SUMMER TRAINING REPORT

ON

RUBBER MOLDING

AT

“JAYANTI RUBBERS”

IMT MANESAR.

Submitted in partial fulfillment of the requirement

for the award of degree of B. Tech (Mechanical).

Aditya Kumar Mandal

1501020023

4th Year

K.R. Mangalam University

(School of Engineering & Technology)

Gurugram

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CERTIFICATE

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 CANDIDATE’S DECLARATION

I, ADITYA KUMAR MANDAL, bearing roll no. 1501020023, a student of B. Tech

(Branch) hereby declare that I own the full responsibility for the information, results
etc. provided in this report titled “RUBBER MOLDING” submitted to K R
Mangalam University, for the award of B. Tech (Branch) degree. I have taken care
in all respect to honor the intellectual property right and have acknowledged the
contribution of others for using them in academic purpose and further declare that
in case of any violation of intellectual property right or copyright I, as a candidate,
will be fully responsible for the same. My supervisor should not be held responsible
for full or partial violation of copyright or intellectual property right.

This is to certify that the above statement made by the candidate is correct to
the best of my knowledge.

Dated:

Aditya Kumar Mandal

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 ACKNOWLEDGEMENT

It’s a great pleasure to present this report of summer training in JAYANTI RUBBERS
in partial fulfillment of B. Tech (ME) under K R Mangalam University. At the outset,
I would like to express my immense gratitude to my training guide Mr. Neeraj
Sharma guiding me right from the inception till the successful completion of the
training.
I would also like to thank my friends and all my group members for their help
and cooperation throughout the training. I also thank my friends, who have helped
me during this study.
In addition I thank one and all who have been instrumental in helping me
complete this project. I am extremely grateful and indebted to my parents and my
siblings for being pillars of strength, for their unfailing moral support, and
encouragement. I treasure their blessings and good wishes and dedicate this study to
them.

Name :- Aditya Kumar Mandal

Roll no :- 1501020023

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 ABSTRACT
Rubber molding is the process of producing usable rubber products. Rubber molding
creates molded rubber parts by pressing a block of rubber into a rubber molding metal
cavity. The rubber is then exposed to heat, activating a chemical reaction. While there
are variations in specific methods, all rubber manufacturers use heat and pressure
method to form molded rubber products. The three most common methods in the rubber
molding process are rubber injection molding, compression molding, and transfer
molding.
In Jayanti Rubbers, we learned about the processes taking place for conversion
of raw material till usable product. The very first step is to add the require chemicals to
the rubber by mixing it in a mixture and preparing a doe of the mixed rubber paste.
Then the doe is passed through set of rollers and thick sheets of rubbers is obtained.
The sheets are then supplied to the distinct machines. The operators of the respective
machines after receiving the required type of raw material for their job starts their
machines.
The different die according to the design of the job are fixed on different presses,
and process for all is same just the cycle time differs according to the complexity of the
job. In molding processes the rubber is being pressed into the molds and then
compressed by hydraulic forces at high temperature. Then it is cooled and undergoes
different tests for quality check. After being approved the job are cleaned and polished
if required and then packed and stored in stores for dispatch.

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 TABLE OF CONTENTS

Certificate i
Declaration ii
Acknowledgement iii
Abstract iv
Introduction 1
1. About the Company 2 to 3
a. Store 2
b. Design 2
c. Die manufacturing 3
d. Compounding 3
e. Mixing 3
f. Molding 3
g. Heat Treatment 3
h. Quality 3
i. Cutting 3
j. Polishing 3
k. Packaging 3
2. Practical Training 4 to 13
2.1 Store 4
a. Natural Rubber 4
b. EPDM 5
2.2 Compounding 6
2.3 Mixing 7
a. EP65065 7
b. REA610 8
c. EPSP0001 8
2.4 Rolling 8
2.5 Molding 9
Molding Process 10

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 2.6 Quality 11
2.6.1 Quality Improvements Methods 11
a. QFD 12
b. Kaizen 12
c. Zero Defect Program 12
d. Six Sigma 12
e. PDCA 12
f. Quality circle 12
g. The Toyota Production System 12
h. TQM 12
i. Top Down & Bottom Up Approach 12
3. Working area – Defects in molding process 14 to 20
a. Flow Lines 14
b. Sink Marks 15
c. Vacuum Voids 16
d. Surface Delamination 16
e. Weld lines 17
f. Short Shot 18
g. Warping 18
h. Burn Marks 19
i. Jetting 19
j. Flash 20
4. Conclusion 21
5. Reference 22

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 INTRODUCTION
Injection molding is a manufacturing process for producing parts by injecting molten
material into a mould. Injection molding can be performed with a host of materials
mainly including metals, (for which the process is called die- casting), glasses,
elastomer, confections, most commonly thermoplastic and thermosetting polymers.
Material for the part is fed into a heated barrel, mixed (Using a helical shaped screw),
and injected (Forced) into a mold cavity, where it cools and hardens to the configuration
of the cavity.
Injection molding is used to create many things such as wire
spools, packaging, bottle caps, automotive parts and components, toys, pock, some
musical instruments (and parts of them), one-piece chairs and small tables, storage
containers, mechanical parts (including gears), and most other plastic products
available today. Injection molding is the most common modern method of
manufacturing plastic parts; it is ideal for producing high volumes of the same object.

Figure 1: Rubber Part

Competitive Price - being manufacturer with in house manufacturing facilities

under one roof enables us to supply quality products at competitive prices to customers.
Advanced Engineering Facility - advance engineering facility enables us to develop and
produce the best quality products as per customer's specifications with minimum lead
time. In house modern tool room equipped with 3D CAD/CAM, CNC lathes.

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 1. JAYANTI RUBBERS

Jayanti Rubber Industries an ISO 9001- 2008 certified company. Situated at IMT
Manesar Industrial Area, sec– 6, plot no :- 240.

Figure 2 - Jayanti Rubbers

It delivers a range of products for the automotive industry. It had been a well reputed
and trusted name with 25 years of technical expertise in serving their esteemed
customers. It has a world class manufacturing facility fully equipped with latest
technology and highly skilled & motivated work force. They are renowned for quality
accuracy reliability and strongly believe in the use of innovative technology to ensure
precise manufacturing process. Their products are designed to address the unique need
of our esteemed customers.
The various sections in the company are as follows :-
a. Store – In this section the in and out flow of the material takes place, the storage
and record of raw material. The component provided by the other manufacturer are
also stored in this place only
b. Design - In this section, the design for dies is being created or modified according
the manufacturing process for that particular job design provided by the customer

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c. Die Manufacturing – The unit has its own CNC machines for manufacturing
dies with complex shapes and according to the drawing of the component
provided by the customer
d. Compounding – This is the process rubber is compounded with suitable additives
which enhances the rubber properties such as reinforcement, strength, hardness /
softness etc. this means the chemicals are prepared on the bases of their properties
and then passed on for mixing
e. Mixing – The chemical compounded are mixed with rubber thoroughly with the
help of a grinder. A homogeneous paste is prepared after it
f. Molding – In this step the paste of the rubber is poured to the respective molds of
the components and then the hydraulic works and we obtain the required part
g. Heat Treatment – In this process the parts obtained from the molds are kept in
high temperatures for certain period of time, as to improve the product strength and
hardness
h. Quality – In this section the quality inspection the component produced is done
by means of various property test as to meet the requirement of the customer.
i. Cutting – In this section the cutting of the parts (such as protector, pipes, covers
etc.) is done according to the demanded size
j. Cleaning/Polishing – In this step the finishing of the final product is done by polishing,
rubbing etc
k. Package – After the product is finished then it is packed and stored in the stores
for dispatch to the respective customer

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 1. PRACTICAL TRAINING

Rubber Technology is the subject dealing with the transformation

of rubbers or elastomers into useful products, such as protectors, covers, automobile
tires, rubber mats and, exercise rubber stretching bands. The materials includes
latex, natural rubber, synthetic rubber and other polymeric materials. Rubber processed
through such methods are components of a wide range of items.
In my training sessions I learnt about all the processes followed in the path of converting
the raw rubber to useful mechanical components. For this I started from the very first
place where the raw material comes first, and then followed the flow of raw material to
the respective sections as follows :-
2.1 Store – Raw Material In
The raw material which is imported in the unit the unit from different parts of the
country :-
a. Natural Rubber
b. EPDM Rubber
c. Blue Rubber – GR444
d. Yellow Rubber – RCEP10

➢ Natural rubber
Natural rubber, also called india rubber as
initially produced, consists of polymers of
the organic compound with minor impurities of
other organic compounds, plus water.
Natural rubber is used extensively in many
applications and products, either alone or in
combination with other materials. Here in
Jayanti Rubbers Natural rubber uses blue
rubber- GR444 as a constituent rubber with it
to fulfil the required properties of the Figure 3– Natural Rubber
component. It is generally used for
manufacturing of less tough parts such as protecting covers, pipes.

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➢ EPDM
EPDM rubber (ethylene propylene
diene monomer rubber), a type of
synthetic rubber, characterized by a
wide range of applications. EPDM is
compatible with polar substances,
such as fireproof fluids, hot and cold
water, and alkalis.

Figure 4 - EPDM rubber

Mechanical properties of EPDM

Property Value

Appearance White sheets

Hardness 40–90

Tensile failure stress, ultimate 25 MPa

Elongation after fracture in % ≥ 300%

Can be compounded from 0.90 to

Density
>2.00 g/cm3

Table 1 - Mechanical properties of EPDM

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EPDM is used for products which requires high thermal resistance and should be tough
in nature, for this purpose there are some basic common additives used among with
EPDM such as :- Silica, calcium, carbon as per component requirement.
Other then these, yellow rubber RCEP101 was used a constituent part of EPDM.
The products from the mixing of these
compounds are used for manufacturing
the exhaust supporting rubber clamps in
automobiles.
Automotive Parts:
• Weather stripping and seals
• Wire and cable harnesses
• Window spacers
• Door, window and trunk seals
Figure 5 - Yellow Rubber

2.2 COMPOUNDING
The unique property of rubber is that it is elastic. When rubber is stretched, the
molecular bonds can be extended out. When released, the molecules coil back to their
original shape.

In it raw state rubber consists of long

randomly linked hydrocarbon chains
which can slide past each other. Raw
rubber is therefore plastic, weak and
permanently deformable. The purpose of
compounding (vulcanization curing) is to
Figure 6 - Compounding
chemically link the rubber chains
together by “crosslinks” to form a three – dimensional network.
In this process there are pre-defined compositions of the mixtures of the chemical
saved in the system. The operator has just to weigh the chemicals respectively as guided
by the system and pour those chemical all together.
The various types of chemicals for mixing are as following:-
a. 2DBC – this helps in baking of the inner links of the compound
b. PVI - this helps in maintaining the temperature of the compound (90-100oC)
c. MBTS – this helps in baking of the compound thoroughly

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d. TMT – it controls the hardness the rubber compound
e. Sulphur – it helps in baking of the compound from outer surface
f. OBSH – it enhances the expanding property of the compound
g. M/C Wax – it helps in flow enhancement compound surface
h. Steric Acid – this also helps on improving property of the compound
i. CI Resin – is used as the excellent processing aid in the compounding of range
of rubber. It is also used as tackifier in the rubber based contact adhesives

1.3 Mixing
In this step the mixing of the chemicals compounded and the raw rubber takes place at
certain temperature. This can be related to the process of making doe.
This process also pre-defined for the different three
varieties of rubber products produced in the
company.
The time duration for different rubber types are as
following :-
a) EP65065 – 35 min
b) REA610-K2 – 22 min
c) EPSP001 – 20 min
The time duration of mixing of these compounds
inhibits different properties such as hardness,
tensile, thermal resistance etc.
Figure 7 - Mixer

➢ EP65065
This is the industrial name for exhaust part. The name it self gives the details about
the product as :- EP – exhaust part.

65– hardness of the rubber compound.

65 – tensile strength of the compound.

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➢ REA610
This is the industrial name given to protector covers
which are softer in nature. Here
61 – is the hardness of the mixed compound.
➢ EPSP0001
These are the soft pipes with minimum hardness
resembles as sponge.

Figure 8 - Mixed rubber compound

2.4 Rolling
After the chemicals are being mixed properly mixed in the mixer, with their respective
time durations. The paste or doe prepared in the
mixture can’t be used directly by the workers in
the machines. Rather the paste is being then
prepared into thin sheets.
This is done by means of rollers, in this there
are two rollers aligned rigidly parallel to each
other in such a way that the gap between both
can be adjusted according to the required
thickness of the rubber paste
• In this section the workers has to just guide
the rubber path in the direction of the rollers
rolling so
Figure 9 - Roller
that a continuous sheet of the paste is prepared
although
After the sheets of rubber are produced, the sheets are left undisturbed to few hours so
that they temperature may cool down and then can be passed on for further processing.

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2.5 Molding
A mold or is a hollowed-out block that is filled with a liquid or pliable material such as
rubber, plastic, metal, as raw material. The liquid hardens or sets inside the mold,
adopting its shape. A mold is the counterpart to as cast.
There are a number of factors to consider when determining the type of molding process
required. Some of these include:
• The size and geometry of your part
• The weight of your par
• The Material required
• The volume of parts require

Figure 10 - Mold

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➢ Molding Process
Processes Similar to compression molding, transfer molding requires secondary raw
material preparation into "pre-forms" that are loaded into a "pot." When the mold is
closed, a "piston" compresses the rubber in the "pot" and forces it through holes or
sprues into the cavity to fill the part cavity. The advantages of transfer molding over
compression molding can include:

Figure 11 - Molding department

• Fewer and simpler pre-forms because one pre-form can fill many of cavities.
• Tighterdimensional tolerance control because the mold is closed, therefore it is not
held open by excess material spilling out of the cavity parting line during molding.
This keeps part geometry more exact and parting lines smaller and less noticeable.
• Colored rubber parts benefit because pre-forms can be cut by hand from raw
material sheets, significantly reducing the chance of contamination that can come
from mechanical prep for compression molding or the injection screw and barrel in
injection molding.
• Material in the "pot" pre-heats before being forced into the cavities. This decreases
the viscosity of the material, allowing it to flow more easily into the cavities for
reduced cure time. The primary disadvantage is increased waste; the "flash pad" or
rubber left in the pot after transfer is typically cured and has to be discarded.

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2.6 Quality
Quality management ensures that an organization, product or service is consistent. It
has four main components: quality planning, quality assurance, quality
control and quality improvement. Quality management is focused not only on product
and service quality, but also on the means to achieve it. Quality management, therefore,
uses quality assurance and control of processes as well as products to achieve more
consistent quality.
These are some include key concepts such as:
• Break down barriers between departments
• Management should learn their responsibilities, and take on leadership
• Supervision should be to help people and machines and gadgets to do a better jo
• Improve constantly and forever the system of production and service
• Institute a vigorous program of education and self-improvement

2.6.1 Quality improvement methods

Figure 12 - The PDCA cycle

There are many methods for quality improvement. These cover product improvement,
process improvement and people based improvement.

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 In the following list are methods of quality management and techniques that
incorporate and drive quality improvement:
a. QFD — quality function deployment, also known as the house of quality
approach
b. Kaizen — Japanese for change for the better; the common English term
is continuous improvement
c. Zero Defect Program — created by Corporation of Japan, based upon process
control and one of the inputs for the inventors of Six Sigma.
d. Six Sigma — 6σ, Six Sigma combines established methods such as statistical
process control, design of experiment and failure mode and analysis in an
overall framework
e. PDCA — plan, do, check, act cycle for quality control purposes. method
(define, measure, analyze, improve, control) may be viewed as a particular
implementation of this.)
f. Quality circle — a group (people oriented) approach to improvement.
g. The Toyota Production System — reworked in the west into lean
manufacturing
h. TQM — total quality management is a management strategy aimed at
embedding awareness of quality in all organizational processes. Promoted in
Japan with the Deming prize which was adopted and adapted in USA as
the Malcolm Baldrige National Quality Award and in Europe as the European
Foundation for Quality Management award (each with their own variations)
i. Top Down & Bottom Up Approach—Leadership approaches to change

Jayanti Rubber also follows these basic principles mentioned above which are suitable
and helps in enhancing the process and productivity with minimum defects and max
efficiency. It follows the policies such as kaizen and TQM. There are basic 3 test
performed for the quality assurance of the product, these are as follows :-

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a. Hardness
The hardness of the produced part is tested
according to the design consideration of the of the
product design provided by the customer. For
hardness testing a Oscillating Disc Rheometer. The
result is being displayed in form of graph. The curve
plotted shows that the product produced is
according to composition required.
Figure 13 - Oscillating disc rheometer

b. Tensile strength
This test is being performed to test weather the
tensile strength of the product manufactured is
reliable or not. This is done with the help of
Oscillating Disc Rheometer. The die and operation
of rheometer is adjusted as per tensile forces.

Figure 14 - Oscillating disc rheometer

c. Composition check
In this process the composition of the component is
being checked to ensure that there is no patterns
change in the rubber composition according to the
properties. This is done by testing a cut piece of the
manufactured product.

Figure 15 - sample

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 3. Defects in molding process
Making injection molded prototypes is both an art and a science. High levels of
technical expertise and attention to detail are required to prevent small mistakes from
costing companies big money when it comes to mass-production of novel parts.
Preventing such a circumstance is all about highly competent design. This article
discusses some of the molding defects that can occur in a part during injection molding,
and ways to fix and avoid them. Design shortcomings we will discuss include:
a. Flow Lines
b. Sink Marks
c. Vacuum Voids
d. Surface Delamination
e. Weld Lines
f. Short Shots
g. Warping
h. Burn Marks
i. Jetting
j. Flash
Most mistakes are caused by personnel without the necessary experience or the right
tools at their disposal. Conversely, creative solutions and ingenuity abound in personnel
with the right experience and the correct combination of hardware and software.
Finding the right team of people with relevant expertise is the most important part of
the process.
a. Flow Lines
Description: Flow lines are streaks, patterns, or
lines - commonly off-toned in color - that show
up on the prototype part as a consequence of the
physical path and cooling profile of the molten
plastic as it flows into the injection mold tooling
cavity. Injection molded plastic begins its
journey through the part tooling via an entry
section called a “gate.” It then flows through the
tool cavity and cools (eventually hardening into Figure 16 - Flow Pattern

a solid).

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Causes: Flow line defects are caused by the varying speed at which the molten plastic
flows as it changes direction through the contours and bends inside the mold tool. They
also occur when the plastic flows through sections with varying wall thickness, or when
the injection speed is too low causing the plastic to solidify at different speeds.
Remedies:
• Increase injection speeds and pressure to the optimal level, which will ensure the
cavities are filled properly (while not allowing the molten plastic time to start
cooling in the wrong spot). The temperature of the molten plastic or the mold itself
can also be elevated to ensure the plastic does not cool down sufficiently to cause
the defect.
• Round corners and locations where the wall thickness changes to avoid sudden
changes in direction and flow rate.
• Locate the gate at a spot in the tool cavity with thin walls.

b. Sink Marks
Description: Sink marks are small craters or depressions
that develop in thicker areas of the injection molded
prototype when shrinkage occurs in the inner portions of
the finished product. The effect is somewhat similar to
sinkholes in topography, but caused by shrinkage rather
than erosion.
Figure 17 - Sink Marks
Causes: Sink marks are often caused when the cooling
time or the cooling mechanism is insufficient for the plastic to fully cool and cure while
in the mold. They can also be caused by inadequate pressure in the cavity, or by an
excessive temperature at the gate. All else being equal, thick sections of the injection
molded part take longer to cool than thin ones and so are more likely to be where sink
marks are located.
Remedies:
• Mold temperatures should be lowered, holding pressure increased, and holding time
prolonged to allow for more adequate cooling and curing.
• Reducing the thickness of the thickest wall sections will also ensure faster cooling
and help reduce the likelihood of sink marks.

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c. Vacuum Voids
Description: Vacuum voids are pockets of air
trapped within or close to the surface of an
injection molded prototype.
Causes: Vacuum voids are often caused by
uneven solidification between the surface and the
inner sections of the prototype. This can be
aggravated when the holding pressure is Figure 18 - Vacuum Voids

insufficient to condense the molten plastic in the mold (and thereby force out air that
would otherwise get trapped). Voids can also develop from a part that is cast from a
mold with two halves that are not correctly aligned.
Remedies:
• Locate the gate at the thickest part of the molding
• Switch to a less viscous plastic. This will ensure that less gas is trapped as air is able
to escape more rapidly
• Increase holding pressure as well as holding time
• Ensure that mold parts are perfectly aligned

d. Surface Delamination
Description: Surface delamination is a
condition where thin surface layers appear on the
part due to a contaminant material. These layers
appear like coatings and can usually be peeled
off.
Figure 19 - Surface Delamination
Causes: Foreign materials that find their way
into the molten plastic separate from the finished product because the contaminant and
the plastic cannot bond. The fact that they cannot bond not only has an affect on the
appearance of the prototype, but also on its strength. The contaminant acts as a localized
fault trapped within the plastic. An over-dependence on mold release agents can also
cause delamination
Remedies:
• Pre-dry the plastic properly before molding
• Increase the mold temperature

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• Smooth out the corners and sharp turns in the mold design to avoid sudden changes
in melt flow
• Focus more on the ejection mechanism in the mold design to reduce or eliminate
the dependence on mold release agents

e. Weld Lines
Description: Weld lines are actually more
like a plane than a line that appears in a part
where molten plastics meet each other as
they flow from two different parts of the
mold.
Causes: Weld lines are caused by the
inadequate bonding of two or more flow Figure 20 - Weld Lines

fronts when there is partial solidification of

the molten plastic.
Remedies:
• Raise the temperature of the mold or molten plastic
• Increase the injection speed
• Adjust the design for the flow pattern to be a single source flow
• Switch to a less viscous plastic or one with a lower melting temperature

f. Short Shot
Description: As the term implies, short shots can
be described as a situation where a molding shot
falls short. This means that the molten plastic for
some reason does not fully occupy the mold
cavity or cavities, resulting in a portion where
there is no plastic. The finished product becomes
deficient because it is incomplete.
Figure 21 - Short Shot
Causes: Short shots can be caused by a number
of things. Incorrect calibration of the shot or plasticizing capacities can result in the
plastic material being inadequate to fill the cavities. If the plastic is too viscous, it may
solidify before fully occupying all the cavities and result in a short shot. Inadequate

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degassing or gas venting techniques can also result in short shots because air is trapped
and has no way to escape; plastic material cannot occupy the space that air or gas is
already occupying.
Remedies:
• Select a less viscous plastic with higher flowability. This plastic will fill the hardest-
to-reach cavities
• Increase mold or melt temperature so as to increase flowability
• Account for gas generation by designing the mold so that gas is not trapped within
the mold and is properly vented
• Increase the material feed in the molding machine or switch to a machine that has a
higher material feed in the event that the maximum material feed has been reached

g. Warping
Description: Warping (or warpage) is the
deformation that occurs when there is uneven
shrinkage in the different parts of the molded
component. The result is a twisted, uneven, or bent
shape where one was not intended
Figure 22 - Warping

Causes: Warping is usually caused by non-uniform cooling of the mold material.

Different cooling rates in different parts of the mold cause the plastic to cool differently
and thus create internal stresses. These stresses, when released, lead to warping.
Remedies:
• Ensure that the cooling time is sufficiently long and that it is slow enough to avoid
the development of residual stresses being locked into the part
• Design the mold with uniform wall thickness and so that the plastic flows in a single
direction
• Select plastic materials that are less likely to shrink and deform. Semi-crystalline
materials are generally more prone to warping

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h. Burn Marks
Description: Burn marks are discolorations,
usually rust coloured, that appear on the surface of
the injection molded prototypes.
Causes: Burn marks are caused either by the
degradation of the plastic material due to excessive
heating or by injection speeds that are too fast.
Burn marks can also be caused by the overheating
of trapped air, which etches the surface of the
Figure 23 - Burn Marks
molded part.
Remedies:
• Reduce injection speeds
• Optimize gas venting and degassing
• Reduce mold and melt temperatures

i. Jetting.
Description: Jetting refers to a situation where molten plastic
fails to stick to the mold surface due to the speed of injection.
Being fluid, the molten plastic solidifies in a state that shows the
wavy folds of the jet stream on the surface of the injection
molded part.
Figure 24- Jetting

Causes: Jetting occurs mostly when the melt temperature is too low and the viscosity
of the molten plastic becomes too high, thereby increasing the resistance of its flow
through the mold. When the plastic comes in contact with the mold walls, it is rapidly
cooled and the viscosity is increased. The material that flows through behind that
viscous plastic pushes the viscous plastic further, leaving scrape marks on the surface
of the finished product.
Remedies:
• Increase mold and melt temperatures
• Increase the size of the gate so that the injection speed becomes slower
• Optimize gate design to ensure adequate contact between the molten plastic and the
mold.

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j. Flash
Description: Flash is a molding defect that
occurs when some molten plastic escapes
from the mold cavity. Typical routes for
escape are through the parting line or
ejector pin locations. This extrusion cools
and remains attached to the finished
product. Figure 25 - Flash
Causes: Flash can occur when the mold is
not clamped together with enough force (a force strong enough to withstand the
opposing forces generated by the molten plastic flowing through the mold), which
allows the plastic to seep through. The use of molds that have exceeded their lifespan
will be worn out and contribute to the possibility of flash. Additionally, excessive
injection pressure may force the plastic out through the route of least resistance.
Remedies:
• Increase the clamp pressure to ensure that the mold parts remain shut during shots
• Ensure that the mold is properly maintained and cleaned (or replaced when it has
reached the end of its useful lifespan)
• Adopt optimal molding conditions like injection speed, injection pressure, mold
temperature, and proper gas venting

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 4. CONCLUSION

It’s always a great opportunity to experience the valuable exposure of an industry.

There is a lot of differences between Theories and Practices. This training enables me
to understand the aspects of professional life. I like the working environment followed
at JAYANTI RUBBER and came to know how to deal with our colleagues. I saw and
experienced how various types of machine processes are done.
I also learned how an industry functions. I could easily relate these concepts to
the theory we studied in class. I now have a better understanding about these concepts.
First of the many things that I learned is how to manage time properly, I had to learn as
much I could in the limited time that I had.
Interacting with the employees and workers gave me the experience that no
book can give me. Understanding the concepts from their point made the concept easier
to understand. They helped me get the hands-on experience how things are done in the
factory. I learnt how to use various types of instruments used in QC. I learnt the
importance of every department of an industry and how they all are connected to each
other.
Apart from all these I also learnt about work place ethics, what to do and not to
do in a factory. Overall the internship program was very knowledgeable as well as
enjoyable. I had a lot of fun working with this company. It gave me the practical
experience which was very important at this stage of my life. This internship gave me
a platform for my professional life.

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 Reference

1. http://exhaustmountings.com/
2. http://www.exhaustmountings.com/products
3. http://www.accurate-prod.com/rubber-molding-process/
4. https://www.creativemechanisms.com/blog/what-cause-injection-molding-defects-
and-how-to-fix-them
5. https://en.wikipedia.org/wiki/Injection_moulding
6. https://www.creativemechanisms.com/blog/basic-steps-of-injection-molding-
process
7. https://en.wikipedia.org/wiki/Injection_moulding

The summer internship process report was in the under guidance of

technical group /department of Jayanti Rubbers Pvt Ltd.

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