Suitable for eight sem Mechanical Engineering Topic seminar

1. ABSTRACT This report consists of details about Blow Mould and procedure that are adopted in the processing. The Report includes observations of conventional machines to CNC machines their applications in the field of manufacturing system. The latest developments in the field of laser manufacturing system are also discussed in the report. In this report details about processing the blow moulds is mainly discussed along with the cost estimation, types of machines used, machining hour’s calculations, different complication involved and inspections done through out the completion of the process.

2. INTRODUCTION The development of the specialized machines like CNC machines, Laser machines rapidly improved the growth of the industrial production along with the quality products with lesser time period. These machines produce accurate and precise works at lesser cost. At the same time the development in the tool manufacturing side the introduction of the new tool promise longer tool life, less cost and more machining capabilities. This technological development improves the rate of production of the material and reduces the overall cost of production this in turn reduces the price value in the market and helps in business competitions with others. Every industrial unit needs specialized system of management where it needs both manufacturing and training units separately but under the same roof. The report brings out the features they adopt in training and method they adopt in manufacturing of the material from raw material stage to finish stage.

3. CONTENTS ACKNOWLEDGEMENT ABSTRACT INTRODUCTION CONTENTS
SL.NO: DESCRIPTION PAGE NO: CHAPTER 1.0: MANUFACTURING DETAILS OF 1.5 LITERS BLOW MOULD.
1.0 BLOW MOULD PROCESS DETAILS
1.1 PROCESS DETAILS CHAPTER 2.0: ANALYSIS OF PROCESSING METHOD 2.0 DESIGN ANALYSIS 2.1 TIME STUDY CHAPTER 3.0: IMPROVEMENT CASE STUDY “COST REDUCTION USING CONDITION MONITORING OF TOOLS” CHAPTER 4.0: LITERATRE SURVEY CHAPTER 5.0: RESULTS & DISCUSSIONS REFERENCES

4. CHAPTER 1.0 MANUFACTURING DETAILS OF 1.5 LITERS “BLOW MOULD”. 1.0 BLOW MOULD PROCESS DETAILS: Fig no: 1 The above figures show the working of a blow mould. The first figure shows the pre heating of the component that is in the form of test tube this pre heated component is inserted into the core and cavity of the design required. The stretch rod which holds the tube stretches up to the bottom. Hot air is blown through the tube and the plastic tube enlarges and fit to the design made. The shrinkage allowances and the cooling system given will automatically create the required design of the part.

5. This is how the blow molding process is done the main components required for these processes are
a) CORE/CAVITY
b) TOP PLATE
c) LOCATING RING
d) BOTTOM INSERT &
e) HEIGHT ADJUSTER
Fig no 2: mould core/cavity In Mold companies these components are manufactured and assembled and supplied to the customers. The processing of pet 1.5 liters blow mold starts from the marketing order, which is given in the form of “work order instructions” to planning department. The instructions given in the work order comprises of the following details. TABLE 1: WORK ORDER INSTRUCTIONS
From: Marketing
To: Planning
Order conformation number
*******
Customer
*******
Description
1500 ml shell mould painted & completed
Scope of work
04 cavity & assembly
Quantity
2 set
Drawing & specification
Design & drawing from GTTC
Raw material specification
AA2014 by customer
Date of delivery
20/09/04
Priority
Normal

6. The products received from the Company were sent to inspection for flatness and right angle perfection. The results obtained from the quality section are given below.
length
Profile area to bottom
Rework y/n
1f=299.997/300.039
0.04
Y
1m=300.018/300.051
0.05
Y
2f=299.94/299.96
0.09
N
2m=299.97/299.96
0.11
Y
The average length will be 299.90mm set as standard value to all the 4 body. After completion of the inspection the planning department analyzes the sequence of procedure that can be suitable for completion of the work and appoint a person specialized in planning and processing of that job. The main requirement for any process to be complete is the design drawings. The skillful designer knowing the requirements of the job will create the design. The designer uses the engineering drawing, which will be the communication language between the technician and the designer. After obtaining the design drawing for all these components the planner decides the requirements of raw materials required along with the raw materials size with the aid of marketing department. 1.1 PROCESS DETAILS As the Raw material arrives the processing of the components starts. The planner appointed will control the process along with allocation of machinery, tools and estimate the time for completion. The job running will be stage inspected and after every finish quality inspection will be done.

7. The processing of the job done by the planner consists of process sheet, job card and the design drawing. The format for each record is as follows: TABLE 2: JOB CARD FORMAT:
Company Name
JOB CARD
UNIT CODE:
OC number
Description:
Dept:
Drg/Part NO:
Qty:
Planned date of loading
Completion date:
Recommended
Estimated time
Actual time
Machine
Section
Operation
Special instruction
Foreman / shift in charge remark
Date:
Signature:
Job card prepared by:
Section
Name:
Date:
Production planning
This card specifies the needed information about the job. This is very important sheet that represents the movement of the component through out the process.

8. TABLE 3: PROCESS SHEET LAYOUT:
Company Name
Process sheet
Sheet no:
Customer
Date:
Part drawing number:
Material specification:
Part description code:
Raw material size:
Qty:
OC no:
Drawing SN/no:
Operation no
Process details/ Drawings
Machine
Tools and gauges
Process prepared by:
Process approved by:
Co-ordinate by:
Process sheet prepared by:
This process sheet describes the types of operation that has to be done and the machine, tool combination along with the process detail drawings. TABLE 4: OPERATION DRAWING SHEET:
Company Name
OPERATION DRAWING
OC NO:
PART NO:
REFERENCE DRAWING NO:
MACHINE:
SECTION:
DATE:
QTY:
DRAWING-------------------------
DRAWN NO:
CHECKED BY:

9. These types of records are always supplied along with the work pieces. This gives the benefits of easy understanding of the work to be done on the job in a machine. After all these bio data ready for each work the processing of the job begins. The following table arranged explains the different operations conducted on which type of machines and components along with the machining parameters. For easy understanding the tables are classified according to the type of parts processed and operations. TABLE 5: PROCESS OPERATION DETAILS
Part name
Machine used
Oper: done
Speed [rpm]
Feed [mm/rev]
D.O.C
Tool used
Time Taken
Height adjuster
NH-32
Rough turning
260
0.1
0.2
Carbide tip
3Hr/com
CNC- turn
Finishing
800
0.025
0.8
Carbide tip
3Hr/com
CNC- milling
Finishing
1200
0.03
0.5
Spotting Drilling Reaming
2Hr/com
Locating ring
NH-32
Rough turning
260
0.1
0.2
Carbide tip
2Hr/com
CNC- turning
Finishing
800
0.025
0.8
Carbide tip
2Hr/com
CNC- milling
Finishing
1200
0.03
0.5
Spotting Drilling Reaming
2Hr/com
Top plate
CNC- mill
Finishing
1200
0.03
0.5
spotting Reaming Flat drill Cot-bore
2Hr/com
CNC- turn
Finishing
800
0.025
0.8
Boring
1/2Hr

10. Part name
Machin used
Oper: done
Speed [rpm]
Feed [mm/rev]
D.O.C
Tool used
Time taken
Bottom insert
NH-32
Rough turning
260
0.1
0.2
Carbide tip
2Hr/com
CNC- turning
Finishing Grooving Step cut
800
0.025
0.8
Carbide tip
3Hr/com
CNC- milling
Slotting Profile
4000
0.02
0.5
Ball nose
18Hr/co
Core /cavity
CNC- Milling
Surfacing Profile Drilling In 3 stage Rough- cut Semi- finish finish
3000 3500 4000
0.04 0.034 0.025
0.1 0.1 0.1
16 dia 8 dia 6 dia drill bits
24Hr/co
Bench works
Hand work
deburring
----
----
----
Deburr tool
1 to 2Hr per required com
Assembly
Hand tooling
Polishing Buffing Pressure test Leak test grinding
----
----
----
Air gun Emery paper Air/water Pr. Supply
6Hr/com

11. CHAPTER 2:0 ANALYSIS OF MANUFACTURING PROCESS 2.0 DESIGN ANALYSIS
CORE/CAVITY----fig no:4
LOCATING RING----fig no: 5
HEIGHT ADJUSTER----fig no: 6
TOP PLATE----fig no: 7
BOTTOM INSERT----fog no:8
GRINDING ALLOWENCES----fig no:9

12. These design features is the communication language between the designer and the
operator. The requirements of the product will be specified in the design drawing and the
features are explained as shown in the above figures. These features will denote the
specific type of operation, the accuracy limits and the surface finish needed to be
achieved.
2.1. TIME STUDY
Fig no: 15
MACHINING TIME
30%
6% 3% 24%
11%
9%
9%
8%
CORE/CAVITY
BOTTOM INSERT
TOP PLATE
LOCATING PIN
HEIGHT
ADJUSTER
BENCH WORKS
ASSEMBLY
INSPECTION
Fig no: 16
MACHINE USAGE
65%
13%
10%
CNC MILL 3% 9%
CNC TURN
NH32
BENCH WORKS
ASSEMBLY

13. The following table explains the actual time taken for completion of the job and the calculated estimated time for each job. The calculation includes machining time with percentage addition of extra time, which is: Tool setting time Job setting time Programming time Etc. TABLE 6: MACHINING TIME
name
M/c type
Operation done
Calculated/estimated M/c time
Actual time taken
No. of setting
Height adjuster
NH-32
Rough turn
2.24hr + 0.4hr setting
3.34hr
2
CNC-T
Step turn Face turn Taper turn Threading Radius turn
0.58hr + 0.25hr programming
1.15hr
2
CNC-M
Drill Tapping
3.22 hr + 0.5 hr setting
4.12hr
2
RDU
NH-32
Rough turn ID/OD
1.33hr + 0.3hr setting
1.73hr
2
CNC-T
Face turn bore ID/OD
0.73hr + 0.25hr programming
1.15hr
2
CNC- M
Profile Drill
0.85hr + 0.5hr setting
1.43hr
2
Top ring
CNC- M
Profile Drill Counter bore
1.25hr + 0.5 hr programming & tool change & setting
1.88hr
1
CNC-T
ID/OD turn
0.22hr + 0.16hr programming
0.45hr
1
FOND
NH-32
Rough
0.41hr + 0.15hr
0.66hr
2

14. turn
setting
CNC-T
OD turn Facing
0.26hr + 0.2 hr setting
0.55hr
2
CNC- M
Profile Drill Tapping engraving
14.22hr + 0.5hr setting
7.4hr RC /9.53hr finishing =16.93hr
2
BODY
CNC- M
Profile Drill Reaming [roughing] [semi- finish] [finish]
18.56hr + 0.5 setting
19.98hr
1
Assembly
Table work Hand instruments
Polishing Buffing Pressure/ Leak test Manual
6hr
7.5hr [including surface grinding]
----
Bench work
deburring
Hand tools Manual
6hr total to all the parts
----
----
Inspection hours
Gauges CMM
Manual
5hr total to all parts
----
----
Total hours
---
---
64.65hr
77.87hr
The table above shows the time taken for the completion of all the components required for the Blow mould. The variation in the estimation time and the actual time exists due to the excess setting time taken for job and tool, part programs editing, ideal time of machines for time breaks & stage or quality inspections. These reasons are unavoidable.

15. CHAPTER 3.0 IMPROVEMENT CASE STUDIES “COST REDUCTION USING CONDITION MONITORING OF TOOLS”
In-process tool condition monitoring was first introduced in the early 1980s and is gaining acceptance as a necessary component of modern machining equipment by many manufacturers. Tool condition monitors provide rapid detection of tool and process failures such as collisions, tool breakage and tool wear. By detecting failures as they occur, manufacturers are able to improve the quality of their products up to 60% while realizing valuable savings. Tool monitoring enables greater automation and faster, more aggressive machining. Tool monitoring is so great that every manufacturer fit each machine in the plant with the latest tool monitoring technology. Whether or not one can benefit from tool monitoring depends on the particular manufacturing process. This article will discuss how to calculate the potential benefits of tool monitoring and describe the type of manufacturers who can benefit from this technology. Detecting collisions immediately can prevent serious damage to the work piece, tool and machine. Broken tools, if not detected, can lead to collisions. Tool monitoring can detect broken tools immediately and minimize damage. Tool inserts are often replaced at fixed intervals. Since normal insert life varies from 10 % to 80 50 %, fixed intervals must usually be set at the low end of the tool life curve. With this policy, inserts are often replaced well before they are 100 % worn. Detecting wear with tool monitoring allows tools to be replaced only when they are worn to a desired level, decreasing the cost of tools and the downtime associated with frequent tool changes. Depending on the application, tool monitoring may provide savings in

16. * Tool cost * Tool holder and fixture cost * Scrap and rework * Direct labour * Machine downtime * Productivity In some cases, potential benefits may be measured not only in terms of direct savings, but also in terms of the advanced machining technology that can be safely and effectively employed when combined with tool monitoring as in the following example.
EXAMPLE: HIGH VOLUME AUTOMATION USING TOOL MONITORING SYSTEM
A volume producer of cast iron parts doubled productivity through the use of sialon ceramic inserts that allowed for a 200 % increase in feed rate. While ceramic inserts can cut at very high speeds, they are more brittle than carbide inserts. Tool monitoring ensures the safe use of higher speed machines and more brittle tool materials by reducing the risk of damage to machine and parts from tool breakage and other tool or process failures. Table 1 shows the performance improvements made with the addition of a Montronix TS20OW tool monitoring system. Running eight-hour shifts, 750 shifts per year, this manufacturer was able to produce 126,000 additional parts per year. In addition to productivity improvements, direct cost savings were achieved with tool monitoring by increasing tool usage, reducing tool holder damage and reducing machine downtime. For example, prior to tool monitoring, the manufacturer-replaced tool inserts every 25 parts. With tool monitoring, the average parts per insert were increased to 37, reducing the cost of inserts and the downtime to change the tools. Tool monitoring allows high volume manufacturers to achieve more aggressive machining rates while protecting the higher cost machines used to achieve higher levels of automation. While tool monitoring always provides benefits and insights into the machining process, some manufacturers may not see sufficient benefits to economically justify tool monitoring for their operation. Tool monitoring is often not suitable for manufacturers who meet most or all of the following criteria:

17. 1. Small lot sizes 2. Low-cost machines 3. Low-cost parts 4. Continuously supervised 5. Non-aggressive conditions A job shop manually producing small lots of non-critical aluminum parts, for example, probably could not cost justify tool monitoring. TABLE 7: COMPARISON BETWEEN TOOLS AFTER MONITORING
Parameter Speed Feedrate Material removal rate Insert Cycle Time Pieces per hour
Before tool monitoring 300m/min 0,5mm/rev 375cm3/min Carbide 102sec 24
After tool monitoring 900m/min 0,8mm/rev 1,800cm3/min Sialon Ceramic 45sec 45

18. CHAPTER 4.0 LITERATURE SURVEY “MIRROR FINISH BLOW MOLD TOOLING” Patented in N.A., Germany and Japan Mirror Finish Blow Molded Products are now possible using our Super Porous Nickel Tooling. Super Porous Nickel should not be confused with our Porous Nickel Tooling. The difference between the two is the initial 0.2~0.5 mm layer of nickel and straight bore micro pores that are found on Super Porous Nickel. It is this initial layer that allows the tooling surface to be polished to a mirror finish without increasing the micro pore diameter. Fig no: 17 A SUPER POROUS NICKEL SHELL IS CAPABLE OF: 1. Withstanding up to 2000Kg/c‡u 2. Polishing and etching is possible with this type of tooling. 3. Micro pores sizes can be made from 30μ200μ According to customer request. MANUFACTURING A SUPER POROUS NICKEL BLOW MOLULD: 1. Manufacture a model. 2. Take a silicone relief of the model 3. Form an epoxy model (mandrel) from the silicone mold, this becomes the plating mandrel. 4. Place the plating mandrel into the plating tank. After applying a layer of approximately 0.2~0.5mm of nickel, the mandrel is removed from the tank. 5. Using a YAG laser, micro pores are drilled into the nickel shell. These Micro pores vary in size anywhere from 30~150μ.
6. The nickel shell is then placed into a porous nickel plating tank and 3~5mm of nickel is applied. The unique quality of the porous nickel bath prevents plugging of the micro

19. pores, and therefore leaving the straight bore micro pore. It is this straight bore design that allows the surface of the nickel shell to be polished to a mirror finish. A straight bore micro pore also provides increased strength to the nickel shell. 7. The plating mandrel is then removed from the nickel shell. 8. In order to provide sufficient strength to the nickel shell, a special back plate is manufactured. The back plate serves four purposes: 1) Provides physical support for the shell 2) Allows entrapped gases to vent out from the tool 3) Provides a momentary thermal insulation barrier

20. CHAPTER 5.0 RESULTS & DISCUSSIONS The precision engineering can be achiever using CNC-machines but cost will be high. The market value should always be specified before under taking the job. The competition for low cost high quality products can be achieved using some of the following methods:
 The machine change over can be done for maximum rough work and to maintain the precision the CNC-machines can act as precision marking machine. Example for set of 12 holes has to be done the CNC- machines can drill the central drill and mark the set of position on PCD and the conventional machine can take over the rest. This type of work can also be done on the profile work where the required amount of rough work can be done on conventional milling. This type of machine change over can result in 25% reduction in the cost of production.
 The discontinuity of work during the breaks can be avoided which gives more machine time, that is during the breaks and lunch hours the shifting of workers can give more machining hours.
 The ratio of actual machining time and the estimated time are greatly affected by quality inspections therefore suitable gauges can be implemented next to the machine and the operator himself be trained for quality inspection this gives more knowledge to the operator about what he is doing and the inspection time gap can be reduces. By this the stage inspections can also be reduces.
 Implementation of special machines like electro chemical machines. Latest versions of existing machines and constant up gradation of the software’s give more knowledge and better results in quality production.

21. “Top Ten Tips for Tooling Productivity”
Ten general tips for tooling productivity. Some of these may be old hat, but one or two may give a new insight that might lead to improved metalworking productivity where you work.” Top Ten" tips are as follows:
1. Focus on minimizing the overall machining cost of the part, not just tooling cost. Tooling represents only about 3 percent of total part cost, much less than machine time or machine labor. Follow the real money. Focus on the 97 percent all about time and not about tooling price tags.
2. When engineering a new process or troubleshooting an existing one target four main areas and set clear and measurable goals for each. Those areas are cycle time, tool life, part quality and surface finish. Rank these by priority. Also, share your goals and priorities with your vendors so they can give you better answers sooner.
3. Understand the forces involved in cutting metal and use these forces to your advantage. Cut in a direction that improves the rigidity of the setup. Consider reducing the depth of cut to convert radial forces into axial forces. Then increase the feed rate to take advantage of the higher axial rigidity.
4. Take advantage of tool geometry to improve throughput. For example, on lead- angle cutters, increase the feed rate to achieve the maximum recommended chip thickness.
5. When troubleshooting, determine whether you have a process problem or a tooling problem. Don't be too quick to blame the tool. Instead, use the mode of tool failure as a clue to the root problem. A chipped edge could indicate use of the wrong carbide grade or excess "play" in the machine or fixture, which would wreck any tool. Look at machine rigidity, feed, and speed, depth of cut, presentation angle, chip clearance and coolant. If the problem lies with the tooling, changing the tool will fix it. If the problem lies with the process, it probably won't matter what tool you use.

22. 6. Question the process. Sometimes the right answer is an unconventional approach. On larger holes in one-off or short-run work, milling a hole from solid with helical milling often makes more sense than drilling it, because large-diameter drills are more expensive and less versatile. Another example of an unusual approach that may be worthwhile is plunge milling, which removes material four times faster than slab milling on average.
7. Understand heat: Metal cutting will always generate heat, not all of it from friction. When machining steel in particular, you want just enough heat to soften the work piece material and form good chips. Avoid heat levels that can trigger hardening reactions in the material, overheat the tool or de-carbonize (crater) the insert.
8. Match tool geometry to the material being cut. Especially in job shops handling a variety of work piece materials, beware of "general purpose" tooling. Take the time to change tools when you change materials. You'll get more throughputs and make more money. Again, the price tag on the tooling is the least important part of the process- economics equation.
9. Plan the cutter path to maximize rigidity and take advantage of higher feed rates.
10. Train the engineers. Companies who send the engineers and programmers to training centers see a return on their investment each time. And that return comes fast, usually within weeks of employees completing their class. Another reason to train to is to keep up with what's new in tooling.
These ten tips are must to be noted in every industrial production. These tips may look old lines but they are applicable in modern machining system also.

23. REFERENCE
1. Philippe Poizat, "Predictive Maintenance: Defect factor: A tool to Monitor Rolling Element Bearings", Industrial products and news reporter, Vol. 9, April – June 1996, pp. 29 – 32.
2. Chen M. F. and Natsuake .M., "Preventive Monitoring System for Main Spindle of Machine Tool", Journal of vibration, acoustics, stress and reliability in design, Vol. 106, July 1989, pp. 179 – 186.
3. Mathew J., Alfredson R. J., "The Condition Monitoring of Rolling Element Bearings using Vibration Analysis", Journal of vibration, acoustics, stress and reliability in design, Vol. 106, July 1984, pp. 447 – 453.
4. Prashad .H, Malay Ghosh., "Diagnostic Monitoring of Rolling Element Bearings by High Frequency resonance Technique”, ASME Transactions, Vol 28, April 1996, pp.439-448.

24. LIST OF TABLES TABLE NO: DESCRIPTION PAGE NO:
Table 1 work order instructions Table 2 job card format Table 3 process sheet layout Table 4 operational drawing sheet Table 5 machining time Table 6 comparison between tools after monitoring

25. LIST OF FIGURES FIGURE NO: DESCRIPTIONS PAGE NO:
Fig no 1 blow mould process Fig no 2 mould core and cavity Fig no 3 assembly of blow mould Fig no 4 core and cavity Fig no 5 locating plate Fig no 6 height adjuster Fig no 7 top plate Fig no 8 bottom insert Fig no 9 grinding allowance Fig no 10 fixture for core/cavity in milling m/c Fig no 11 fixture for height adjuster in milling m/c Fig no 12 fixture for height adjuster in milling m/c Fig no 13 fixture for fond in milling m/c Fig no 14 fixture for locating plate in milling Fig no 15 machining time–graph Fig no 16 machine usage Fig no 17 super porous nickel