This Report contains the industrial aspect of injection moulding. the defects and the possible rectifications possible.

1. A PROJECT REPORT
Submitted in partial fulfillment for the certification
Of summer training
Of
BACHELOR OF TECHNOLOGY
ON
INJECTION MOULDING AND VARIOUS ERRORS ASSOCIATED
IN THE PRODUCTION OF HEADLAMPS
OF VEHICLES
at
SUBMITTED BY: SUBMITTED TO:
ABHINAV BHATT DEPARTMENT OF MECHANICAL
ST: 003 COLLEGEOF ENGG. ROORKEE

2. ACKNOWLEDGEMENT
It is a great opportunity & pleasure for me to express my profound gratitude
towards all the individuals who directly or indirectly contributed towards
completion of this project.
Working on this project was a great fun, excitement, challenges and a new
exposure in the field of PRODUCTION OF HEADLAMPS.
I am greatly indebted to under whose guidance and concern i am able to bring the
report into its real shape.
 Mr. OM BABU JI (HRD, LUMAX INDUSTRIES LTD SIDCUL RUDRAPUR)
 Mr. NAVIN CHANDRA UNIYAL (SR. ENGINEER MAINTENANCE)
I am thankful to all faculty members of Production department in providing me
useful guidance for the completion of this report.
I convey my gratitude to all those who are directly or indirectly related in the
completion of this project report.
ABHINAV BHATT

3. DECLARATION
I ABHINAV BHATT ,student of College Of Engg. Roorkee, Roorkee
here by solemnly declare that the project titled “INJECTIONMOULDING AND
VARIOUS ERRORS ASSOCIATED INTHEPRODUCTIONOF HEADLAMPS OF
VEHICLES” is my original as all the information, facts and figure in this
report is based on my own experience and study during my summer
training procedures.
ABHINAV BHATT

4. ABSTRACT
Making injection molded prototypes is both an art and a science. High levels
of technical expertise and attention to detail are required to prevent small
mistakes from costing companies big money when it comes to mass-
production of novel parts.
Preventing such a circumstance is all about highly competent design. This
article discusses some of the molding defects that can occur in a part during
injection molding, and ways to fix and avoid them. Design shortcomings we
will discuss include:
1. Flow Lines
2. Sink Marks
3. Vacuum Voids
4. Surface Delamination
5. Weld Lines
6. Short Shots
7. Warping
8. Burn Marks
9. Jetting
10. Flash
Most mistakes are caused by nescient personnel without the necessary
experience or the right tools at their disposal. Conversely, creative solutions
and ingenuity abound in personnel with the right experience and the correct
combination of hardware and software. Finding the right team of people with
relevant expertise is the most important part of the process.
This Project works on rectifying and improving the associated error in the
molding process.

5. TABLE OF CONTENTS
1. Lumax Industries overview
2. History
3. Process of Production of lamps
1.1. Silo
1.2. Molding machine
1.3. SurfaceTreatment
1.4. Assembly
1.5. Quality/Control
4. Errors in molding
5. Need of project
6. Results and Improvements
7. Conclusions

6. 1. OVERVIEW OF LUMAX INDSUTRIES
As the most experienced automotive lighting solutions company in South Asia, LUMAX ,
enjoys a history of more than half a century of innovation, Technology, Manufacturing
and Market Leadership. Today, Lumax Industries Limited is a full-capability provider
of high quality automotive lighting solutions for Four wheelers and Two wheeler
applications, serving automobile manufacturing in India as-well-as worldwide.
Lumax strives for continual improvement of
manufacturing processes with emphasis on consistent
quality and cost effectiveness. Lumax signifies
LUMINOSITY MAXIMA for today's demanding
automobile users.
Lumax has come a long way since its inception as a
trading company in the year 1945, under the aegis of its founder Late Sh. S.C. Jain .
Today Lumax accounts for over 60% market share in Indian Automobile Lighting
Business, fueled in no small measure by its more than two decade old technical and
financial collaboration with , Japan , a world leader in Vehicle Lighting and
illumination products for Automobiles.
Lumax has nine ultra-modern manufacturing plants in India. Of these, three are located
in cities of Gurgaon , Dharuhera and Bawal in the state of Haryana, near New Delhi and
two plants in Pune , near Mumbai in Maharashtra, two plants in Uttarakhand -
Pantnagar, Haridwar, one in Sanand in the state of Gujrat and one is located in Bidadi in
the state of Karnataka. These facilities have been laid out to match world's best plant
engineering standards and as you hear this, our plants are busy producing automotive
lighting products in large quantities to our customer's exacting standards.
Lumax has a futuristic vision with an experienced and customer focused management
team. This is clearly evident from our financial growth which has seen a steady upward
trend right since our inception. Lumax posted a growth of 36% for the financial year
2010-11.
Lumax facilities are manned by over a 2073 (31-03-2013) highly skilled and specialized
personnel composed of associates, executives and managers. Lumax is listed on major
stock exchanges in India and depicts a shareholding of 35% by Indian Promoters , 35% is
held by and 30% by Public and Corporate Bodies. (As per the agreement and
understanding between Lumax Industries and Stanley).

7. 1. History Of Lumax Industries Pvt. Ltd.
Pantnagar
The pantnagar unit of lumax industries pvt. Ltd. was established in 2006. For the
production of the lamps for OEM’s like
Tata Motors pvt. Ltd.
Ashok Leyland
Mahindra & Mahindra
Hero Moto Corp.
The company is also awarded with the JIPM-TPM (Total Productive Maintenance)
in 2014.
Company has also achieved ISO TS-16949:2009 aimed at the development of
a quality management system that provides for continual improvement,
emphasizing defect prevention and the reduction of variation and waste in the
automotive industry supply chain.
Both the C (Country Level) & E (International) code headlights are manufactured
in this plant.
This plant plans to sign with OEM’s like MAN, AMW.

8. 2. Process Of Production Of Lamps
2.1 FEEDING SYSTEM & SILO:
Plastic injection molding, PVCextrusion type machinery are widely
used in plastics industry. PEpellets, PP pellets, HDPEpellets, PVC
powders, calcium carbonate, plastic compounds, regrinds can be
transferred between different equipments within the production site.
Powder, granular, flake, regrind or pellet type bulk solids are handled
by conveying, mixing and dosing systems.
Process begins with bulk material loading to silos. Bulk materials within
big bags, sacks or tanker trucks are conveyed to storagesilos. They are
weighed and transferred to mixers. After mixing plastic materials are
transferred to injection molding or plastic extrusion machinery. Central
conveying systems areused instead of standalone vacuumconveyors
for large capacity plastic production factories.
Figure 1. Automatic PVC feeding system

9. 2.2 Molding Machine:
Injection molding uses a ramor screw-typeplunger to force
molten plastic material into a mould cavity; this solidifies into a shape
that has conformed to the contour of the mould. Itis mostcommonly
used to process both thermoplastic and thermosetting polymers, with
the volumeused of the former being considerably
higher. Thermoplastics are prevalent due to characteristics which
make them highly suitable for injection molding, such as the ease with
which they may be recycled, their versatility allowing them to be used
in a wide variety of applications, and their ability to soften and flow
upon heating.

10. 2.3 Surface Treatment
3.3.1. Lens:
Lens is the covering of the headlamp that protects the
reflector, and also passes the light at best angle to the road for the
comfortability of the driver.
The lens is treated with IPA(Iso-Propyl Alcohol) which has a flash
point of 12.50
C. So, it is typically hard to handle and work. A robotic
arm has been setup and a chamber which is maintained below
110
C to spray it on the lens.
IPA provides a dynamic strength to the lens which can withstand
the sunlight (UV), Rain and even the extreme temperatures.
This provides a good strength to the headlight.

11. 3.3.2 REFLECTOR:
A Reflector is a component of headlight which is of concave shape and
provides a parallel direction to the light emitted from the source at the
centre.The reflector is metalized with aluminum on its surface.
PVD(Physical Vapour Deposition), PECVD(Plasma Enhanced Chemical
Vapour Deposition) setups are used for the coating of reflector.
The reflector passes the light in parallel direction from a concave
structure.

12. 2.4 Assembly:
The parts that complete the assembly are:
 Bazzle
 Reflector
 Lens
 Housing
 Bulbs & Harness
2.5 Quality/Control:
LAMPS
Current Measurement  A constant source of light
 Detection of correct ignition curve during Xenon start-up
 Measurement of current to the coil aperture shuttering
the main beam
Positioning and
measuring positions of
LED sources
 The placement of LEDs on the base of the robot-guided
camera
 Measuring position of LED sources with a precision
positioning accuracy of 0.01 mm and an angle of 0.1
degree
 Measuring the luminance of LEDs (comparative)

13. CORNER AND FOG LIGHTS
Measuring the intensity
of light
Scanning the projected beam of the camera and
comparing the reference sample. Finding the
homogeneity and intensity of the light at selected points
or areas.
Measuring and adjusting
the volume in a vertical
position
Scanning the projected beam of the camera and
comparing the reference sample. Finding the angle of
the central bundle and its settings using positioning
mechanisms in the headlight.
 HEADLIGHT
High beam  Sharpness of the border as the intensity gradient
between lit and unlit parts of the screen on which the
beam is projected.
 Measuring of the intensity of the center portion of the
beam by camera and comparing the reference sample.
 Position of the center of the projected beam as the
focus area to which the intensity is higher than the set
value, eg 85% of the maximum intensity.
Low beam  Location of the kink point between the light and dark
parts of the projected beam, including the ability to
automatically a just the beam position along the
horizontal and vertical axes.
 Measuring the angle of the lines between the light and
dark parts of the projected beam.
 Measurement of beam intensity at selected points and
areas compared to the reference sample.
 Measuring and adjusting sharpness and color between
the light and dark parts of the projected beam.
Daily parking, designer
light fixtures
The camera test looks directly at the camera light
source. Detection of the presence of light sources,
waveguides and the homogeneity of the light emitted

14. Protective layer Detection of the protective layer of varnish and its
features on the glass covered complete automobile
headlight.
Stepper Motors
Lights VAC system
(Vertical Aim Control)
Checking of the vertical position of the beam controlled
by a stepper motor tracking the projected beam on a
screen
Lights of AFS (Adaptive
Front-light System)
Checking of the dipped beam break point angle in the
horizontal and vertical axis at several points. Control of
the stepper motor light using LIN, CAN, RS-232 port.
Test The Quality Of Other Parts Of Lights
Assembly errors using
cameras
The presence of parts, screws, stickers, seals
Communication Verifying communication with the light via LIN, CAN, RS-
232 port.

15. 3. Errors in Production
Flow Lines
Description: Flow lines are streaks, patterns, or lines - commonly off-toned in
color - that show up on the prototype part as a consequence of the physical
path and cooling profile of the molten plastic as it flows into the injection mold
tooling cavity. Injection molded plastic begins its journey through the part
tooling via an entry section called a “gate.” It then flows through the tool cavity
and cools (eventually hardening into a solid).
Causes: Flow line defects are caused by the varying speed at which the
molten plastic flows as it changes direction through the contours and bends
inside the mold tool. They also occur when the plastic flows through sections
with varying wall thickness, or when the injection speed is too low causing the
plastic to solidify at different speeds.
Remedies:
1. Increase injection speeds and pressure to the optimal level, which will
ensure the cavities are filled properly (while not allowing the molten
plastic time to start cooling in the wrong spot). The temperature of the
molten plastic or the mold itself can also be elevated to ensure the
plastic does not cool down sufficiently to cause the defect.
2. Round corners and locations where the wall thickness changes to avoid
sudden changes in direction and flow rate.
3. Locate the gate at a spot in the tool cavity with thin walls.

16. Sink Marks
Description: Sink marks are small craters or depressions that develop in
thicker areas of the injection molded prototype when shrinkage occurs in the
inner portions of the finished product. The effect is somewhat similar to
sinkholes in topography, but caused by shrinkage rather than erosion.
Causes: Sink marks are often caused when the cooling time or the cooling
mechanism is insufficient for the plastic to fully cool and cure while in the
mold. They can also be caused by inadequate pressure in the cavity, or by an
excessive temperature at the gate. All else being equal, thick sections of the
injection molded part take longer to cool than thin ones and so are more likely
to be where sink marks are located.
Remedies:
1. Mold temperatures should be lowered, holding pressure increased, and
holding time prolonged to allow for more adequate cooling and curing.
2. Reducing the thickness of the thickest wall sections will also ensure
faster cooling and help reduce the likelihood of sink marks.
Vacuum Voids
Description: Vacuum voids are pockets of air trapped within or close to the
surface of an injection molded prototype.

17. Causes: Vacuum voids are often caused by uneven solidification between the
surface and the inner sections of the prototype. This can be aggravated when
the holding pressure is insufficient to condense the molten plastic in the mold
(and thereby force out air that would otherwise get trapped). Voids can also
develop from a part that is cast from a mold with two halves that are not
correctly aligned.
Remedies:
1. Locate the gate at the thickest part of the molding.
2. Switch to a less viscous plastic. This will ensure that less gas is trapped
as air is able to escape more rapidly.
3. Increase holding pressure as well as holding time.
4. Ensure that mold parts are perfectly aligned.
Surface Delamination
Description: Surface delamination is a condition where thin surface layers
appear on the part due to a contaminant material. These layers appear like
coatings and can usually be peeled off (i.e. “delaminate”).

18. Causes: Foreign materials that find their way into the molten plastic separate
from the finished product because the contaminant and the plastic cannot
bond. The fact that they cannot bond not only has an effect on the
appearance of the prototype, but also on its strength. The contaminant acts as
a localized fault trapped within the plastic. An over-dependence on mold
release agents can also cause delamination.
Remedies:
1. Pre-dry the plastic properly before molding.
2. Increase the mold temperature.
3. Smooth out the corners and sharp turns in the mold design to avoid
sudden changes in melt flow.
4. Focus more on the ejection mechanism in the mold design to reduce or
eliminate the dependence on mold release agents.
Weld Lines
Description: Weld lines are actually more like a plane than a line that
appears in a part where molten plastics meet each other as they flow from two
different parts of the mold.
Causes: Weld lines are caused by the inadequate bonding of two or more
flow fronts when there is partial solidification of the molten plastic.
Remedies:
1. Raise the temperature of the mold or molten plastic.

19. 2. Increase the injection speed.
3. Adjust the design for the flow pattern to be a single source flow.
4. Switch to a less viscous plastic or one with a lower melting temperature
Short Shot
Description: As the term implies, short shots can be described as a situation
where a molding shot falls short. This means that the molten plastic for some
reason does not fully occupy the mold cavity or cavities, resulting in a portion
where there is no plastic. The finished product becomes deficient because it is
incomplete.
Causes: Short shots can be caused by a number of things. Incorrect
calibration of the shot or plasticizing capacities can result in the plastic
material being inadequate to fill the cavities. If the plastic is too viscous, it may
solidify before fully occupying all the cavities and result in a short shot.
Inadequate degassing or gas venting techniques can also result in short shots
because air is trapped and has no way to escape; plastic material cannot
occupy the space that air or gas is already occupying.
Remedies:
1. Select a less viscous plastic with higher flowability. This plastic will fill
the hardest-to-reach cavities.
2. Increase mold or melt temperature so as to increase flowability.

20. 3. Account for gas generation by designing the mold so that gas is not
trapped within the mold and is properly vented.
4. Increase the material feed in the molding machine or switch to a
machine that has a higher material feed in the event that the maximum
material feed has been reached.
Warping
Description: Warping (or warpage) is the deformation that occurs when there
is uneven shrinkage in the different parts of the molded component. The result
is a twisted, uneven, or bent shape where one was not intended.
Causes: Warping is usually caused by non-uniform cooling of the mold
material. Different cooling rates in different parts of the mold cause the plastic
to cool differently and thus create internal stresses. These stresses, when
released, lead to warping.
Remedies:
1. Ensure that the cooling time is sufficiently long and that it is slow
enough to avoid the development of residual stresses being locked into
the part.
2. Design the mold with uniform wall thickness and so that the plastic flows
in a single direction.
3. Select plastic materials that are less likely to shrink and deform. Semi-
crystalline materials are generally more prone to warping.
Burn Marks
Description: Burn marks are discolorations, usually rust colored, that appear
on the surface of the injection molded prototypes.

21. Causes: Burn marks are caused either by the degradation of the plastic
material due to excessive heating or by injection speeds that are too fast.
Burn marks can also be caused by the overheating of trapped air, which
etches the surface of the molded part.
Remedies:
1. Reduce injection speeds.
2. Optimize gas venting and degassing.
3. Reduce mold and melt temperatures.
Jetting
Description: Jetting refers to a situation where molten plastic fails to stick to
the mold surface due to the speed of injection. Being fluid, the molten plastic
solidifies in a state that shows the wavy folds of the jet stream on the surface
of the injection molded part.
Causes: Jetting occurs mostly when the melt temperature is too low and the
viscosity of the molten plastic becomes too high, thereby increasing the
resistance of its flow through the mold. When the plastic comes in contact with
the mold walls, it is rapidly cooled and the viscosity is increased. The material
that flows through behind that viscous plastic pushes the viscous plastic
further, leaving scrape marks on the surface of the finished product.
Remedies:

22. 1. Increase mold and melt temperatures.
2. Increase the size of the gate so that the injection speed becomes
slower.
3. Optimize gate design to ensure adequate contact between the molten
plastic and the mold.
Flash
Description: Flash is a molding defect that occurs when some molten plastic
escapes from the mold cavity. Typical routes for escape are through the
parting line or ejector pin locations. This extrusion cools and remains attached
to the finished product.
Causes: Flash can occur when the mold is not clamped together with enough
force (a force strong enough to withstand the opposing forces generated by
the molten plastic flowing through the mold), which allows the plastic to seep
through. The use of molds that have exceeded their lifespan will be worn out
and contribute to the possibility of flash. Additionally, excessive injection
pressure may force the plastic out through the route of least resistance.
Remedies:
1. Increase the clamp pressure to ensure that the mold parts remain shut
during shots.
2. Ensure that the mold is properly maintained and cleaned (or replaced
when it has reached the end of its useful lifespan).
3. Adopt optimal molding conditions like injection speed, injection
pressure, mold temperature, and proper gas venting.

23. 5. NEED OF PROJECT
There ishuge cost associatedwiththe productionof the headlamps.
So , to avoidany lossof the resources.
Each factor like the productioncostaddsaftereach step,solossesof energyandresourcesisminimized
to the maximumthatcan be done.
The projectdealswiththe minimizationof the errorsfoundinmoldingandother issuesduring
assembly.

24. 6. RESULTS, IMPROVEMENT &
SUGGESTION
The variations in the temperature for the molding machine , resulted in
flaw less molding.
Also, At SurfaceTreatment maintaining low temperature, is bit hard as it
has ovens, and moulding machines working at high temperatures .
So, a proper insulation at the IPA Spray cabin insures better spray and good
finish of the lens.
At the assembly line Introduction of Ferris wheel for the process after the
application of lens on housing and kept to dry. After a span till the sealant
cools and reaches its adhesivestrength the line is further processed
forward. This gavea pause for the person standing next. Ferris wheel
reduces the total time consumption of assembly after the application of
sealant.

25. 7. CONCLUSION
The project aims at reducing the errors induced in the molding process of
headlights.
Also ,
 The project undertaken is a very long term project requiring both practical and
analytical reasoning, proofs and conclusions.
 In my short term involvement of the project I helped the team to collect the
floor data.
 In the continuing stage the data and the observations will be checked on
various prototypes and results would be drawn.
 If the phase succeeds the data will be examined analytically and
mathematically where the charts, graphs and further calculations would be
out.
 If the project goes through the plan it would be tested economically and on
success it would be implemented in the production line.