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2003 Course Mould & Die Design

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Total No. of Questions : 12] [Total No. of Pages : 4 [3664] - 296 P1319 B.E. (Polymer) MOLD AND DIE DESIGN (2003 Course) Time : 4 Hours] [Max. Marks : 100 Instructions to the candidates: 1) Answers to the two sections should be written in separate books. 2) Neat diagrams must be drawn wherever necessary. 3) Figures to the right indicate full marks. 4) Use of logarithmic tables, slide rule, mollier charts, electronic pocket calculator and steam tables is allowed. 5) Assume suitable data, if necessary. SECTION - I Q1) Design a two cavity two plate mold for component in fig. 1. Draw at least two views with one sectional view to bring out all the details of the feed system, ejection system and cooling system. Material : HDPE; cavity pressure : 250 kg/cm2. total heat content : 171 cal/g. [35] OR Q2) Design a two cavity three plate mold for the component in fig.2. Draw at least two views with one sectional view to bring out the details of feed system, ejection system and cooling system. [35] Material : ABS; Cavity pr : 300 kg/cm2; heat content = 72 cal/g. Q3) Calculate the size of core and cavity inserts for the mold designed in Q.1 or Q.2. [5] OR Q4) Calculate the size of guide pillar for the mold designed in Q.1 or Q.2. Q5) a) b) [5] Write a note on angled lifted splits. [6] State the relation between length of finger cam and opening of splits. Also state the same for dog leg cam. [4] OR Q6) a) With a neat figure, explain any method used for achieving delay in split opening motion. [6] P.T.O. b) Q7) a) b) Explain with neat figures, spring actuation of splits. [4] SECTION - II Explain the construction of any 3 secondary nozzles used in hot runner molds. [8] Explain the various heating systems used to raise the temperature of hot runner manifold. [8] OR Q8) a) b) Q9) a) b) Draw a neat sketch of cylindrical hot runner manifold block. Explain its construction in detail. [8] Write a note on advantages and disadvantages of hot runner molds over undefed molds. [8] Write a process sheet for manufacturing of guide pillar and sprue bush for the mold designed in Q.1 or Q.2. [8] Explain the process of electro discharge machining with a neat sketch. Bring out any 3 differences between EDM and wire cut EDM. [8] OR Q10)a) b) Explain the process of costing of injection molds. Explain up milling and down milling in detail with neat sketches. [8] [8] Q11)a) b) Draw a proportionate sketch of a blown film die. [8] Calculate the die gap for a blown film die using the following data : Material - LDPE; film thickness : 0.15 mm, lay flat width : 550 mm; blow ratio : 2; draw down ratio : 10; linear velocity : 20 mm/sec. = 2.4 x 105 N/m2; g = 4.2 x 104 N/m2; BSH : 2.15; BSW : 1.5. [10] OR Q12)a) b) Draw a neat sketch for a in-line pipe die. [10] Write down in details, steps involved in determining pressure drop through a rod die. Clearly mention all the formulaes used. [8] [3664] - 296 -2- [3664] - 296 -3- [3664] - 296 -4-

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