Fundamentals of Plastic Mould Design Syllabus 4th Semester

                           DIPLOMA IN PLASTIC MOULD TECHNOLOGY (DPMT)

SEMSETER -IV 

Engineering materials and Heat Treatment

(Overview of key concepts of structure and properties of the metals and alloys. Role of heat treatment to suit specific requirement and testing of the properties for ascertaining)

 25.1 Understanding different structure, Unit cell and calculation of atoms/Coordination number/packing factor 

25.2 Describe different types of cast iron and steel application in Engineering field. Identify cast iron, steel, and alloys steel as-per their uses. 

25.3 Select nonferrous metals and understand their uses 

25.4 Study of nonferrous alloys and its applications 

25.5 Describe phase transformation stages in iron with respect to the temperature and effect of heat treatment on properties of iron. 

25.6 Draw the iron-carbon equilibrium and TTT diagram and explain briefly the effect of temperature on microstructure of steel and iron. 

25.7 Explain different types of microstructure with neat sketch. 

25.8 Explain the significance of heat treatment in the Manufacturing process. 

25.9 Explain the different types of heat treatment process. 

25.10 Study on Advanced Heat treatment techniques 

25.11 escribe Mechanical Properties and its Testing

Plastics Product and Mould Design

(Describe the concepts product design for plastic parts. Study of various mold designs based on materials and applications)

26.1 Knowledge of product design features and its application while designing for plastic parts. 

26.2 To study injection mold machine specification 

26.3 General injection mold construction and its design features 

26.4 Exposure on different mold parts and its functions 

26.5 Study of external undercut molds, spilt molds, cam track molds 

26.6 Study of internal undercut-form pin-collapsible core - loose cores, threaded inserts - internal and external threads 

26.7 Describe the blow mold and extrusion die design & its considerations 

26.8 Understanding Compression and transfer mold design and Its considerations.

Machine Shop Technology-II

(Role of milling machines and Grinding machines on shop floor)

27.1 Identifying milling machine parts, cutters and work holding/tool holding devices and their purposes 

27.2 Cutting parameters 

27.3 Study on different milling operation 

27.4 Different milling methods and its applications

27.5 Knowledge on coolants and lubricants used 

27.6 Maintenance and Safety precaution while working on the machine 

27.7 Identifying surface grinding parts, Types of Grinding and working principle 

27.8 Selection of grinding wheels 

27.9 Knowledge on balancing, glazing and loading of wheels 

27.10 Speed and feed parameters 

27.11 Study on attachments used 

27.12 Maintenance and Safety precaution while working on the machine 

27.13 Identifying surface and cylindrical grinding parts, Types and working principle 

27.14 Selection of grinding wheels and its shapes/ sizes for different operations 

27.15 Knowledge on balancing, glazing and loading of wheels 

27.16 Speed and feed parameters 

27.17 Study on attachments used 

27.18 Maintenance and Safety precaution while working on the machine 

27.19 Identifying Pedestal and Tool and cutter grinding machine parts, Types and working principle 27.20 Selection of grinding wheels for different materials 

27.21 Knowledge on single and multi-point cutter and drill bits 

27.22 Study on accessories and attachments used 

27.23 Maintenance and Safety precaution while working on the machine 

Plastics Processing Techniques

(Study of different processing method, understands related operations, monitor process parameters and troubleshoot the process/product)

28.1 Introduction to Injection Molding – machine specifications - parts and their functions. 

28.2 Process variables. Influence of processing parameters on the quality of the moulding - Setting of moulding conditions for a particular job 

28.3 Causes & remedies of common moulding faults. 

28.4 Operator safety aspects and routine quality control involved Safety procedures to be adopted to complete mould removal process 

28.5 Introduction to advanced injection molding - gas assisted, reaction injection and multi-colour 

28.6 Knowledge of Blow Molding –types, parison programming, setting and operation –quality control and operator safety 

28.7 Knowledge of Extrusion process- machine parts and their functions 

28.8 Study of processing parameters and their effect on product quality 

28.9 Understanding of Causes and remedies of the common extrusion faults 

28.10 Knowledge of film, pipe, sheet, profile and coatingdies for different processes, process control systemsprocess variables- quality control and operator safety 

28.11 Knowledge of Compression And Transfer Molding Process – principles- effect of molding pressure, mold temperature, defects and their causes- quality control 

28.12 Knowledge of Thermoforming methods Thermoforming moulds, Thermoforming equipment description 

28.13 Rotational moulding working principle, process requirement for the moulding - water tank, Dust Bin, faults and remedies, operator safety 

28.14 Automation – use of robots in part handling, application of robotics in molding process, material handling, conveying 

28.15 Introduction to Secondary processes – electroplating, various printing techniques, and different welding techniques

Machine Shop Practice II 

(Demonstration and Practice on Milling/Grinding/Lathe machines to acquire skill on operation of Tool room machines)

29.1 Knowledge of milling machines and their parts and accessories, Attachments and applications. 29.2 Knowledge of milling cutting tools and tool holding devices 

29.3 Understand safety precautions 

29.4 Learn to do Plain surface milling, slot –plain and angular milling 

29.5 Learn to do different types of milling -Pocket, Indexing and rotary. 

29.6 Be able to operate Milling machines in a safe and competent manner. 

29.7 Knowledge of Surface grinders, work holding device, grinding wheels and their set up, maintenance and procedures for use. 

29.8 Types of surface grinders and accessories used for surface grinding operations and describe their applications 

29.9 Considerations used to determine feed, speed and depth of Cut for grinding operations. 

29.10 Procedures used to set up grinders and align the work piece 

29.11 Demonstrate ability to do plain surface, slot, angular surface and form grinding 

29.12 Demonstrate knowledge of cylindrical grinders, , work holding device, grinding wheels and their set up, maintenance and procedures for use. 

29.13 Ability to operate cylindrical Grinding machines to produce precision parts by executing different types of grinding operations 

29.14 Be able to operate Cylindrical Grinding machine in a safe and competent manner. 

29.15 Demonstrate knowledge of Tool and cutter grinders, their set up procedures for use. 

29.16 Ability to operate Grinding of single point, Form Tool, Drill, Reamer and Milling Cutters. 

29.17 Ability to operate lathe machines to produce precision mold parts – guide pillar and bush, sprue bush, support pillar and bush, ejector pins and push back pins 

                                                                   practical

Plastics Processing Lab

(Demonstration and practice on various plastic processing machine operation and its maintenance)

 30.1 Familiarization with basic concepts, job requirements & Basic related process. 

30.2 To know safety precautions to be taken on the shop floor 

30.3 Knowledge of semi-automatic injection molding machine parts and their functions 

30.4 Operate semi-automatic injection molding machine both pneumatic and hydraulic types 

30.5 Demonstrate ability to determine cycle time and adjust process parameters 

30.6 Knowledge of automatic injection molding machine parts and their functions – clamping system, locating ring, machine daylight, dimensions, ejector stroke, tie-bar distance etc. 

30.7 Understanding of process parameters and study of controls in machines 

30.8 Knowledge of semi-automatic and automatic blow molding machine parts and their functions 

30.9 Operate semi-automatic and automatic blow molding machines, familiar with control switches, cycle-time analysis. 

30.10 Knowledge of compression and transfer molding machine parts and their functions 

30.11 Demonstrate ability to perform compression an d transfer molding 

30.12 Knowledge of extruder machine parts and their functions 

30.13 Operate the extrusion machine & its trouble shooting 

30.14 Have basic knowledge of maintenance – hydraulic and pneumatic systems-viscosity, directional valves, hydraulic pump- types and functions, electrical system, electrical heating systems, timers and motors

CAD Lab I 

(Hands on experience on using AutoCAD software to draw product and mold design)

31.1 Basic knowledge of Computer Aided Drafting and its advantages over manual drafting, Hardware and Software requirements 

31.2 Understanding CAD basics –main menu, starting a new drawing, drawing editor, entering commands using mouse, pull down menu, getting help, data entry, entity selection, error correction. 31.3 Develop ability to use CAD- Set limits of Drawing, grid, snap, co-ordinates, orthomode, zooming, drawing lines, arcs, circles, erase, undo, oops – commands, save and end commands- Editing, 

31.4 Ability to add dimensions and text, Edit drawings using various modified commands. 

31.5 Ability to add dimensions and text on drawings, copy, mirror, array, fillet, chamfer, hatching the sectional views. 

31.6 Demonstrate ability to Develop simple orthographic views and dimension it with text. 

31.7 Demonstrate ability to Develop detailed orthographic views with all features.