MINOR PROJECT

DESIGNING AND ANALYSIS OF

INJECTION MOULD FOR A HELICAL
GEAR

PRESENTED BY:- GROUP I

PROJECT MENTORED BY Mr. Kanwarjeet Singh
Co-Mentors Mr. Gaurav Arora & Mrs. Swati Varshney
 CONTENTS
1. Introduction
2. Conventional Injection Moulding machine
3. Process Cycle (injection moulding)
4. Our Product
5. Helical gears
6. Advantages of plastic gears
7. Typical plastic gear applications
8. Plastic material chosen
9. Industrial applications of Nylon 66
10. Characteristics and Applications of Nylon 66
11. Component Design
12. Mould Design
13. Analysis
14. Errors
GROUP MEMBERS
HIMANSHU JHA
00170208613
SAGAR KAPOOR
00570208613
GAURAV KHANDELWAL
00670208613
GURMANAN SINGH
00970208613
DEVESH TIWARI
01270208613
DHEERAJ NANDAL
Introduction

Project Objective :-
Basically, the specific objectives of this
project are:-
To design the mould for the given
product
To find a better and more
economical way of manufacturing
the product.
Project Scope :-

The scope for this project is to make a

helical gear with a metallic insert using
thermoplastic material.
Nylon 66 material was used for
 Injection Moulding

The main components of an injection molding machine are

Clamping Unit (Required Force)
Hopper (Feeding )
Chamber (Plasticizing)
Lead Screw (Pushing)
Nozzle (Injection)
Mold (Impression)
Process Cycle

CLAMPING
INJECTION
DWELLING
COOLING
OPENING
EJECTION
(A) Clamping and Plasticization (B) Injection

(C) Cooling (D) Ejection

Helical Gear :-

A gear is a rotating machine part to transmit

torque and power.
Operates smoothly and quietly than other
gears.
Typical range of helix angle is 15o to 300 .
Most commonly used gear in transmission of
power and torque.
Teeth cut out at some angle to the face of the
gear.
Considered as simple machine.
It can mesh with a linear toothed part.
Mechanical advantage is produced with
rotational speeds and torque.
Our Product
Advantages of plastic gears
Lighter ,quieter and corrosion resistant.
Variety of types such as bevel gears, spiral bevel gears, helical gears,
metric gears, plastic worm gears etc.
Door to low production cost.
Preferred for heavy load applications.
Used to transmit motion and power .
Helical gears have more capability to transmit load as compared to
spur gears.
Typical Plastic Gear Applications
Negative image for a very long time.
Revolution in plastic technology.
Benefits of using plastic over metals.

List of applications:
i. Automotive
ii. Blenders
iii. Electronics
iv. Food processing
v. Office machines
vi. Robotics
vii. Printing
viii. Conveyers
Plastic Material Chosen
Nylon 66
Chemical formula (C12H22N2O2)n
Nylon 66 is synthesised by polycondensation of
hexamethylenediamine and adipic acid
Glass transition temperature is 29-42c
Stability under loads is excellent.
Good heat , chemicals and impact resistance.
Industrial Application of Nylon 66
Textiles
Automotive
Furniture
Packaging
Mechanical engineering
Characteristics of Nylon 66
Highly Resilient
Good mouldability
Melts instead of burning
High elongation
Excellent abrasion resistance
Variation of luster

Applications of Nylon 66
Drive
Gears
Airbags
Bearings
Hoses
Tires
Ropes
COMPONENT DESIGN
Mould Design
Injection Simulation
Analysis of Component
Manufacturing Process
Raw Material
Power Hacksaw
Shapper
Grinding
VMC
EDM Wire-cut
Polishing
Assembly
 Errors

Short Shot

Burn Marks
 Vacuum voids

Flash
Thank You