Plastic Moulding Techniques detailed Syllabus for Plastic Engineering (PS), I – scheme has been taken from the MSBTE official website and presented for the diploma students. For Subject Code, Subject Name, Lectures, Tutorial, Practical/Drawing, Credits, Theory (Max & Min) Marks, Practical (Max & Min) Marks, Total Marks, and other information, do visit full semester subjects post given below.
For all other Diploma in Plastic Engineering (PS) Syllabus for 3rd Sem I – Scheme MSBTE, do visit Diploma in Plastic Engineering (PS) Syllabus for 3rd Sem I – Scheme MSBTE Subjects. The detailed Syllabus for plastic moulding techniques is as follows.
Rationale:
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Competency:
The aim of this course is to help the student to attain the following industry identified competency through various teaching learning experiences:
- Maintain various types of plastic moulding plants.
Course Outcomes:
The theory, practical experiences and relevant soft skills associated with this course are to be taught and implemented, so that the student demonstrates the following industry oriented COs associated with the above mentioned competency:
- Maintain operating parameters of injection moulding process.
- Operate compression moulding machine.
- Operate the transfer moulding processes.
- Maintain the process parameters for rotational moulding machine.
- Troubleshoot the thermoforming process.
Suggested Exercises:
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Major Equipment/Instruments Required
The major equipment with broad specification mentioned here will usher in uniformity in conduct of experiments, as well as aid to procure equipment by authorities concerned.
Equipment Name with Broad Specifications
- Injection moulding machine with auxiliary equipment and mould for Screw Diameter-25mm, Plasticizing capacity-15 Kg/hr., Shot weight-40g, Screw L/D ratio- 1:20, Mould clamping force – 25 ton.
- Compression moulding machine with auxiliary equipment. Min. 30 ton capacity, Stroke min. 150mm, daylight opening 0 – min. 300mm., mode of heating platen – electrical.
- Izod charpy impact testing machine. Pendulum impact energy maximum 300J, Max. scale graduation – 2 J, Pendulum velocity- 5 34 m/sec., Izod support, depth notch gauge, caliper gauge, template for test specimen, V and U notch milling cutter.
- Moulds for izod impact testing specimen, electrical switch, and 50 litre water storage tank.
- Transfer moulding machine with auxiliary equipments. Maximum transfer pressure-210 bar, Transfer cylinder capacity- 5 ton, Clamping force – 10 ton., Maximum daylight- 350mm, Heating capacity of platen – 3kw.
- Rotational moulding machine with auxiliary equipments. Carousel type, Mould volume – 50 litre, Independent arm.
- Vacuum forming machine. Draw Maximum – 150mm, width of roll (adjustable) – Max. 530mm and min. 230mm, Max. speed (adjustable) upto 35 approx, in PP, Chiller 5 ton capacity, Max. real diameter 850 mm.
Unit 1
Injection Moulding
Total Teaching Hours – 12
Distribution of Theory Marks
R Level – 04
U Level – 08
A Level – 10
Total Marks – 22
Unit Outcomes (UOs) (in cognitive domain)
- Explain with sketches the working of the given injection moulding process.
- Describe with sketches the constructional features of the specified injection moulding machine.
- Describe the common causes and their remedial measures for the given defects in injection moulded product.
- Justify the setting parameters of injection moulding machine for the given application.
Topics and Sub-topics
- Injection Moulding: Principle, materials, applications, advantages and limitations.
- Types of machines: Hand operated, Automatic – construction and setting parameters.
- Preheating: Concept, types;
- Postcuring: cause, description and advantages.
- Moulding compounds or materials used in injection moulding.
- Trouble shooting: defects their causes and their remedies.
Unit 2
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Unit 3
Transfer Moulding
Total Teaching Hours – 08
Distribution of Theory Marks
R Level – 02
U Level – 04
A Level – 06
Total Marks – 12
Unit Outcomes (UOs) (in cognitive domain)
- Describe with sketches the construction and working of given type of transfer moulding machines
- Select the relevant transfer moulding machines for the given application with justification.
- Compare with sketches the given pot type, plunger type and screw type transfer moulding machine for the given application.
- Describe common causes of defects and remedies in the given transfer moulding process.
- Select setting parameters of transfer moulding machine operation with justification.
Topics and Sub-topics
- Transfer Moulding: Principle, moulding materials and applications.
- Types of transfer moulding machines: Pot type transfer moulding, plunger type transfer moulding, and screw type transfer moulding machines. – their diagram, construction and working. Merits and demerits
- Compression and transfer moulding process – loading the mould, material temperature before moulding, pressure in the cavity, breathing the mould, cure time, moulding temperature, shrinkage.
- Trouble shooting guide in transfer moulding i.e defects, their causes and their remedies.
Unit 4
Rotational moulding
Total Teaching Hours – 08
Distribution of Theory Marks
R Level – 02
U Level – 04
A Level – 06
Total Marks – 12
Unit Outcomes (UOs) (in cognitive domain)
- Explain with sketches the working of the given rotational moulding process.
- Describe with sketches the constructional features of the given batch type, independent arm type, straight line, jacketed moulding machine, Carousel type rotational moulding machines.
- Describe with sketches the given types of heating and cooling systems on basis of modes of heat transfer.
- Describe common causes, their defects and remedies in the given rotational moulding process.
- Justify the setting parameters of rotational moulding machine for the given application.
Topics and Sub-topics
- Rotational Moulding: Principle, moulding materials and applications.
- Types of rotational moulding machines: Batch type, independent arm type, straight line, jacketed mould, and Carousel type machines their diagram, and construction, Merits and demerits
- Types of heating and cooling systems: modes of heat transfer -water, air, oil heating and cooling.
- Trouble shooting guide in rotational moulding process i.e. defects, their causes and remedies.
Unit 5
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Suggested Student Activities:
Other than the classroom and laboratory learning, following are the suggested student-related co-curricular activities which can be undertaken to accelerate the attainment of the various outcomes in this course: Students should conduct following activities in group and prepare reports of about 5 pages for each activity, also collect/record physical evidences for their (student’s) portfolio which will be useful for their placement interviews:
- Collect different moulding parameters for different thermoplastic and thermosetting materials, standard operating procedure and best practices from the surrounding industrial area and prepare a report. Give presentation in class.
- Download from internet operational mechanism of rotational, transfer and compression moulding and prepare a power point presentation.
- Gather the information of plastic moulding machinery (manufacturers and suppliers, material grades, rates, minimum quantity, bulk discounts, taxes, delivery perio
- Prepare a report and give presentation in class.
- Collect the information of troubleshooting guidelines for various moulding processes used in industry. Prepare a report and give presentation in class.
Suggested Special Instructional Strategies:
These are sample strategies, which the teacher can use to accelerate the attainment of the various learning outcomes in this course:
- Massive open online courses (MOOCs) may be used to teach various topics/sub topics.
- Z in item No. 4 does not mean only the traditional lecture method, but different types of teaching methods and media that are to be employed to develop the outcomes.
- About 15-20% of the topics/sub-topics which is relatively simpler or descriptive in nature is to be given to the students for self-directed learning and assess the development of the COs through classroom presentations (see implementation guideline for details).
- With respect to item No. 10, teachers need to ensure to create opportunities and provisions for co-curricular activities.
- Guide student in undertaking microproject
- Demonstrate moulds and machinery components in classroom.
- Encourage students to refer different websites to have deeper understanding of the subject.
- Observe continuously, monitor the performance and provide feedback to students in laboratory.
- Guide students for information search.
- Arrange visits to industrial fairs.
- Conduct brainstorming sessions on product features, productivity improvement.
- Invite industry experts for guest lectures.
- Assign micro projects to group of 4 to 5 students and let them prepare and present the project through PPT. Group shall submit a report which is limited to 5 pages.
Suggested Micro-Projects
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Suggested Learning Resources:
- SPI Plastics Engineering Handbook Berins, M. L. Kluwer Academic Publishers, Boston, 2000, ISBN: 9781461576068
- Plastic Processing Strong, B. Prentice Hall, New Jersey 1999 ISBN:9780130216267
- Injection Moulding Handbook Rosato, Dominick V., Rosato, Donald V., Rosato, M. G. Springer Science and Business Media, 2000, ISBN: 9781461545972
- Injection Moulding: Theory and Practice Rubin, john Wiley and Sons, Inc., 1974 ISBN: 9780471744450
- Dym, J. Elsevier Science, 1989. ISBN: 9780444989024
- , Martin, D. CRC Press book, Taylor and Francis Group, 2001, ISBN: 9780824705299
- L. Hanser Gardner Publications, 2 nd edition.2008, ISBN:9781569904282
- J. Research Studies Press, 2 1111 edition,1996. ISBN:9780863801945 _
Software/Learning Websites:
- https://www.youtube.com/watch?v=YPXCeY24Mjs
- https://www.youtubc.com/watch?v=XqoecH2AtaQ
- https://www.youtube.com/watch7vM4F9jvMBkOY
- https://www.youtube.com/watch?v=SufKCjYRqh4&list=PLQylljXTi51q2Gohzlg68jKjEFHXw66eq
- https://www.youtube.com/watch?v=eOr-lpny13U
- https://www.youtube.com/watch7vMVVkTPagybQ
- https://www.youtube.com/watch7v~ZG6YnM5UgQ
- https://www.youtube.com/watch7v~FxiWMnY4aQ
- https://www.youtube.com/watch?v=GqE93pbV_9I
- https://www.youtube.com/watch7vMyIFWYIAARoAc
- https://www.youtube.com/watch?v=VscL0Uw7GRI
- https://www.youtube.com/watch7vMDVyaaxic9U
- https://www.youtube.com/watch?v=Lp7go_TMe28
- https://www.youtube.com/watch?v=plPbX7pdT00
- https://www.youtube.com/watch7vMu-2GvhghQA
- https://www.youtube.com/watch?v=jnlc9AzygjY
- https://www.youtube.com/watch7vMYoJ2hE0SIQ
- htt.ps://www. youtube. com/watch?v=sDJpf6pKyuE
- https://www.youtube.com/watch?v=yzxlBrcn2Fg
- https://www.youtube.com/watch?v=jnlc9AzygjY
- https://www.youtube.com/watch7vMiQ6m_NQtAk
- https://www.youtube.com/watch7vMr s xG78AA
- https://www.youtube.com/watch?v=83ob7tg7vf4
- https://www.youtube.com/watch?v=q6Xk6f5rMfE
- https://www.youtube.com/watch?v=qDvML 22m4M
- https://www.youtube.com/watch7vMq3RDZN4jo
- https://www.youtube.com/watch?v= z6RgDJxZSs
- https://www. youtube. com/watch?v=Oh-MXjMFxT4
- https://www.youlube.com/watch7vMh-MXjMFxT4
- https://www.youtube.com/watch7vM4Bh4mxbm 0
For detail Syllabus of all other subjects of Plastic Engineering, I – scheme do visit Plastic Engineering 3rd Sem Syllabus for I – scheme.
For all Plastic Engineering results, visit MSBTE Plastic Engineering all semester results direct links.