Design and Manufacturing of Injection Mould for Rotor Assembly

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INTRODUCTION

OVERVIEOVERVIE


Injection Moulding requires that the material be heated to plastic state in a barrel and then forced into the mould cavity with a plunger under high pressure. The plasticization of the material in the barrel is facilitated by shear and friction from a rotating screw that also feeds the raw material. In thermoplastics, the material is cooled in the mould until it can be ejected. With thermo-sets, the material is heated in the mould to “cure” the material before ejection. The construction of mould depends upon the shape of component, quantity required, its size and complexities of the parting surface/plane.


PLASTIC MATERIAL

The selection of plastic material depends on the application of the product.Themost commonlyused plastic raw materials in injection moulding process are Polypropylene (PP),Polycarbonate (PC), Polyvinylchloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS), Polystyrene (PS), PA-66 (Polyamide), etc. Among these, only a few namely PC, PVC, PP, PA, ABS and Nylon are used in automotive components due to their specific characteristics and strength.
In this project the plastic material used is Nylon-6/6 (13% glass filled) manufactured by Dupont. Zytel is the material specified material by the customer.


ZYTEL 70G13HS1L NC010, BLACK
Generic Class: Nylon 6/6, 13% Glass filled
Trade name: ZYTEL 70G13HS1L
Applications: Automotive (Gears, Bearings and equipments requiring high strength and durability, air intake manifolds, various types of covers, throttle bodies, fasteners, ski bindings, switch gears circuit breakers, etc.)


Chemical and Physical Properties of Nylon
The polyamides are a group of polymers characterized by a carbon chain with -CO-NH- groups interspersed at regular intervals along it. They are commonly referred to by the generic name nylon and may be produced by the direct polymerization of amino acids or by the reaction of a diamine with a dibasic acid. Different nylons are usually identified by a numbering system, which refers to the number of carbon atoms between successive nitrogen atoms in the main chain. Polymers derived from amino acids are referred to by a single number; for example, nylon-6 is polycaprolactam