TRAINING

REPORT
SUBMITTED TO
HONDA CARS INDIA LTD.

SUBMITTED BY
MANIT SACHDEVA
2K14/AE/046
DELHI TECHNOLOGICAL UNIVERSITY
DEPTT. PLASTIC OBJECTS (PO)

TRAINING
REPORT
SUBMITTED TO
HONDA CARS INDIA LTD.

SUBMITTED BY
AMANDEEP
JAN NAYAK CH. DEVI LAL MEMORIAL COLLEGE OF
ENGINEERING

DEPTT. PLASTIC OBJECTS (PO)

ACKNOWLEDGEMENT
I wish to express my sincere gratitude to my mentor Mr.
for providing me an opportuinity to do my internship and
project work in Honda Cars India Ltd.
I sincerely thank Mr. Sumit Kapoor, H.R. at Honda Cars
India Ltd. For their guidance in carrying out my project
work. I also wish to express my gratitude to the officials
and other staff members who rendered their help during
this period.

INJECTION MOULDING MACHINE

The injection moulding machine is one of the most significant and
rational forming methods for processing plastic materials. A major
part in this development has been by forward thinking machining
industry which is been quick to the sieze on innovation and
incorporate them into plastic moulded projects. The examples are
hybrid and electric IMMs.
Even though modern IMM with all its ingenious microprocessor
control technology is in principle suited to perform flexible tasks.
It nevertheless takes a whole series of peripheral auxillary
equipments to guarantee the necessary degree of flexibility.
Examples include
1. Raw materials supply system
2. Mould transport facility
3. Mould preheating facility
4. Mould changing devices
5. Plasticizer cylinder changing devices
There are different types of IMM to meet different product and
cost production requirement. The types are principally horizontal
single clamping units with reciprocating and two stage
plasticators. According to the capacity the moulding capacity can
be
a. 50 ton injection moulding process
b. 100 ton injection moulding process
c. 150 ton injection moulding process
d. 200 ton injection moulding process
e. 250 ton injection moulding process

f. 400 ton injection moulding process

Plastic injection moulding process are classified or rated based on

tonnage or more specifically claming pressure or force. Pressure
can run in size from less than 5ton of clamping pressure to over
6000 ton. The higher the press ton rating the larger is the
machine.

TOOLING
The injection moulding process uses moulds typically made of
steel or aluminium as a custom product.
The mould has many component but can be split into two halves.
The two main components of the mould are mould core and
mould cavity.
When the mould is closed the space between the mould cavity
forms the part cavity that will be filled with molten plastic to
create the deserved part.

PROCESS OF MAKING CAR BUMPERS BY PLASTIC

MOULDING

A Car bumper is made by the process called reaction injection

moulding (RIM) which basically consists of making of special
polypropylene compound and introducing it into a large bumper
moulding.
RIM is a process that conserves raw material and reduces the
cost. It is similar to injection moulding except thermosetting
polymers are used which require a curing reaction to occur within
the mould.
Common items made by a RIM include car bumpers, air spoilers.
As to automobile bumper, it is the frontmost part ostensibly
designed to allow the car to sustain impact without damage to the
vehicle safety system. They are not capable of reducing injury to
vehicle equipments in high speed impacts but are increasingly
being designed to mitigate injury to pedestrians struck by cars.
In the process of making car bumpers there are two steps
The first step of making a polymer. Liquid plastic percussors are
mixed with a catalyst that causes them to combine and
polymerise rapidly. Material then are poured or injected into a
large mould where they are combined rapidly. The result is
polymer of polyurethane. With the help of gas the polyurethane
expands to fill the bumper moulds.
The serial operation performed in PO are
1. Raw materials granules mixing
2. Moulding (robotic parts)
3. Gate cutting
4. Quality check
5. Storage
6. Loading

7. Tack rag wax layer

8. IPA (Isopropyl alcohol wiping)
9. Primer
10.

Base coat

11.

Clear coat

12.

Oven baking

13.

Unloading

14.

Quality check

15.

Polishing

Various defects occur after painting are sag (flow of liquid

paints), craters, dust, random isolated deep scratches, paint
oxidation and color fading from UV exposure.
Mottling (clouding, shadowing, bleaching, misting etc.) is a color variation type of paint problem due to uneven
distribution of metallic flakes. This type of problem occurs to
metallic base coats specially to silver color with coarse metallic
particles. Mottling is caused due to Incorrect spray gun setup,
incorrect nozzle size, wrong type of air cap used, too high
atomization air pressure in the cap, spray pattern is not correct.
These defects are marked down in quality inspection and then
sanding is done. After that polishing of bumpers is done for the
final finishing.