• Journal of the korean Society of Automotive Engineers
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• v.15 no.1
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• pp.17-24
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• 1993

사출성형 문제는 열전달과 유체유동이 복합된 문제라고 할수 있다. 사출성형 공정은 충진(filling), 보압(packing) 및 냉각과정(cooling phase)으로 이루어 진다. 충진과정은 높은 점성의 Non-Newtonian유체가 몰드내의 캐버티로 사출됨으로써 이루어지며 플라스틱의 점성도는 플라스틱의 온도 및 유동속도와 관련이 크며 이 flow-rate는 점도와 더불어 변화한다. CAE 유동해석 프로그램은 유체의 흐름과 열전달을 이용하여 충진과정을 이해하는데 이용되고 있다. 본 고에서는 사출성형 과정 중 충진과정에 대한 컴퓨터 시뮬레이션과 그 적용사례에 대하여 살펴본다.

• Proceedings of the KAIS Fall Conference
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• 2008.11a
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• pp.371-374
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• 2008

본 연구에서는 무도장 Weldless 평가금형을 이용하여 사출성형 공정조건에 따라 다양한 형태의 변형이 생기는 성형품을 CAE를 통하여 ABS와 PC의 사출조건 냉각시간, 보압의 유/무 등에 따라서 발생되는 문제점과 변형량을 예측하고, 실제 사출성형 되어진 성형품과의 비교 분석을 통하여 사출성형 CAE 해석을 실제 사출성형 공정에서의 활용방안에 대하여 검토하였다.

• Elastomers and Composites
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• v.48 no.4
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• pp.300-305
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• 2013

Part shrinkage in injection molding is inevitable phenomenon. Thus, it is necessary not only study on the reducing part shrinkage but characterization of part shrinkage. In this study, part shrinkage in injection molded 2.5 dimensional annular shaped specimens has been studied using glass fiber reinforced PC. Annular shaped specimens were designed with various sizes of outer diameter and thickness. Injection temperature, packing time and packing pressure were selected for operational conditions. Profile variations of outer and inner diameters of molded specimens for various operational conditions were investigated. Sizes of outer and inner diameters of injection molded specimens were smaller than the sizes of mold. Part shrinkage decreased as outer diameter and thickness increased. Part shrinkage showed anisotropic behavior and it depended upon gate location. Subsequently, molded specimens were not circular but oval in shape, and showed the largest shrinkage in the direction of gate. It was realized that the mold design such as gate design is important to control the shape of molded products.

• Proceedings of the KSME Conference
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• 2004.11a
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• pp.916-921
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• 2004

The penalty method has been widely applied to analyses of incompressible fluid flow. However, we have not yet found any prior studies that employed penalty method to analyze compressible fluid flow. In this study, with an eye on the apparent similarity between the slight compressible formulation and the penalty formulation, we have proposed a new approximate approach that can analyze compressible packing process using the penalty parameter l. Based on the assumption of the isothermal flow, a set of reference solutions was obtained to verify the validity of the proposed scheme. Furthermore, we have applied the proposed scheme to the analysis of the packing process of different cases.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.10a
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• pp.46-50
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• 2001

Due to its ability in producing a net-shape product to high precision in a very shot cycle time, injection molding has become one of the most important polymer-processings in the industry today. Recently the CAE applications in the field of injection molding have provided significant contributions to the mold design and process optimization. As a part of such an application the packing process has been studied using C-PARK. The prediction of pressure variations during post-filling stage for amorphous material has been compared with an experimental observation for a simple rectangular geometry of uniform thickness. And the optimal packing processes were calculated using the cavity pressure curve near the gate. As a case study, a warpage simulation was carried out for a DY-HOLDER with the variable number of gates.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.04b
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• pp.281-286
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• 1993

Projection TV에는 시각 품질을 최종적으로 표시하는 디스플레이 소자인 비구면플라스틱 렌즈를 적용하고 있으나 전량 일본에서 완제품으로 공급 받고 있다. 플라스틱 비구면 렌즈를 성형하기 위해서는 사출 공정에 대한 철저한 이해 와 폴리머의 광탄성 거동에 대한 개념이 핵심이라고 말할 수 있다. 복굴절성 실험은 폴리머의 유변학적 거동을 파악 하는데있어 가장 유용한 실험중의 하나이다. 본 글에서는 이와 관련된 사항인 복굴절성, 잔류 응력 형성 메카니즘, 밀도이완 작용의 상관관계와 비구면 렌즈의 성형 조건 및 공정에대해 기술 하였고, 또한 측정된 수지데이타를 이용 상용 S/W를 사용하여 유동, 냉각, 보압 ( 압축) 및 수축 해석을 실시 하여 각 stage에서 경험한 온도 와 압력의 이력에따라 변화하는 열 응력에 기인한 잔류 응력 계산 Pg을 개발 상용 S/W 와 비교 검증 하였다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.5
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• pp.94-101
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• 2013

Injection molding process is one of the most important methods to produce plastic parts with high efficiency and low cost. The objective of this study is to implement the best plastic injection molding process for LED TV speaker frame. Moldflow analysis and simulation of plastic injection molding process were carried out in order to predict optimal modeling operation conditions and then injection molded part was produced various type of resin temperature, filling time and injection pressure variation. the result was that the best injection molding condition is set as 60bar pressure, 2sec filling time and $310^{\circ}C$ degree. The study result would be useful to variety of plastic injection molding process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.811-814
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• 2001

Warpage analysis of bobbin, molded by injection molding process was performed. Concerned with a mold design, cooling system was designed based on Taguchi method, the distance between cavity wall and cooling channel was most influent factor amongst four design variables like an inlet temperature of coolant, a coolant flow rate, a diameter of cooling channel, and the distance between cavity wall and cooling channel. Optimal packing processes to reduce the warpage of molded part was analyzed based on the response surface method by considering holding pressure. Their optimal processing conditions were 9.4 seconds, 5.3 seconds, 15.2 seconds, and 85MPa, respectively.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.2
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• pp.64-72
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• 2001

Weld line is one of serious troubles which are observed in a plastic part manufactured by a injection molding process. This is caused by many process factors, which are molding pressure, temperature, velocity, location of a injection gate, mold geometry and material properties. investigation on the effects of these process factors to the appearance of a weld line was carried out using a finite element method. Filling and packing analyses were carried out by modifying both the configuration of the injection gates and cavity thickness. Proper locations of the injection gates could be determined by considering molding pressure, temperature, velocity and frozen layer, and whereby the weld line was controled. In order to make a weak appearance of the weld line, flow velocity and flow front in a cavity were also investigated by modifying a cavity thickness. As a result, flow front was extended around the corner in the cavity by changing the flow velocity and hence the appearance of the weld line was much weakened.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.3
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• pp.224-229
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• 2016

Recently, polymeric micro-fluidic biochips with numerous micro patterns on the surface were fabricated by injection molding for realizing low-cost mass production of devices. To evaluate the effects of process parameters on large-scale micro-structure replication, a $50{\times}50mm^2$ tool insert with surface structures having a patterns of trapezoidal shapes (height: $30{\mu}m$) was employed. During injection molding, PMMA was used; packing phase parameters and mold temperature were investigated. The replicated surface textures were quantitatively characterized by confocal laser microscopy with 10-nm resolution. The degree of replication at low mold temperatures was found to be higher than that at high mold temperature at the beginning of the packing stage. Thereafter, the degree of replication increased to a greater extent at higher mold temperatures; application of higher mold temperatures improved the degree of replication.