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ABSTRACT
Metal injection molding (MIM) is a metal working process by which metal powder is mixed with the binder material ...
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  1. 1. ABSTRACT Metal injection molding (MIM) is a metal working process by which metal powder is mixed with the binder material to form a mixture known as feedstock that will be injected by plastic processing equipment through a process known as injection mold forming. There is two common injection molding machine used in industry which are vertical and horizontal type of molding machine. There are also different sizes of the machine. The small injection molding machine usually been used to inject small product that will be used for testing. Control system is main important part in every modern machine operation. Without control system a machine cannot operate smoothly. Control systems consist of important parameter that will be consider when operating the machine. In this project, a simple new design of the control system has been designed and fabricated for the injection molding machine for the metal powder. Two parameters should be controlled were the pressure for the pneumatic cylinder and temperature for heating element that has been placed around the heating chamber. The study has been made at the earlier stage of the project in order to identify the problem statement that can be related to the project. Then designing was done by using 3D modeling software. After designed, the fabricating process was undergo using standard manufacturing process such as drilling, grinding, bending, cutting and many more. After the assembly process and testing been done, the machine was successfully been operated and the injection process was taken place after the machine operated. This conclude that the project was successfully been designed and fabricated based on the problem statement that been stated and the objectives of the project was successfully achieved. Keywords: Metal Injection Molding, Control system, Injection, Molding, Design, Fabricate, Machine INTRODUCTION Small injection molding machine has been develop and its innovation always been renewed to meet with the new technology and demand. The small injection molding machine usually been used to inject small product that will be used for testing. In order to study about the small injection molding machine, the design project has been selected to fabricate the machine that can functionally operate. This main purpose for this part is to design the functional control system for the vertical injection molding machine OBJECTIVE 1.To design and fabricate complete functional portable vertical injection molding machine. 2.To design the functional control system for the vertical injection molding machine. 3.To indicate the type of pneumatic cylinder use that will be connected with plunger for the injection process. METHODOLOGY START Gathering Information 1. Research about vertical Injection Molding Machine and Pneumatic System. 1. Design the new product 2. Analyze the existing design of the vertical injection Molding machine Literature Review Generate the Idea and Design selection Product realization FINISH Design Testing DESIGN AND MODELLING TC4S Controller Wiring system for temperature controller Pneumatic cylinder Pneumatic System RESULTS AND DISCUSSIONS Design of the mold that been injected Complete MachineController Box Mold Flow Mold Flow 1 2 3 4 Time (s) 0.32 4.68 1.07 2.03 Pressure (Mpa) 1 0.3 0.8 0.6 Temperature (C) 240 240 220 200 CONCLUSION As the conclusion, the objectives of this project which are, to design and fabricate complete functional portable vertical injection molding machine, to design the functional control system for the vertical injection molding machine and lastly to indicate the type of pneumatic cylinder use that will be connected with plunger for the injection process was successfully achieve. The product was successfully injected into the mold by using the new machine that has been designed and fabricated. The two important parameters were identified in the studied and fabrication process of the project. The parameters are pressure of the injection process and heating chamber temperature. Not enough pressure causes the mold not to be fully filled due to material crystallizations that taken placed because of the longer time taken for injection process. While different temperature cause the different of time taken for the mold to be filled. ® MOHD LUTHFI JAN 2015 MOHD LUTHFI BIN SHAHABUDIN Bachelor of Engineering (Hons) Mechanical (EM220) Faculty of Mechanical Engineering 2011505047 Advisor: SAHRIL KUSHAIRI Commercial Vertical Injection Molding Machine

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