SHREE N.M.GOPANI POLYTECHNIC INSTITUTE KINARA, RANPUR 363-610, DIST. AHMEDABAD.

( AN ISO 9001 : 2008 CERTIFIED POLYTECHNIC)

PROJECT REPORT: METALLURGY (MET 2) BATCH

“ROTATIONAL MOULDING

WORKING MODEL OF

ROTATIONAL MOULDING (ROCK AND ROLL TYPE)

GUIDED BY:- N.A. RANPURA.

HELPED BY:- SANGHANI MAULIK (SANGHANI ENGG)

PREPARED BY:- PATEL MAYANK .B (S062506010)

GOHIL NIKUNJ.B (S062506019)

SHAH DHWANISH.N (S062506020).

We are very thankful to Shree:- H.H.JADAV SIR.

And the other staff members who have given us

proper guidance and advice in this project.

Also we are especially thankful to all classmate and

friends who encouraged and help us in this project.

CERTIFICATE

This is to certify that the below students

Reg no :- PATEL MAYANK(S062506010)

Of Diploma programme in Metallurgy

has satisfactorily completed their project with in four

walls of N.M.G.P during term 092.

Date of submission:-

Staff incharge:-

Head of department:-

Index

Acknowledgement

Aim of project

Selection of project

Process planning

Project introduction

Raw material

Types of rotational moulding

Material list

Construction

Machine tools use to do project work

Merits

Application

Unique features

Cost estimations

Product range obtain by this process

Acknowledgement

S-Met 602 project is incorporated in the syllabus of

diploma metallurgical engineering by technical education

board of Gujarat state. The real practical work is very

important for the engineering students with study which

shows the knowledgement and interest of them in

technical field. The same is done while performing the

activities to construct the project.

During making the project student get opportunity

to be connected with vast industrial field (material, m/c

tools, tools, equipments, measuring instruments) then

know how to face problems of at practical field.

The successful completion of this project has

required a lot of assistant advice and support we are

gratefull deeply indepted to all those who have assisted

and guided us always for completion of project this is not

only success but also achievement of collaborative effort

of so many people who guided and helped us through

out this project.

Also we are especially thankful to all classmate

and friends who encouraged and help us in this project.

Aim of project

To develop on altitude of inquiry

To work as a leader and member of a team.

To measure physical phenomena.

To develop ability of report writing.

To develop planning and decision making skill

To develop and store the records how to keep

SELECTION OF PROJECT

Before selecting the project brain storming and

discussion has to between the team member on various

technical or engineering machines, availability and their

requirement in routine and professional activities then

we think on a similar product whether it is available in

market or not by thinking on different kind of machines

we can manufacture

Product having more advantage at economic cost we have consider the feasibility as well As suitability for available resources and facilities to carry

out the project work.

PROCESS PLANNING

Process planning is the fundamental of industrial

activities an efficient economy planning leads the firm

and to success planning. We can know that problems

which cause actual production.

We know that for the manufacture of a part

there are many methods and process we should chose

cheaper and process theme consumed during this

process should be less and material westage should be

less .

Advantages of process planning.

1) It determines the most economical process from all

possible processes.

2) It determines the sequence of operation to be

performed.

3) It determines the raw material requirement and its

gross weight.

4) It helps in estimating and costing.

5) Process planning helps to prepare delivery schedule.

(1) OPERATION PLANNING

No operation sequence should be accepted blindly.

first of all we should make the list of all the operations,

which we have to perform during the project work.

Operation planning is section of the best of the

method manufacturing so wastage of materials

,manpower and machine power can be eliminated to get

more production with least wastage the best operation

sequence should be selected for each operation which

has to be manufacture.

Establishment of the operation sequence is

possible of the engineer is provided with the following

information.

1) List the available machine in workshop.

2) List of available general purpose tool.

3) Capacity of equipment.

4) Plan layout maybe product type or process type.

5) Manual operation of each machine.

6) Proper safety precaution .

7) Availability of different type of gauge for inspection of

Product.

PROJECT INTRODUCTION

Rotational Molding: -

Broadly the process is classified in to following sub processes.

1. Compounding to produce colored of Granules 2. Pulverizing to convert material in to Resin form 3. Rotational Molding to produce the final product

» First Process: Compounding by means of Extrusion

The LLDPE raw material with suitable masterbatch is being fed in to the barrel cylinder through storage hopper. The barrel is preheated by heating zones and suitable temperature control system to process the input material. The rotating screw pushes the material towards die end with uniform and homogenized plastics melt. The screw is rotated by suitable AC motor coupled with heavy duty gearbox.The plastics strands extruded from die are fed in to high speed Pelletiser unit after they get cooled and traveled through SS water cooling tank. Pelletiser cuts the strands in to desired size of pellets which can be collected in to storage silo.

» Second Process: Pulverizing

The compounded or colored granules are being fed in to Pulverizing machine as Input material. The granules are

fed in to Disc Mill via vibratory feeder which feeds the material as per rate of vibration of the device. The fed material is being crushed in to Mill at very high speed by one Rotating blade and one stationery blade. The crushed material is conveyed in to cyclone hopper at height via efficient suction system.

The Rotary Air lock devise separates the blown air and pulverized resin and allows the powder passes in to Screen Vibro unit. Vibro screen unit screens the powder as per mesh used and discharge the final product in to the storage silo. The course particles are fed again in to the Mill to repulverise the same.

Compounding by means of High speed Mixer (Incase the Extrusion process is not used to produce the colored Granules)

The pulverized resin is being mixed with other ingredients to prepare a ready formulation. This process is also being adopted by many processors instead of producing granules from Extrusion Plant.

In the process the polymers mixed with other ingredients is being loaded in to Mixer vessel. The mixer vessel is made from special double wall construction of SS and MS Plates. In which the material is being mixed by means of specially designed two nos blades running at very high speed. The mixing cycle is decided by the certain set temperature. Normally batch time is 10- 15 minutes depending upon grade, quantity and formulation of material to be mixed. After cycle time is over, the the material is being discharged and collected in to silo. The final material is uniformly and homogenized mixed which is ideal to use as for Rotomoulding process.

» Third Process: Rotational Moulding

In the other Plastics processes like Injection Moulding, Blow Moulding & Extrusion Process ,the plastics material is being melt at certain higher temperature and conveyed forward in to die or mould by special designed Screw. Unlike such processes ,Rotational Moulding is a very simple process. In which it is easy to produce hollow and seamless products of all the sizes and profiles. Since Rotational Moulding is a very simple and economical process along with low cost Moulds , it is very popular in India especially to produce the water storage tanks.

It comprises of mainly four steps as per following.

1. Material Loading : The polymer powder is being loaded in to two parts Rotational Mould as per size and shape of product. After loading material manually in to mould , the mould is closed. According to type and shape of Mould , some times the mould are also closed by insulating covers.

2. Rotational Moulding : The closed Moulds mounted on to Arm are swinged in to closed heating chamber where Hot and forced Air is circulating. The moulds are already rotating in two perpendicular axis at certain low speed as per size of the mould. The moulds are in Rotation in two axis so as to distribute the loaded powder uniformly inside surface of the moulds. The moulds are heated by forced hot air in to chamber up to certain heating time. The material in to moulds fuses after heating and it forms a uniform layer inside the mould.

3. Cooling: Now the moulds are taken out form heating chamber and swinged to cooling station. The moulds are cooled at cooling station by means of forced air or by spraying water where the moulds are in rotation mode in both axis. After certain cooling period, the raw material gets solidifies in to shape of the mould.

4. Unloading the finished product: The mould is taken to unloading/ loading part where the mould is opened to get the finished product. After getting the finished product, again fresh polymer powder is being charged in to mould so as to keep ready for next cycle.

Raw material

» Raw material for Rotational Moulding:

LLDPE (Liner Low density Polyethalene) is being used with density of 0.930 to 0.936 gms/ Cm cube and Melt Flow Index in the range of 3 to 6 gm per 10 minutes. To produce the good quality water tanks by Rotational Moulding, the material should have following properties.

Good mechanical strength. Good material stability over a wide range of

temperature and cycle time. Good resistance over wrapage. Consistency in Shrinkage at least 2.5 % or slightly

more. High ESCR ( Environmental stress crack resistance )

» Other Ingredients:

The original LLDPE granules are of natural colour which have to be converted in to either black, white, blue or other colours as per requirement of final product. To produce the coloured granules , basic LLDPE granules have to be mixed with colour concentrate which are called as master batches.

These master batches are readily available in market which are to be added along with LLDPE.

The master batch should be of grade which is LD based. The master batch with antioxidants are more preferred. Anti oxidants protects the material from oxidation during

the Moulding process which helps to avoid the pin holes on surface of finished product.

Incase of black master batch, carbon contents are very important. Carbon contents act as UV stabilizer. It helps to improve the life of tanks if tanks are exposed to sunlight for longer period and to avoid the crack on tanks.

Types of rotational moulding

Rotational Moulding machines

Types of Rotation Molding Machine

Bi-Axial type rotomolding Machine Independent arm rotomolding machine Rock n roll type rotomolding machine Shuttle machine

Rock N Roll Machine

Material list

Sr.No. Part Name Specification Qty.

01 Base Frame m.s. Rectangular pipe-

25mmx10mm

1 Nos.

02 Main Frame m.s.Sq.pipe- 20mm x 20mm 1 Nos.

03 Acceleration Shaft m.s.Round Dia10mm 1 Nos

04 Main Shaft m.s.round dia 10mm 2 Nos.

05 Rotating wheel Aluminum round,dia 45mm 4 Nos.

06 Coupling Aluminum round,dia-25mm 1 Nos.

07 Burner m.s round,pipe 3 Nos.

08 Acceleration wheel m.s.round 1 Nos.

09 Brg.Housing m.s. flate 4 Nos.

10 DC Geared Motor 12V, DC Geared Motor 1 Nos.

11 Springs,Nutbolts. 2Nos, 12 Nos

12 Mold Aluminum 1 Nos.

Construction

Base Frame is made from M.S. Square Pipe.

Main Frame is made from M.S. Square Pipe

The machine includes a fix shaft which is made

from EN-24

The machine includes 2 rotating shaft which is

made from EN-24

There are three burners for heating the mould are

prepared from M.S.

There are 4 rotating wheels prepared from

Aluminium.

The machine includes a mould which is prepared

with the help of aluminium..

The machine even includes the four bearing

housing which are prepared from En 8.

Machine tools used for project work

Lathe Machine

Drill Machine

Power hacksaw Machine

Welding Machine

Bench Grinder

Polishing machine

Merits

Economic Tooling Costs One-piece construction; virtually stress-free-totally

enclose parts or with openings Weight reduction - as compared to most metals

Uniform wall thickness - no thinning in the extremities

Thickness can be varied if required Variety of finishes and color Resistance to stress-cracking and corrosion Excellent load-bearing properties Variety of materials The ability to produce multi-wall mouldings Design flexibility - from small and intricate to large

and complex Metal inserts as integral parts Economical for short production runs and prototypes

as well as volume production Minor undercuts are possible - with no draft angles

required Short lead-time

Application

Household & Commercial

Water Tanks ( Vertical & Horizontal ) Refuse containers & Bins, Buckets, Barrels & Drums

Telephone Booths & Cabins Book cases and Recks Insulated Ice Boxes Show cases & Display stands Building Interior & Exterior Gadern & Pool Furniture Traffic barriers, Dividers Portable Toilet and Urinal Cabins Industrial

Oil tanks & Chemical tanks Containers & Waste Bins Septic tanks & Insulated tanks Oil Dispensing tanks Special pupose tanks Special pallets Material Handling Trolleys Crates, Baskets & Carts for storage Boxes & Bunkers for storage Sheltar Cabins Canes for Fuel, Oil & Milk Housing & Cases for Appliances

Construction & Transport

Unique features

Various thicknesses in the product are possible

Flexibility of different models to produce from 200 ltr to 25000 Ltr vertical tanks

Special article like Drainage Pipes, Boats, up to 6.5 Mtr. Can be produced in Rock n Roll comfortably

Sturdy Machine suitable for manufacturing large size hollow products. Up to 40000 Itrs / 10000 USG. Capacity

Speed variable drive for Rocking & Rolling for better control of the product

Low pressure Burners which are very simple & can be adjusted from outside

Microprocessor based machine control panel with digital display

Most economical with less investment Faster return of investment due to lesser production

cost even for wide range of products to produced.

Cost estimation Sr.

No.

Part Name Specification Qty. Wt.

Kg.

Rate/

Kg. Rs.

Total

Cost Rs.

01 Base Frame msRectangularpipe 1

Nos.

4 55 220

25x10x1650mm

02 Main Frame m.s.Sq.pipe-

20x20x1200mm

1

Nos.

3 55 165

03 Acceleratio

n Shaft

m.s.Round

Dia10mmx450LG

1 Nos 0.6 90 54

04 Main Shaft m.s.round

dia 10mmx370

2

Nos.

2.5 100 250

05 Rotating

wheel

Aluminum round,

dia 45mmx60mm

4

Nos.

0.4 300 480

06 Coupling Aluminum round,

dia-25mmx50mm

1

Nos.

1.5 280 420

07 Burner m.s 1set. 1200 1200

08 Acceleratio

n wheel

m.s.round 1

Nos.

1 250 250

09 Brg.Housing m.s. flate 4

Nos.

0.5 55 220

10 DC Geared

Motor

12V, DC

Geared Motor

1

Nos.

4000 4000

11 Springs,Nut

bolts.

2Nos, 12 Nos 150 150

12 Mold Aluminum 1

Nos.

5 350 1750

TOTAL 9159.00

Product range obtained by

“ROTATIONAL MOULDING”

Thank you

Any questions