ride this cart! "And since it has constant width, it would just fit inside a square whose sides are that width," I continued, trying to regain their attention. I carefully drew a square circumscribing the Reuleaux triangle (Figure 4). The triangle is normally tangent to two sides of the square with two vertices touching the square directly opposite the points of tangency (why?), as in Figure 4a. The exception is Figure 4b, where the Reuleaux triangle has one point of tangency and all three vertices on the square (one directly opposite that point of tangency).

"If the Reuleaux triangle just fits inside the square, no matter what position it's in, couldn't it rotate around the inside of the square?" They needed convincing -- a model would have to be built. "But if it did rotate around the inside, doesn't that mean that a sharp Reuleaux triangle could carve out a square as it rotated?" I had them. "Drill a square hole?", one countered. "No way!"
That night I cut a four inch Reuleaux triangle from a manila folder to take to class the next day. With a lot of effort, I was able to show the triangle rotate around the inside of a four inch square. "And if this was metal at the end of a rotating shaft, it would cut out a square", I continued, racking up two more falsehoods. Firstly, it was implied that the center of the Reuleaux triangle would coincide with the center of a drill's shaft; it cannot. And secondly, the corners of the holes are not right angles, but slightly rounded.
Trying to show the triangle should be centered at the end of a rotating shaft, I stuck a pen through the triangle's center which, while a student manually rotated the triangle within the square, traced the center's path on paper beneath (Figure 5). "It's definitely not a single point," I had to admit, holding up the traced curve, "but it sure looks like a circle!" Falsehood #4.

Just what is the path of the centroid of a Reuleaux triangle boring a square hole? Assume the square and the equilateral triangle have sides of length 1. Center the square about the origin and position the Reuleaux triangle so vertex A is at (-1/2,0), as in Figure 6a. Using (1), the triangle's centroid will be P (-1/2+sqrt(3)/3,0). Now imagine rotating the triangle clockwise through the position in Figure 6b, and ending up in Figure 6c, where the centroid is P''(0,-1/2+sqrt(3)/3). The path from P to P'' lies in quadrant I. Let a be angle MA'B', ß the angle formed by A'P' and a horizontal line through A', and c the y-coordinate of point A'. We are interested in the coordinates of P'. Note that cosa=1/2+c and that ß=270°+a+30°=300°+a. Also note that during this rotation, a goes from 60° to 30°. Because A'P'=sqrt(3)/3, if we measure from the coordinates of A'(-1/2,c), the x and y coordinates of P' can be found.

-1   sqrt(3)                -3 + sqrt(3) cos(a) + 3 sin(a)
(2)  x = - + ------- cos(300°+a) =  ------------------------------,
         2      3                               6

and

sqrt(3)
(3)  y = c + ------- sin(300°+a)
              3

                        sqrt(3)
       = (cosa - 1/2) + ------- sin(300°+a)
                           3

         -3 + 3 cos(a) + sqrt(3) sin(a)
       = ------------------------------
                    6

as a goes from 60° to 30°. Finding the path of the triangle's center in the other three quadrants is similar in procedure and produces equations symmetric to the origin and both axes.

3 - sqrt(3) cos(a) - 3 sin(a)
Quadrant II:   x = -----------------------------
                            6

                   -3 + 3 cos(a) + sqrt(3) sin(a)
               y = ------------------------------
                            6

                   3 - sqrt(3) cos(a) - 3 sin(a)
Quadrant III:  x = -----------------------------
                            6

                   3 - 3 cos(a) - sqrt(3) sin(a)
               y = -----------------------------
                            6

                   -3 + sqrt(3) cos(a) + 3 sin(a)
Quadrant IV:   x = ------------------------------
                              6
 
                   3 - 3 cos(a) - sqrt(3) sin(a)
               y = -----------------------------
                              6

But these equations do not describe a circle. In equations (2) and (3), when a=30°, P is on the x-axis at approximately (0.07735,0). But when a=45°,

-6 + sqrt(6) + 3sqrt(2)
             x = y = ------------------------,
                                6

which makes the distance from P' to the origin about 0.08168. This non-circularity is also shown by graphing the four parametric equations above with a circle whose radius is slightly smaller or larger. In Figure 7, the circle is the outer curve. Notice that the centroid's path is farther from the circle at the axes than mid-quadrant.

So the Reuleaux triangle's centroid does not follow a circular path. How then is the Reuleaux bit contained within the square outline it's to cut? Harry Watts designed a drill in 1914 with a patented "full floating chuck" to accommodate his irregular bits. Bits for square, pentagonal, hexagonal and octagonal holes are still sold by the Watts Brothers Tool Works in Wilmerding PA. The actual drill bit for the square is a Reuleaux triangle made concave in three spots to allow for unobstructed corner-cutting and the discharge of shavings (Figure 8).

Even the modified bit leaves slightly rounded corners. How rounded? Assume the starting position in Figure 9a, in which the Reuleaux triangle is just tangent at point C. As the triangle rotates counterclockwise, C leaves that edge of the square temporarily (labeled C' in Figure 9b) only to rejoin another at position C'' in Figure 9c. In Figure 9b, let a be angle MA'B', ß be the angle formed by A'C' and the horizontal line through A', and c the y-coordinate of A'. Then ß = a+60°-90° = a-30° and cosa = 1/2+c. To generate the corner by C, a starts at 30° in Figure 9a and ends up at 60° in Figure 9c. Using A'C' = 1 and measuring from the coordinates of A', the coordinates of C' are described by

-1                   -1 + sqrt(3) cos(a) + sin(a)
     x = - + 1 cos(a-30°) =  ----------------------------,
         2                              2

and

1
     y = c + 1 sin(a-30°) = (cosa - -) + sin(a-30°)
                                    2
                                    
          -1 + cos(a) + sqrt(3) sin(a)
       =  ----------------------------.
                    2

The equations for the other three corners are similar, and when graphed with the rest of the square yield Figure 10.

Not only does the Reuleaux triangle have practical and interesting applications, and is easy to describe geometrically, but it generates a lot of discussion due to its nonintuitive properties. With this background, you can avoid the blunders I made. Further explorations into the topic might include other figures of constant width (see Gardner and Rademacher/Toeplitz); further identifying the curve of the Reuleaux triangle's center as it cuts a square; and the shapes of bits for pentagonal, hexagonal and octagonal holes.

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Tool Making - How to Choose the Right Drill...

2012-02-13T23:28:00.000-08:00

Drilling in mold manufacturing often differs from conventional drilling with respect to several key factors. For one thing, there is a greater frequency of contoured drilling surfaces. For another, the industry employs tougher materials than are typically encountered in general machining. Successfully dealing with these conditions requires an application-specific machining strategy.

Contoured surfaces or interrupted cuts can present problems whether you are using an indexable drill, a replaceable point drill, a solid carbide drill or even a high-speed steel (HSS) drill. That’s because the more irregular the surface, the greater chance of deflection.

Before looking at deflection, though, let’s consider which type of drill to use. The answer depends on both technical and business considerations.

Holes 0.5 in. diameter and under with depths up to 70xD are best suited for solid carbide. When confronted with larger diameter holes, indexable drills often provide the most efficient solution for holes up to 5xD. Above that, up to 10xD, replaceable tip drills are the prime candidates. For all of these applications coolant-thru drills are recommended.

There is also the economics of the application to be considered. For very low volumes where cycle time and cost per hole are not critical, an economical HSS drill might suffice. For higher volumes, a solid carbide drill could be advantageous because even though it is more expensive, it can run at higher speeds with higher cutting parameters. This provides lower cost per hole and higher throughput.

However, for holes from 0.5 in. diameter and up, and for depths up to 5xD, indexable insert drills will typically provide the best cycle time and cost per hole. This is because they bring less cutting tool material into contact with the hole wall, so there is less friction, allowing higher cutting speed. They also have an advantage, since unlike HSS or solid carbide drills, reconditioning is not necessary. The tradeoff is in precision (i.e., hole location and diameter tolerance). That’s because indexable drills are more prone to deflection than solid carbide drills.

A variety of strategies can be employed to minimize deflection and/or improve hole precision. You can use precision ground rather than production inserts on the periphery of the tool to reduce tolerance stack up. Also, offset toolholders can be used. Inner inserts encounter higher cutting forces than do the outer ones, due to the lower cutting speeds, thus promoting higher deflective forces. To compensate, insert placement within the tool can be adjusted by the tool design engineer. Regardless of drill type, irregular surfaces can be pre-machined then pilot drilled. Strategies like these can improve performance, depending on the customer’s needs and priorities.

Because mold manufacturing employs tough materials, insert grades and geometries need to be evaluated for the best combination. The inner insert encounters higher cutting forces than the outer, so here you will typically want a very tough grade and a geometry not prone to chipping. In the outer pocket, running at higher speed, use a more wear-resistant carbide. This mixing and matching can optimize the process.

High-performance solid carbide coolant thru drill machining a progressive die.

Choosing the right drill for your application can be a complex affair. That’s why a final tip is: Choose the right drill supplier, one with the applications engineering expertise needed to help optimize your holemaking operations.