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CONSTRUCTION OF SOAP
MOULDS, TABLE AND CUTTERS
ABSTRACT
A mould can generally be defined as a pattern constructed for the production of
the same shape and size. The constructional material differs from one
operation to another. When one considers the money at hand, he decides
whether to start from the primary production level or secondary production
level. Referring to the project, the aim is for the establishment of
small-scale production. This would employ the use of the manual soap
cutters, which is either used to cut the soap produced into bars or tablets
depending on specification.
In the construction works flat hard woods of 20m thickness were cut and
assembled by nailing. The constructed woulds have the following
dimensions : 15cm long, 38cm wide and 15cm high.
The moulds are rectangular in
shape. Handles was incorporated in the mould to make it convenient to be
carried about during soap production.
Finally, the five moulds produced were capable of presenting relatively
resistance to impact and bending forces as a result of the hard wood that was
used. With this the moulds can carry a reasonable volume of soap Surry
without collapsing
TABLE OF CONTENTS
CHAPTER ONE
INTRODUCTION
TYPES OF MOULDS
MOULDS FOR THERMOSETTING POLYMERS
MOULDS FOR THERMOPLASTICS
USES OF MOULDS IN INDUSTRIES
IMPORTANCE OF MOULD INDUSTRIES
CHAPTER TWO
LITERATURE REVIEW
TYPES OF MOULDING
NOULDING OF PLASTICS AND ELASTOMERS
CHAPTER THREE
MATERIAL SELECTION
PLASTICS AS CONSTRUCTION MATERIAL
PROPERTIES OF ENGR MATERIALS
WOOD AS A CONSTRUCTION MATERIAL
FACTORS TO CONSIDER IN SELECTION OF
MATERIALS
CHAPTER FOUR
FABRICATION PROCEDURE
TOOLS FOR CONSTRUCTING MOULDS, TABLE
AND CUTTERS
CONSTRUCTION METHOD
SAFETY PRECAUTONIS
CONSTRUCTION OF CUTTERS AND TABLE
CHAPTER FIVE
DISCUSSION
CHAPTER SIX
COST EVALUATION
CHAPTER SEVEN
CONCLUSION
CHAPTER EIGHT
RECOMMENDATION
REFERENCES
CHAPTER ONE
INTRODUCTION
The equipment mostly used or applied in the industries and manufacturing setups
requiring the production of definite patterns, shapes and different designs,
embossments and others, are usually moulds.
The moulds used for the numerous types
of plastic and the several types of moulding methods in commercial use
constitute a controlling factor in the molding industry. The most
advantageous utilization of both plastic and molding equipment requiring a
properly designed and constructed mould.
The application of moulds depends on
its ability to withstand pressure, corrosion and distortion.
Mould can be defined as a pattern constructed for the manufacture of the same
protype. The material of construction of moulds varies from one operation
to another. The need for the designing and development of moulds of
different materials, composition, texture, shape, resistance arises as a result
of the diverse application of moulds in manufacturing industries.
Early moulds were used by blacksmiths
in construction and designing materials of different shapes and sizes.
Moulds basically consists of a cavity and a plunger, or force. Most
moulds also include an ejection mechanism for removing the moulded article.
TYPES OF MOULDS
Moulds can be divided into four general group or classes: prototype, hand,
semiautomatic and automatic moulds. The best type to be used depends on
the product design, moulding material, equipment available, production
requirement and economic factors.
1.
PROTOTYPE MOULDS
They
are used when a limited number of items is to be produced, as for example, for
the evaluation of a new product. These moulds are made from easily
machined metals or from casting materials, and the molds details are assembled
into supporting frames.
2.
HAND MOULDS
Are
the oldest type of moulds, and can be constructed in either simple or
sophisticated designs. They must be removed from the press for loading
and unloading are used for short production runs or for designs requiring many
inserts and complicated coring geometly. Use of hand moulds results in
higher labour cost, lower production rates, and thus high unit cost than those
for the used of semiautomatic and automatic molds.
3.
SEMIAUTOMATIC MOULD
They
are mounted into a press for the duration of a production run. The
moulded part is automatically ejected from the cavity as the press opens, but
an operator is required to load the moulding material, actuate press control
for the moulding sequence, and remove the piece from the mould this method is
widely used for all types of moulding.
AUTOMATIC
MOLDS: This include additional mechanical
component such that, when the mould is mounted in press, the complete operation
sequence from the time the material is loaded until the completed parts are
discharged from the mould is carried out automatically.
Automatic moulds offer the most
economical approach to long production runs, because labour cost are kept to a
minimum and all moulding approach or operations are accurately
controlled. The thermoplastics can be moulded at rate up to 700 cycles/hr
and thermosetting polymers at up to 450 cycles/hr tooling must be of the
highest quality to meet the exacting demands of high speed production.
MOULDS FOR
THERMOSETTING POLYMERS
Thermosetting polymers are commonly moulded by either compression or transfer
moulding. In compression moulding, moulding material of a specified
weight or volume, as either powder or perform, is placed in a displacement
cavity; single or multiple cavity moulds may be used. The press has a
stationary platen and a moving platen actuate to close the mould and to
maintain pressure and heat on the moulding material for the time necessary to
form and cure the part. Excess materials flows out of the cavity at the
parting line of the mould to form flash, which must be removed by auxiliary
operation.
In transfer moulding, the moulding
material is preformed to a particular size and then into a chamber to tube from
which it is moved through a runner and gate system into a closed cavity and
lunger sections of the mould. This method makes it possible the mould of
foagile and delivate designs, inserts, and deep holes of small diameters.
Single or multiple cavity may be
employed. Ordinarily, parts made in this process have little or not flash
at the parting lines. Cycling is more efficient, tool life is long
(except in areas where high wears is caused by abrasion through runner and
gates), and fewer auxiliary operations for hole forming are required than is
compression moulding. In most cases a degating operation.
Generally, the material required for a given number of parts is greater than
for compression moulding owing to the transfer runner system. However, in
most cases, this is offset by greater moulding efficiencies; in other cases,
the product design could be realized except by this method because of the high
cost of operations that would be required if compression were used.
Ordinarily, values of physical properties furnished by suppliers are those of
compression moulded specimens, these values are often lower for transfer
mouldings, materials suppliers’ recommendation should be consulted on this
point in designing equipment.
TRANSFER MOULDS
Transfer mould are usually of the flash type since no extra loading space is
required. Two basic mould arrangements are utilized for transfer
moulding, with modifications to suit a particular moulding or equipment.
The older of the two is integral, or pot-type, transfer. The mould
cavities and plungers are similar to those of a flash mould, but includes gates,
runners, and transfer chamber. The transfer chamber is above the cavity
the area of the transfer chamber normally must exceed the total cavity area
(including the sprues and runners) by at least 25% to ensure that the mould
does not open during the moulding cycle.
MOULDS FOR
THERMOPLASTICS
Thermoplastic
material are commonly moulded by injection moulding, material is fed froma
hopper into a heating chamber where a double acting plunger forces the material
from the cylinder through a nozzle and a system of runners and gates into the
cavity. Single cavity moulds eliminate the runner system.
The first stage of two stage plunger
injection is similar to single stage plunger injection except that instead of
flowing directly into the mould, the material flow into a second stage chamber,
normally for transfer moulding.
Equipment available for transfer
moulding includes (a) Heat transfer (b) Integral floating pot transfer.
In this method conventional single movement presses may be used with the mould designed
for transfer moulding. (c) plunger, or top-ran transfer. This
moulding equipment has a main cylinder to actuate the mould opening and
closing, and an independent cylinder for forward and return strokes of the
transfer plunger to move the moulding material from the transfer chamber
through the runner and gating system into the mould cavity.
There are many variations of this
equipment in which the plunger cylinder may be mounted at the top or bottom of
the press in some cases horizontal plunger cylinders may be employed for
special application.
Compression Moulds
There are several basic types of moulds
designed in use for compression mould. In flash mould a charge of
predetermined weight or volume is placed directly into the mould cavity and the
moulding formed under pressure and heat. Excess materials flows
horizontally away from the closed cavity into clearance area between the
stationary and moving halves of the mould. The excess material or flash,
requires finishing operations to remove it from the moulded part. Single
or multiple cavity mould may be used. This design may be used for all
general types of mould materials of larger capacity, from which a double acting
plunger transfers the material into the mould. This system improves
plasticizing of the material, improves control of metered weight, and makes
possible a machine of large capacity.
The reciprocating screw system
employs a screw to mix and melt material in a cylinder. After the
material is melted it builds up in front of the screw tip, forcing screw to
retract; the revolving motion stops and the screw becomes the plunger with a
forward motion which moves the material into the mold.
Hand, semiautomatic, or automatic
moulds may be used in injection moulding.
USES OF MOULDS IN THE
PRODUCTION INDUSTIRES
1.
The metallurigical industries uses mould patterns for different casting
operation and application for the production of metal blocks, building blocks
etc. It is also sued in production of both industrial and household
plastics ware moulds are used.
2.
The food industries uses moulds processes for their production.
Production of brick, cake and other confflectionary products is usually a mould
patterns process.
3.
Mechanical Engineers uses mould set ups for the production of different parts
of machines with intricate shapes that cannot be conveniently manufacture on a
lathe.
4.
Mould is also used in candle making industries. This has resulted
increase in candle production activities.
5.
In building technology, mould is used in the production of blocks and bricks
needed for building construction.
6.
In pharmaceuticals industries, ninety percent (90%) of the tablets drugs of
different shape and texture are made using mould system process.
7.
Lastly, moulds are highly needed in soap making industries for the production
of both bar and tablets soaps.
IMPORTANCE OF MOULD
MANUFACTURING INDUSTRIES
Setting up of moulds manufacturing industries in any country has a lot of
economic benefits attached to it.
1.
The high foreign exchange cost spent in the importation of moulds and different
machines could be saved and used for other developmental projects.
2.
Establishing mould manufacturing industries will go a long way in providing job
opportunities for the increasing number of unemployed citizens thereby reducing
the high crime rate associated with unemployment.
3.
This will encourage proper harnessing of abundant metallic ores deposited in
different part of the nation.
4.
This will serve as source of income for the nation. Thus turning her from
an importer of moulds to exporter of moulds.
5.
These mould industries will help in manufacture of high texture and corrosive
resistance mould that would serve efficiently in accordance with climate
condition of the nation.
6.
This will encourage the production of different spare parts of machines
previously abandoned in many industries due to the lack of spare parts or high
cost of their importation.
7.
Lastly, setting up mould producing industries will have a positive effect on
all facts of projects associated with lack of spare parts and accessories.
TABLE
A table is one of products of furniture
makers. The general term furniture has wide meanings but from the
standpoint of the cabinet makers, furniture was classified into four classes as
follows:
Supporting unit, which include tables,
desks, writing fitments.
Seating units, like chairs, stools, settees
etc
Reclinding units: like Beds, Divans etc
Storage units: like cabinets, side
boards, wood robles and bookcases.
The normal height of any working top in
the seated position is between 28½ in (720m) to 29 in (73.5cm) with chair seats
10½ in (27cm) to 11½ (29cm) lower.
TYPES OF TABLES
(1)
Refectory tables: They have long narrow trestle type table with
fixed tops used in dimming room in the middle ages.
(2)
Extending tables: They incorporate same form of lengthening top for
additional sitters, of which the type is the draw leaf extension table dating
from the 15th century and still one of the most popular form.
Examples are boardroom and conference tables.
(3)
Pedestal
tables:
They are usually circular or D – end and are supported by a central podium or
pillar terminating in three or four legs.
(4)
Sofa tables: They are rectangular tables with draws or the long side and small
flaps at the end supported by brackets.
(5)
Coffee tables: This is originally small
and circular tables with tray type logs, but now embracing a wide a range of
low occasional tables.
(6)
This will encourage the production of different spare parts of machines
previously abandoned in many industries due to the lack of spare parts or high
cost of their importation.
(7)
Lastly, setting up mould producing industries will have a positive effect on
all facts of projects associated lack of spare parts and accessories.
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