National Skill Competitions

Skill- Plastic Die

Engineering
Category: Manufacturing & Engineering
Technology

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Table of Contents
A. Preface ............................................................................................................................. 3
B. Test Project* ..................................................................................................................... 4
C. Marking Scheme .............................................................................................................. 9
D. Infrastructure .................................................................................................................. 11
E. Instructions for candidates .............................................................................................. 12
F. Health, Safety, and Environment ..................................................................................... 13

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 Section - A

A. Preface

Skill & Role Explained:

Plastic Die Engineers are engaged in the mass production of plastic products of high quality
at low cost. This is achieved by producing a mould based on drawings created by a competent
designer who understands design for manufacturing and assembly principles, having hands
on injection moulding, mould making, plastic part design, and mould design software
experiences.

The designing and processing of a mould is done with the help of CAD/CAM (Computer Aided
Design/Computer Aided Machining) systems. Most of the machining is done on CNC
(Computer Numerical Control) machining centres. The machined parts are then polished
according to requirements and assembled as per drawing to keep them ready for trial. A
completed mould will be then installed in an injection moulding machine. The raw plastic
material is melted in the moulding machine and then injected into the mould, where it cools
and solidifies into the final product.

This is a very rewarding profession. Plastic Die Engineers are increasingly in demand. An
industrial market research consultancy specializing in plastic products and appliances,
predicts that the world’s use of commodity plastic will reach 510 million tons in 2020. Plastic
Die Engineering is a fast-paced world which is highly creative and full of opportunities for
skilled and talented people. It is an essential aspect of engineering because most plastic parts
cannot be made without a die. Therefore, Plastic Die Engineers are a critical link in the overall
plastic injection moulding process.

Light weight, availability of various designs, and cost reduction are the greatest advantages to
industries. Since plastics are used in thousands of products that add comfort, convenience
and safety to our lives the demand for plastic die engineering skills has significantly increased
over the years. Plastic injection moulded components are used in telecommunications,
medical, aerospace, and automobile industries, for home appliances, office automation,
entertainment, and electronics. Thus the range of different fields of requirements provide many
challenges, ranging from, designing an appropriate mould to programming for machining
mould elements, working on machines, inspecting, polishing, matching, assembling of parts,
moulding and trouble shooting of moulding defects for good mass production.

The skilled practitioner needs excellent levels of skill in numeracy, hand and machining skill,
polishing, assembling, testing, and troubleshooting.

Eligibility Criteria (for IndiaSkills 2018 and World Skills 2019):

Competitors born on or after 01 Jan 1997 are only eligible to attend the Competition.

Total Duration: As per Module

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 Section – B
B. Test Project*

The Drawings of Test Project is mentioned below. The final Test Project has undergone upto 30% change including Main and Secondary
Dimensions.

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 Module 1*

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 Module 2*

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 Module 3*

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 *Base Skills Copy Right: World Skills International

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Section – C
C. Marking Scheme

Marking Scheme:
The Assessment is done by awarding points by adopting two methods - Measurement and
Judgments.

• Measurement - One which is measurable

• Judgments - Based on Industry expectations
Aspects are criteria’s which are judged for assessment
ASSESSMENT AND MARKING USING JUDGEMENT
Judgment uses a scale of 0-3. The 0-3 scale to indicate:

❖ 0: performance below industry standard

❖ 1: performance meets industry standard

❖ 2: performance meets and, in specific respects, exceeds industry standard

❖ 3: performance wholly exceeds industry standard and is judged as excellent

Example-Judgment Marking
If maximum marks for Judgment criteria is 1 and if all 3 Experts (Juries) give 3 points to a
candidate, the candidate will get 1 mark for that aspect. If 2 Experts give 3 and 1 Expert gives
2 points, then candidate will get (3+3+2)/9*1 = 0.89 marks for that aspect out of 1 mark.
Marking Pattern
The marking format will follow the World Skills Marking Pattern

Criteria Mark
A Part Modelling 15.00
B Mould Design 20.00
C Machining 30.00
D Assembly & Injection Moulding 35.00

PDE_Draft
marking_scheme.xlsx

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COMPLETION OF SKILL ASSESSMENT SPECIFICATION

A － Mould Design

• 3D model: • Presence of part features; • Shrinkage added; • Placement of component; • Size of

the insert; • Parting surface; • Creation of sprue, runner and gate; • Ejector pin holes; • Assembling
all elements; • Converting 3D into 2D.

• Drawings and Presentation: • Assembly drawing title block (title block should contain title,
designed by, date, scale, sheet no. etc.) • Assembly drawing in isometric shaded view; • Assembly
drawing part list (all the parts should be included); • Assembly drawing balloons (all the parts should
be ballooned); • Top view (core half - all visible details); • Section view (assembly as per section); •
Top view (Cavity half - all visible details); • Dimensions (as required); • Tolerances (GD &T as
required); • Surface finish (as required); • Visual clarity.

B － Machined parts (die)

• Main dimensions of die: • Main dimensions are specified in the drawing and known to Competitor;
• Secondary dimensions; • Secondary dimensions are specified in the drawing and known to
Competitor; • The dimensions are calculated and indicated on drawings by the Competitors
themselves in consideration of shrinkage of the product; • For the shrinkage percentage of the
plastic material, the value indicated on the data sheet must be known to the Competitors.

• Use of material: • The Workshop Manager must prepare sufficient spare material for machining; •
A Competitor has only one opportunity to request one piece of material per module; • There will be
loss of marks for any additional material used.

C － Assembly and injection moulding

• Assembly conditions: • Assembly condition of the die will be checked for completeness of assembly,
proper tightening of screws, ejector working conditions, and appearance of the total die excluding the
product moulding area; • Ejector working conditions; • Bolt tightening; • Scratch on surface excluding
the product area. • Process: • Automatic moulding; • Teams of Experts must evaluate if an automatic
moulding of the product is possible. Setting of the basic process parameters is the task of the Injection
Moulding Machine Technician. If the Competitor makes a special request to the technician, the
technician adjusts the parameters. Ten shots are taken to evaluate the process. For each shot, where
the product falls without anybody pulling it out or kicking it off the ejector pins the Competitor gets
one point. • A team of Experts assigned together with the Injection Moulding Machine Technician will
evaluate the process; • The Competitor will select any two samples from the lot for product
evaluation.
• Conformity to product forms product layout, etc. • Arc, round, fillet and chamfer size (only visual
inspection); • Position of features (only visual inspection); • Main dimensions • Main dimensions
are specified on the product and known to the Competitors. • Secondary dimensions • Secondary
dimensions are specified on the product and known to the Competitors. • Surface quality (Experts
visually inspect the product and looks for surface quality.) • Ejector pin unevenness; • Burn mark; •
Scratch at ejection; • Weld mark; • Machine mark; • Burr.

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 Section – D
D. Infrastructure

• Workshop Installation-Tools & Equipment positioned by Organizers

• Tool Kit-Tool & Equipment allowed to be brought by competitors for competitions

The above will be decided during the Skill Manager & Jury. The details need to be worked out
by candidates.

Infrastructure
The students are advised to bring their Toolkit.
The specifications of the machines and control panel details have been shared with
participants along with the specifications of software and hardware.

3. Plastic Die Engineering

S. Key Aspects Machine Type-1 Machine Type-2
No
1 CNC Machine CNC MILLING MACHINE JYOTI PX- CNC MILLING MACHINE BFW
make and Model 30 (SURYA)
1.Axis Traverse:- X-Axis Travel = 1.Axis Traverse:- X-Axis Travel =
760mm 800mm
Y-Axis Travel = Y-Axis Travel =
410mm 350mm
Z-Axis Travel = Z-Axis Travel =
510mm 380mm
2.Table Size :- 915mm x 360mm 2.Table Size :- 315mm x 1060mm
3. Table Loading Capacity: - 500Kg. 3. Table Loading Capacity: - 300Kg.
4.Spindle Motor Power :- 5.5/7Kw 4.Spindle Motor Power :-
5.Tool Adaptor :- BT-40 3.7/5.25Kw
6.Rapid Traverse :- 25M/min 5.Tool Adaptor :- BT-40
7.Cutting Feed :- 10000mm/min 6.Rapid Traverse :- 10 m/min
8.Positioning Accuracy :- 0.010mm 7.Cutting Feed :- 5000 mm/min
9.Repeatability :- 0.005mm 8.Positioning Accuracy :- 0.010mm
10.USB Support :- Yes 9.Repeatability :- 0.005mm
RPM: 8000 R.P.M 10.USB Support :- Yes
11. RPM: 6000 R.P.M
2 CNC Programming ISO ISO
Language
3 CNC Controller SIEMENS 828D SIEMENS 828D
4 Tools Carbide (Participants can also bring Carbide (Participants can also bring
(HSS/Carbide) and use their tools) and use their tools)

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 5 Job Type As per WSS; Also Refer Past WSC As per WSS; Also Refer Past WSC
drawings drawings
6 Software Available • For designing the Core and • For designing the Core and
Cavity- Auto Desk Inventor Cavity- Auto Desk Inventor
• For Machining: Mastercam 2018
2D-Version – MasterCAM- • For Machining: Mastercam
X9 and 2018(Participant 2D-Version – MasterCAM-
can select) X9 and 2018(Participant
can select)
7 Raw Material of Aluminium & Steel Aluminium & Steel
the Job
8 Allocation of Allocation of Machines and Tools to participants will be done by Lottery;
Machines and Decision of Jury will be final in case of any other requirement/variation.
Tools to
Participants

Tough the specification of Machines may be different but the specifications such as RPM,
feed etc are made similar.

Section – E
E. Instructions for candidates

Instruction for Competitors

• Interpret engineering drawings and follow the specifications
• All must have clear understanding of the drawing and the task before commencement
• In case of malfunctioning of the machines the competitor must report to the Jury
• The candidates should bring their standard PPE and Safety Shoes.
• Candidates should read, enquire and follow machine safety manuals.

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 Section – F
F. Health, Safety, and Environment

1. All accredited participants, and supporting volunteers will abide by rules and
regulations with regards to Health, Safety, and Environment of the Competition venue.

2. All participants, technicians and supporting staff will wear the required protective
Personnel clothing. Protective clothing must be selected according to the activity and
related risk. When working with rotating machines, individuals must ensure that close-
fitting clothing is worn, in order to avoid clothing becoming entangled in the equipment.
Jewellery and long hair are a safety hazard and shall be taken off or covered.

3. All participants will assume liability for all risks of injury and damage to property, loss of
property, which might be associated with or result from participation in the event. The
organizers will not be liable for any damage, however in case of Injury the competitor
will immediately inform the immediate organizer for medical attention.

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