Thesis Abstract

Abstract
Metallic moulds are widely used in various industries for the production of plastic, rubber, and metal parts. The construction of a simple metallic mould involves several key steps to ensure its effectiveness and durability. This research project aims to provide a detailed guide on the construction process of a simple metallic mould, focusing on the selection of materials, design considerations, fabrication techniques, and quality control measures. The selection of materials is a crucial step in the construction of a metallic mould. The choice of material should be based on the specific requirements of the part to be produced, considering factors such as mechanical properties, thermal conductivity, and wear resistance. Common materials used for metallic moulds include tool steel, aluminum, and copper alloys. The material selection process involves evaluating the trade-offs between cost, performance, and tool life. Design considerations play a significant role in the effectiveness of a metallic mould. The design should take into account factors such as part geometry, draft angles, gating and venting systems, cooling channels, and ejection mechanisms. Proper design optimization can help improve part quality, reduce cycle times, and minimize production costs. Computer-aided design (CAD) software is commonly used to create detailed mould designs and simulate the injection molding process. Fabrication techniques for constructing a metallic mould vary depending on the selected material and design complexity. Common fabrication methods include machining, milling, grinding, and electrical discharge machining (EDM). Precision is essential during the fabrication process to ensure that the mould components meet tight tolerances and surface finish requirements. Post-fabrication treatments such as heat treatment and surface coatings may also be applied to enhance the performance and durability of the mould. Quality control measures are essential to ensure the reliability and consistency of a metallic mould. Inspection techniques such as dimensional metrology, surface roughness measurement, and non-destructive testing can be used to verify the accuracy and integrity of the mould components. Quality control procedures should be implemented throughout the construction process to identify and rectify any defects or deviations promptly. In conclusion, the construction of a simple metallic mould requires careful consideration of material selection, design optimization, fabrication techniques, and quality control measures. By following a systematic approach and paying attention to detail, manufacturers can produce high-quality moulds that meet the demands of modern industrial applications.

Thesis Overview

1.0         INTRODUCTION

The equipment mostly used in the industries and manufacturing establishments requires the production of definite shape, pattern, different design, embossments and others, are usually moulds. The ability of moulds to withstand pressure, distortion and corrosion determines the application.

A mould has been defined as a pattern constructed for the production of the same type of the prototype. The constructional material differs from one operation to another. The diversity of the application gives the need for the designing and development of moulds of different materials, compositions, shapes, textures and crossing resistances.

Mould is as old as man, the early days of the blacksmiths were able to construct, design materials of different shapes and sizes using mould.

1.1                   USES OF MOULDS IN PRODUCTION INDUSTRIES.

–           The metallurgical Industries use mould pattern for different casting operations and diverse application for the productions of metal blocks, building blocks, e.t.c like in the production of both industrial and household plastic wares.

–           In the manufacturing set –up, the different types of accessories that have different profiles are usually produced using moulds.

–          In the mechanical engineering set-up, moulds are usually used for the production of different machines parts with intricate shapes that cannot be easily manufactured on a lathe.

–          The food industry applies for moulds processes for their production. Production of bread is usually a mould patterns process. The still applies to the other foods items like Biscuits, sausage rolls, cakes and others.

–          In pharmaceutical companies where tablet drugs of different sizes and textures are made, ninety – percent (90%) of the tablet drugs are produced in moulds.

–          The electrical components – manufacturing industries utilize moulds for the different production of accessories and fittings used in the household and commercial lighting activities

–          In the candle producing and making industries mould application is for the processes.

This has resulted to the increase of activities in that section. In smaller mould production application, the building industry makes use of mould system in the production of blocks, bricks and others.

Conclusively, the costs of applications of moulds. In the solution of society problems are inexhaustible and very relevant for economic development of any nation.

1.2                         IMPORTANCE OF MOULD MANUFACTURING INDUSTRIES TO THE NATION.

The setting up of mould manufacturing industry in the nation has a lot of implications. Thus practice of importing most machine parts from the overseas have really rendered the action of setting up moulds making industries useless. The economic implications of mould industries are discussed below.

–          The high foreign exchange cost in the importation of moulds and different machines parts could be saved for the nation.

–          The mould industry will assit in producing high texture and corrosive resistant mould that would serve effectively rather than importing moulds that are not manufactured in consideration to the tropical kind of Nigeria environment.

–          In mould industries, the different machines that are usually abandoned due to lack of spare pars are easily moulded and constructed since the material construction is known.

–          The setting-up of mould factory would assist greatly in harnessing the abundant metallic ore deposition in different parts of our country.

–          The mould industry would definitely lead to industrial and commercial growth, since the diverse operations that are usually projected by mould formation would begin to thrive.

–          Conclusively, setting up of mould producing industries will have a positive effect on all facets of projects associated with lack of spare parts and accessories.