Hydraulics and Pneumatics: Hydraulic Pump Design - Term Paper Example

Hydraulics and Pneumatics: Hydraulic Pump design Number Semester ID Number Due Submitted TABLE OF CONTENTS 1.0 Design of Hydraulic pump rotor 3 2. Specifications and design consideration 4 3. Operating principles 4 4. Performance and limitations 5 Design of Pumps 6 1. Introduction 6 2. Specifications and design consideration 7 3. Operating principles 9 4. Performance and Limitations 11 4.1. Determination of performance using Moody Charts 14 5. Theoretical and actual Efficiencies 17 5.1. Evaluation of performance curves 19 6. Discussion 36 7. References 40 Design of Hydraulic pump rotor From a range of applications of computational fluid dynamics of use to design engineer, the major examples that have been chosen for detailed discussion includes an experimental data in addition to 3D Euler and 3D Navier-Stokes results for flow on a rotor. This paper involves the use of 3D potential flow codes that have been used over the years whose design is limited to design point, the use of Euler codes to describe flow in fields within turbo machinery as well as velocity effects with the assumption that there is no turbulent effect. 2. Specifications and design consideration Generation of power by use of hydraulic pump turbines has a long historical tradition. The first actually operating inward flow turbine was created and tested in Massachusetts. Present Francis turbines have been improved into a number of forms from the original but they operate under the principles of radial inward flow turbines (Dunn, 2001). The impulse flow pump turbine that were developed initially operated in the USA in the form of Pelton wheel with split bucket and a central edge in 1880.Pelton wheel with double elliptic buckets that includes a notch for the jet and a needle that controls the nozzle. 3. Operating principles For rotor flow at the inlet and outlet are radial, while the inflow and outflow at the runner are totally axial. Generally, the system involves the use of steel scroll cases for heads between 35 and 65 m in addition to spiral casing for heads between 35m and 65m. The runner diameter for the largest hydraulic turbine pump is up to 10 m (Massey, 1996). The design of horizontal bulb hydraulic pump turbines include horizontal axis with the advantage of having a straight flow path through the intake and draft tube. 4. Performance and limitations It is possible to estimate the torque on any turbo machinery rotor from the inlet and outlet velocity triangles resulting into Euler equation that assists in calculation of specific energy transferred by the runner. In the case of hydraulic turbines the degree of reaction is defined as the ratio of a drop in static pressure across the runner to the static pressure drop across the stage. Pelton turbines are small turbines that do not have reactions with the occurrence of pressure drop across the stationary structures while no drop in pressure across the runner. For pumps, the flow coefficient Φ and the head coefficient Ψ are normalized with the speed of the rotor blade in the same way to other turbo machines as follows: Design of Pumps 1. Introduction Pumps provide mechanisms of moving fluids from one level to another and are excellent areas of application of hydrostatic principle (Eastop, 1997). The main types of pumps in use are hydrostatic or positive displacement pumps and centrifugal pumps. This paper focuses on centrifugal pumps that can be understood by hydrostatic considerations. This paper provides a report about the types of modern pumps that are commonly used to accomplish functions of pipes and the aims of this report is to provide detail regarding the types of pumps used in industries, their design considerations and specifications during design. It also includes an experimental framework for assessing efficiency of the pump and explains the theory behind the experiments. It also includes an evaluation of techniques for finding power consumption features of hydraulic pumps. It includes a description of procedures used to determine power consumption of pumps and the nature of equipment that can be used to measure these performance characteristics. 2. Specifications and design consideration Manufacture of hydraulic pumps is based on different functional and hydraulic considerations such as medium of operation, range of pressure and type of drive. There are a large number of design principles behind hydraulic pumps thus not every pump has the capacity to meet all the recommendations of an optimum degree. In the design of hydraulic gear pumps, the main design considerations are focused on application in machine tools, transfer of fluid power and oil pump engines (Massey ,1996). The main factors to consider during their design is that they must be of relatively low weight, operate at moderately high pressures, operate at a high speed range and a wide range of temperature and viscosity and they are of low cost during manufacture. The other design considerations for gear pumps is that the displacement volumes should be 0.2 to 200 cc, maximum limiting pressure should be up to 300 bars and the operating range of speed should be between 500 and 6000 rpm. In the case of hydraulic piston pumps, the main design considerations include ensuring that the pump has a compact size, high power density, optimum efficiency high torque and high operating pressure. The main design considerations for axial piston pumps include displacement volume being between 5 and 1000 cc, maximum limiting pressure should be about 450 bars while speed range should be between 1500 and 11000 rpm. For radial pumps, the main design considerations include when there is the need for a pump that can operate under a high pressure zone such as 400 bars and 700 bars. These pumps can be obtained in two different configurations. In the case of eccentric blocks, rotation of the piston takes place within an external ridge. Thus stroke is determined by the amount of eccentricity of the shafts. The design considerations for such pumps include displacement volumes between 0.5 and 100 cc, maximum permissible pressure of 700 bars irrespective of the size, and range of speed from 1000 to 3000 rpm independent of size. 3. Operating principles In the case of positive displacement pumps, the force lift pumps there are two valves one located in the cylinder and the other located in the piston. The amount of lift is determined by level of atmospheric pressure and the cylinder has to be within this height of a free surface. The operating principle of a pump is dependent on the nature of the pump. Centrifugal pumps are either radial, axial or mixed flow pumps. In radial pumps, pressure is developed by centrifugal force, in mixed flow pumps; pressure is developed partly by centrifugal force and partly by lift of the vanes of the impeller on the fluid. In axial flow pumps, pressure is developed by lifting action of the vanes of the impeller on the water. In centrifugal pumps, the energy of the prime mover is converted into velocity or kinetic energy and finally converted into pressure energy of the fluid that is being pumped. Changes in energy occur as a result of two major parts of the pump, the impeller and the volute. The impeller is the rotating member which converts the driver energy into pressure energy (Bolton,1998). The volute refers to the stationary part that performs the function of converting kinetic energy into pressure energy. When liquid enters the suction nozzle and then moves into the eye of a revolving mechanism referred to as the impeller as the impeller rotates it spins the liquid located in the cavities between the vanes towards the outer region and provides centrifugal acceleration. When the liquid leaves the impeller there is a low pressure resulting into flow of more liquid towards the inlet. The action of impeller blades takes place on the inner sides of the pump, and keeps the water within the bucket that is rotating at the end of the string. In positive displacement pumps, there is an expanding cavity on the suction side and the cavity decreases towards the discharge side. Liquid flows into the pump during expansion of the cavity on the suction side and the liquid is made to discharge as it collapses. In positive displacement pumps, the same flow is obtained at a given RPM rate of revolution irrespective of the discharge pressure. In external gear pumps, only a single gear wheel is connected to the drive while the other is allowed to rotate in the opposite direction to ensure interlocking of the teeth of the rotating gear. The use of bearing clock ensures gear wheels are positioned in a manner that interlocking occurs with minimum clearance. 4. Performance and Limitations Performance of pumps is affected by losses in head and shear stresses within the liquid as well as turbulence that occur within the walls of the pipe due to roughness of the pipe materials. This is usually referred to as pipe friction and is considered as feet of head of the fluid. There are a number of factors that affect head loss in pies, such as the viscosity of the fluid runner consideration, size of pies as well as roughness of the material making up the pipe and changes in elevation within the pipe system. Head loss is also affected by resistance through various valves that have an effect on overall head loss. A method of modelling the resistances through the valves and fittings is of major importance to the ultimate head loss. There are a number of studies that have been conducted to determine head losses in pipes and they are based on experimental data. One of these studies is the Chézy formula that deals with flow of water in open channels. By using the concept of ‘wetted perimeter’ concept and internal diameter of a pipe, this formula can be adapted to determine head loss in pipes. Shaft power of a pump refers to the mechanical power conveyed to the pump by the shaft. It is given by finding the product of the speed of the shaft and torque transmitted. This is explained by the equation below: In the equation above, w represents the angular speed in radians/s while T represents torque in Nm. Since measurements of speed are usually in rev/min, the alternative formula is as shown below: In the new equation, N represents speed in rev/min. Fluid power refers to the energy transferred per second carried by the fluid and is obtained in terms of pressure and quantity. The equation used to determine fluid pressure is as shown below: In the above equation, Q represents flow rate in m3/s and ∆p represents drop in pressure over the pump in N/m2. The overall efficiency of the pump is given by the ratio of power output to the power input. Since friction and internal leakages exist, the power input of the pump is usually larger than the power output. Hence, the overall efficiency is given by the following equation: Example: When a pump delivers 10dm3/min with a pressure rise of 80 bar and shaft speed of 1420 rev/min and the displacement of the pump is 8 cm3/rev. The operating characteristics of the pump can be determined as follows. Assuming torque transmitted is 11.4Nm. Ideal flow rate =Nominal Displacement X speed = 8 X 1420= 11360 dm3/min = 11.36 dm3/min Volumetric efficiency = Actual Flow/Ideal Flow = 10/ 11.36 = 88 per cent Q = (10X10-3)/60m3/s=16.7X10-6 m3/s. ∆p = 80 X105 N/m2 Hence, fluid power = Q∆p = 16.7 X 10-6 X80 X 105 = 1333.3 Watts Shaft Power is obtained by 2πNT/60 = 2πX1420/60 = 1695.2 Nm Overall efficiency is given by F.P/S.P = 1333.33/1695.2 = 78 per cent. 4.1. Determination of performance using Moody Charts This is the process where the user can plot Reynolds number and the Relative Roughness of a pipe and to determine accurate value of the friction factor for turbulent flow situations. The Moody-Chart encouraged the use of Darcy-Weisbach friction coefficient and this has been adopted by hydraulic engineers. There are a number of head loss calculators that have been developed to assist in these estimations. The time needed for calculation of friction factor has been simplified by development of personal computers from the 1980’s and it has been possible to calculate head loss by use of Darcy-Weisbach formula to all areas where other formula are not used. Pressure drop can be calculated by use of the dimensionless chart and flow rate can also be calculated. In the above equation, V is the velocity in the pipe, f is the friction factor from the Moody Chart, l is the length of the pipe while d is the diameter of the pipe. The chart plots Darcy-Weisbach friction coefficient against Reynolds number for a number of relative roughnesses’s and flow conditions. Relative roughness is determined as the ratio of mean height of roughness of the pipe to diameter of the pipe l/d. Figure 1. Moody Chart 5. Theoretical and actual Efficiencies Rating systems for pumps is based on maximum operating capacity and the corresponding output, in gpm. Mechanical efficiency of a pump is also less than the ideal efficiency because some of the energy is used to overcome friction. Overall efficiency is obtained by finding the product of volumetric efficiency and hydraulic efficiency. Pump performance measurements are done by measuring certain elements related to their performance. They include the following: Pressure measurement: measurement of pump pressure is done by the use of a strain based pressure sensor that has an in-built signal conditioning. It is used to measure back pressure drop in pumps as a result of automated flow control valve. Temperature measurement: measurement of temperature in pumps is done in two areas; at the test tank and at the storage tank. The measurements from these locations are used to control heater and cooler systems of the rig. Tachometer: A tachometer powered from a DC supply is used to determine the speed of the test pump. This is useful in monitoring the speed for data logging. Flow meter: In order to measure delivery rate of the pump, a positive displacement floe meter is used. The three major categories of efficiency used to describe hydraulic pumps include volumetric efficiency, mechanical efficiency and hydraulic efficiency. Actual flow is measured by use of flow meter while theoretical flow is determined by multiplying displacement per revolution by driving speed. Mechanical efficiency of a pump is determined by dividing theoretical torque required to drive it by the exact torque required to drive it. A hydraulic or mechanical efficiency is 100 per cent if the pump is operating at zero pressure; no force is required during its driving process. In a case where a positive displacement pump is operating under a slip condition, there is a loss in the ability to deliver the volume of liquid it has the capacity to pump. For a specific pump and fluid the slip is directly proportional to difference in pressure from the outlet to the inlet. When the pump has no slip, volume pumped is proportional to the rate of rotation in RPM. Overall efficiency can be determined by multiplying mechanical and hydraulic efficiency. For instance, when hydraulic efficiency is 0.9 while mechanical efficiency is 0.91, the overall efficiency is obtained by 0.9X0.91 which gives 0.82. During the process of evaluating volumetric efficiencies on the basis of actual testing, there is the need to be aware that leakage paths existing in the pumps are generally constant. This implies that if a pump is tested at a less than full displacement, there will be a skew in calculated efficiency except when the leakage is treated as a constant. 5.1. Evaluation of performance curves This involves the use of Navier-Stokes codes in the simulation methods as well as a review of the process of generating the right grid for complex geometry in hydraulic machines and demonstration of CFD applications to determine flow fields and hill charts for vane pumps. Generally, there is no particular grid generation approach that accomplishes the requirements caused by various components of hydraulic pumps. Due to geometrical complexity of most hydraulic machines structures under study, these components are constructed with the use of high quality block-structured meshes for geometrically and topologically complicated domains. In order to prevent highly skewed grid cells, there is a construction of the main body of the mesh by use of a butterfly design of sub blocks. To capture all important flow phenomena, grid resolution has to be considerably high. The grids for guide vane passages have and draft tubes have been constructed by application of grid generation software TASC grid that forms a section of the CFX-TASC flow software package. A significant advantage of using TASC grid is its capacity to parameteze a number of geometrical descriptions. This allows changing the guide vane angle within particular limits by changing the value of single parameter in the input file. In determination of stage capability, steady state interaction between stationary and rotating structures in turbo machinery undergoes simulation by mixing plane between components. It involves a calculation of each component in its own frame of reference and allows reduction of blade rows to single-blade channels with periodic boundaries. This method is based on stage simulation that has been incorporated into TASC flow estimation process. 6.0 Clamping and Press System design: Small Moulding Machine In this paper, a simple small moulding machine will be developed for the very purpose of making plastic items in on a small scale (Khurmi, 2003). The paper work will involve designing, constructing and testing the small moulding machine. This machine will be applicable in the formation of plastic items where it produces resins into cooled and closed mould. In the process, the mould produced solidifies to produce the items desired (Khurmi, 2003). The machine design operation, concept and components assembly will be considered. The selection of materials and drawings used in this machine will also be used accordingly as per the calculations made. The material selection and drawing are based on the diameter calculation of the teeth number needed for the plunger rack, angular velocity, power, torque, spur gear, angular velocity, number of revolution and the plunger diameter. 6.1 Process design The process consists of the introduction of the mould which is the granules as the raw materials into the cylinder end part (Khurmi, 2003). These raw materials are then heated in the hot chamber, then forming this molten in the form of a closed mould. The Mould cavity configuration takes place in the very last solidification of the metal in molten form. The simple small moulding machine will consist of medium carbon steel and mild steel. Mild steel is weldable, and is workable though is not that responsive to the treatment of heat (Khurmi, 2003). This way the machine shall consist of 2 main components; the clamping unit and the injecting unit. For the injecting moulding it can be applied with a combination of different plastic resins. The most suitable resin for this process is polyethylene since it can be shaped in a variety of ways easily (Khurmi, 2003). The major benefit of using the process of small injection is that the end product gets a good finishing with less flashes and scrap coupled with low cost on the labor. Design analysis and concept This consists of the following; (i) The greatest melt volume required to make the mould full. This is involves the distance the plunger travels (l), the barrel diameter as d, the density of the melt and the mass of the melt (m). (ii) The Barrel design involves the barrel diameter and the greatest piston travel distance. (iii) Plunger design. On the other hand, the analysis of this design consists of the following; (i) The clamping unit made up of the platens, mould, and the locking device which is the handle. (ii) The electrical panel consisting of the contactors, temperature control, heat resistance wire, thermocouple, and the control button otherwise known as the knob. (iii) The injection unit consisting of the barrel, hopper, injection plunger, heater bands, and nozzle. Injection plunger design The diagram below shows the design of the injection plunger where the melt volume (V) that the plunger can push with success is determined by getting the plunger diameter value (Khurmi, 2003). Rack Press Part: Injection Plunger Using the above diagram the plunger diameter can be obtained from the below equation as follows; …………Equation 1 …………Equation 2 The above expression 1 can put in diameter terms as follows ………………………………Equation 3 In the same way, the volume (V) of the barrel melt can also be expressed in the following way Following way; ………………………..Equation 4 Thus, V1 =V2 This means that. ……………………………….. Equation 6 By making ……………………………..Equation 7 Thus, the diameter of the plunger can be found from the above equation 7 as follows; Teeth number needed on the rack of the plunger These can be determined as follows Teeth number needed on the pinion (spur gear) Teeth number needed on the pinion (spur gear) = Selection of the Motor The motor velocity which is the angular velocity can be determined from below equation; In the same way the revolution number given by N can be determined by the following equation. Also, the motor torque (T) can be found by using the following equation; In this respect, the power (P) is calculated by the following formula: Handle design In this design, the handle leverage of the simple small moulding machine is determined as in the following way (Khurmi, 2003); =g Calculations of the machine design In this part of the work, the calculations of the machine design will be made (Khurmi, 2003). These design calculations are inclusive of the following; Teeth number needed for the plunger rack Teeth number required for the plunger rack Teeth number needed for the pinion or the spur gear Injection plunger diameter Handle leverage Selection of the motor 3.0 Procedure used In the design of this machine, testing, performance, the parts specification and construction are the major parts of the methods that were needed to be used in order to get the right results. 3.1 Machine assembly The methods followed in assembling the machine were as follows: Fixing the machine main frame Positioning of the bolt and supporting plates to join with the tie bars Bolting the barrel to the plate 2 of support Mounting the plunger assembly via the plates of support which are plates 1 and 2. Putting into position the driven unit to the plunger assembly; the driven unit consists of; reduction gear, electric motor and the spur gear. Mounting the locking device which is the handle through the plate 4 as the support and then to the platen. Installing the mould to the support of the platen and the plate 3 as the other support. 3.2 Drawing working The drawings are all on the basis of the designs set above. The internal and the external machine components have specifications (Khurmi, 2003). This construction is based on the machine design. The construction techniques adopted The main methods of construction adopted in the design of the machine are as follows; Drilling using the drilling machine. Using oxyacetylene gas welding machines to cut. Using the lathe machine in the machining operation Using arc welding machine in electric welding Grinding for the purpose of a good finishing Mainly, these operations were all divided further into the following; welding operation, assembly, machine operation, cutting operation and the finishing operation (Khurmi, 2003). 6. Discussion The study of pump characteristics is significant in understanding a number of pump characteristics that are necessary to know when selecting a pump for a particular purpose. This is based on understanding of various pump characteristics that are significant in achieving high efficiencies. During selecting of a pump for a particular purpose, there are certain factors that have to be considered. They include flow rate, line pressure pumping lift, power specifications, and pipe sizes with consideration of each of these components separately during pumps selection. However, the most important characteristic that needs to be considered in selecting the right pump is the pumping lift and the total dynamic pressure head. Other factors to consider include the total dynamic heads such as total static head and pressure head. Static head and suction head are other factors to consider during pump selection. Suction head involves the vertical suction lift as well as friction losses that occur in valves and elbows or pies and other fittings located on the suction side of the pump. To assist in understanding the reasons behind leakages in pumps at a particular pressure and temperature, the analysis of pump characteristics assist in determining rates of flow and pressure drops across the pumps as well as fluid viscosity. By studying these variables, rates of internal leakage can be studied and the expected performance determined. Calculation of overall efficiency is significant in determining the power required to drive a pump at a particular pressure and flow rate. Conclusion The construction, testing and design of the simple, small, moulding machine with clamp and press system was successful. It was observable that the efficiency and application of this machine all is dependent on the ability to comply with the operation steps of this machine. 7. References Dunn. (2001). Fundamental Engineering Thermodynamics (Longman Press 2001) Eastop T. D ,(1997). Applied Thermodynamics for Engineering Technologist (Longman Press 1997) Khurmi, R.S.; and Gupta, J.K. (2003). Machine design. S. Chand and Company Limited, New Delhi, India, 920-959 Massey B.S (1996). Mechanics of Fluids (Chapman & Hall, 1996) W.Bolton,(1998) Engineering science Longman 1998 W.Bolton (1998).Control Engineering Longman 1998 http://www.freestudy.co.uk/ http://www.roymech.co.uk/Related/Fluids/Fluids_Jets.html Appendixes Appendix A – System Schematic Appendix B – Detailed Calculations Appendix C – List of Components Appendix D – Component Catalog Sheets Appendix E – Supporting Documentation Appendix F – Design Specifications Appendix A – System Schematic Diagram 1. Front View of Classic Clamp and Press System Diagram 2. Press Part: Injection Plunger Diagram 3. Schematic Operation Diagram 4: Side View Appendix B – Detailed Calculations …………Equation 1 …………Equation 2 Thus The above expression 1 can put in diameter terms as follows ………………………………Equation 3 In the same way, the volume (V) of the barrel melt can also be expressed in the following way Following way; ………………………..Equation 4 Thus, V1 =V2 This means that. ……………………………….. Equation 6 By making ……………………………..Equation 7 Thus, the diameter of the plunger can be found from the above equation 7 as follows; ……………………………………….Equation 8 Cylinder 1 Equation 8 will be used to calculate the diameter of cylinder as follows: Where mass (m) = 3200 lbs. to kgs = since 1 pound is equivalent to 0.453592 Kilogram 3200 Pounds is equivalent to: 1 lb. = to 0.453592 Kg 3200 lb. = (0.453592 *3200)/1 = 1451.49 Kg Resin density of melt = 7900kg/m^3 Length moved = 5 inches since 1 inch = 2.54 cm then 5 inches = (2.54*5)/1 = 12.7 cm converting to meters 100cm = 1meter 12.7cm = (12.7*1)/100 = 0.127m So that Equation 8 will give the following after substitution will get = Cylinder 2 Equation 8 will be used to calculate the diameter of cylinder as follows: Where mass (m) = 27000 lbs. to kgs = since 1 pound is equivalent to 0.453592 Kilogram 27000 Pounds is equivalent to: 1 lb. = to 0.453592 Kg 27000 lb. = (0.453592 *27000)/1 = 12246.984 Kg Resin density of melt = 7900kg/m^3 Length moved = 6 inches since 1 inch = 2.54 cm then 5 inches = (2.54*6)/1 = 15.24 cm converting to meters 100cm = 1meter 15.24cm = (15.24*1)/100 = 0.152m So that Equation 8 will give the following after substitution will get = Teeth number needed on the rack of the plunger These can be determined as follows ……Equation 9 Consequently substitution of the values in Equation 9 above to get Teeth number needed on rack of plunger = 0.18m/(0.006m/tooth) = 30 as the number of teeth Teeth number needed on the pinion (spur gear) Teeth number needed on the pinion (spur gear) = ……………………………………………………………Equation 10 Pitch circle diameter = 0.076m while Distance of circular pitch = 0.006m/tooth Substituting these values into above Equation 10 to get Teeth number needed on the pinion (spur gear) = Selection of the Motor The motor velocity which is the angular velocity can be determined from below equation; …………………..Equation 11 Given that Motor Shaft radius, r = 0.012m Linear velocity of injection v = 1.61m/s Substitution of the values into Equation 11 to get Since many motors function using running speeds ranging from 500 rev/m and 3000 rev/m as stated by Hughes. Therefore the revolution number (N) can be evaluated below: Implying N = 1280 rev/m Also, the motor torque (T) can be found by using the following equation; Given that the G.80 electric motor shaft has a turning force of 0.112N and the motor shaft radius is given by: 0.012m, thus Torque In this respect, the power (P) is calculated by the following formula: P = 0.18kWatts Handle design In this design, the handle leverage of the simple small moulding machine is determined as in the following way =g ……………………………………………….Equation 15 Given that plate mass, = 5.39kg G which is acceleration as a result of gravity = 9.81 m/s2 so that the handle moves a distance Consequently, substitution of the values into Equation 15 above to get = Appendix C: List of Components Component list 8. Bolts Mild steel 16. Knobs(Button of control) 1.Plunger for injection 9. Main frame Mild steel 17. Carbon steel nozzle 2. Barrel 10. Handle Mild steel 3. Hopper Mild steel 11. Electric motor 4. Supporting plates 12. Contactors 5.Tie bars Mild steel Plate 13. Temperature controls 6. Platen Mild steel 14. Thermocouples 7. Mould Mild steel 15. Limit switches Appendix D: Component Catalog sheet Component list Production Component list Production Component list Production 1.Plunger for injection Fabrication 8. Bolts Mild steel Bought out 15. Limit switches Bought out 2. Barrel Fabrication 9. Main frame Mild steel Bought out 16. Knobs(Button of control) Bought out 3. Hopper Mild steel Fabrication 10. Handle Mild steel Fabrication 17. Carbon steel nozzle Fabrication 4. Supporting plates Bought out 11. Electric motor Bought out 5.Tie bars Mild steel Plate Bought out 12. Contactors 10 amps Bought out 6. Platen Mild steel Bought out 13. Temperature controls Bought out 7. Mould Mild steel Fabrication 14. Thermocouples Bought out Appendix D: Component Catalog sheet Continuation Component list Quantity Component list Quantity Component list Quantity 1.Plunger for injection 1 8. Bolts Mild steel 18 (for M6 Thread) 6 (for M18 Thread) 20 (for M12 Thread) 15. Limit switches 2 2. Barrel 1 9. Main frame Mild steel 1 16. Knobs(Button of control) 2 3. Hopper Mild steel 1 10. Handle Mild steel 1 17. Carbon steel nozzle 1 4. Supporting plates 4 11. Electric motor 1 5.Tie bars Mild steel Plate 4 12. Contactors 4 6. Platen Mild steel 1 13. Temperature controls 2 7. Mould Mild steel 1 14. Thermocouples 2 Appendix E: Supporting Documentation Component list Material used Component list Material used Component list Material used 1.Plunger for injection Medium Carbon Steel 8. Bolts Mild steel Mild steel 15. Limit switches 2. Barrel Medium Carbon Steel 9. Main frame Mild steel Mild steel 16. Knobs(Button of control) 3. Hopper Mild steel Mild steel 10. Handle Mild steel Mild steel 17. Carbon steel nozzle Medium Carbon Steel 4. Supporting plates Mild steel 11. Electric motor G-80 type 5.Tie bars Mild steel Plate Mild steel 12. Contactors 6. Platen Mild steel Mild steel 13. Temperature controls 7. Mould Mild steel Mild steel 14. Thermocouples Appendix F: Design Specifications Component list Design specifications Component list Design specifications Component list Design specifications 1.Plunger for injection φ22 mm × 900 mm 8. Bolts Mild steel M6, M8, M12 15. Limit switches T85 2. Barrel φ45 mm × 470 mm 9. Main frame Mild steel 1 1233 mm × 380 mm ×870 mm 16. Knobs(Button of control) Φ28mm 3. Hopper Mild steel 92 mm × 92 mm × 115 mm 10. Handle Mild steel φ124 mm × 260 mm 17. Carbon steel nozzle 4. Supporting plates 242 mm × 22 mm × 250 mm 11. Electric motor G-80 type G-80 5.Tie bars Mild steel Plate 1 to 2 plate 12. Contactors 10 Amps 6. Platen Mild steel 240 mm × 12 mm × 240 mm 13. Temperature controls J-type 7. Mould Mild steel 122 mm × 25 mm × 1 14. Thermocouples Bought out Read More