• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.8
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• pp.50-55
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• 2020

This study investigates the injection molding of a plastic rack gear and focuses on deflections in the part. The causes of deflections were found and resolved through a trade-off study by injection molding analysis. Based on a warpage analysis, the fiber orientation was found to be a dominant factor in the occurrence of deflections. Changes in the part design and various injection conditions were analyzed for their effects in reducing deflections. Based on the trade-off study, a new part bottom design, injection time, and melt temperature were recommended. A trial injection was done for the new plastic rack gear, and measurements showed that its flatness surpassed that of the original part and met the specified requirement. The short injection time, low melt temperature, and symmetric similar configuration of the part contributed to the reduction in deflections. Therefore, optimized gate design and injection conditions as well as a new part design were validated through injection molding analysis in this study.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.4
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• pp.507-514
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• 2003

Most of CAE analyses for injection molding have been based on the Mele Shaw's approximation: two-dimensional flow analysis. in some cases, that approximation causes significant errors due to loss of the geometrical information as well as simplification of the flow characteristics in the thickness direction. Although injection molding analysis software using three-dimensional solid elements has been developed recently, such as Moldflow Flow3D, it does not contain a deformation analysis function yet. The present work covers three-dimensional deformation analysis or injection molded plastic parts using solid elements. A numerical scheme for deformation analysis has bun proposed from the results of injection molding analysis using Moldflow Flow3D. The accuracy of the proposed approach has been verified through a numerical analysis of rectangular plates with various thicknesses in comparison with the classical shell-based approach. In addition, the reliability of the approach has also been proved through an industrial example. an optical plastic lens, in comparison of real experiments.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.11
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• pp.163-170
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• 2004

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, however, numerical analysis based on solid elements has been reported as more reliable approach than shell -based one. The present work covers three-dimensional injection molding simulation using MP1/Flow3D and relevant deformation analysis of an injection molded plastic lens based on solid elements. Numerical analysis has been applied to the injection molding processes of an aspheric lens for a photo pick-up device. The reliability of the proposed approach has been verified in comparison with the experiments.

• The Korean Journal of Rheology
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• v.10 no.4
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• pp.217-226
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• 1998

The anisotropy caused by the fiber orientation, which is inevitably generated by the flow during injection molding of short fiber reinforced polymers, greatly influences dimensional accuracy, mechanical properties, and other quality of the final product. Since the filling stage of the injection molding process plays a vital role in determining fiber orientation, an accurate analysis of flow field for the filling stage is needed. Unbalanced filling occurs when a complex or a multi-cavity mold is used leading to development of regions where the fiber suspension is under compression. It is impossible to make an accurate calculation of the flow field during filling with the analysis assuming incompressible fluid. A mold with four cavities with different filling times was produced to compare the numerical analysis results with the experimental data. There was a good agreement between the experimental and theoretical results when the compressibility of the polymer melt was considered for the numerical simulation. The fiber orientation states for compressible and incompressible fluids were also compared qualitatively as well as quantitatively in this study.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.22 no.4
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• pp.580-586
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• 2021

The CAT methodology is a numerical analysis technique using CAE. Recently, a methodology of applying artificial intelligence techniques to a simulation has been studied. A previous study compared the deformation results according to the injection molding process using a machine learning technique. Although MLP has excellent prediction performance, it lacks an explanation of the decision process and is like a black box. In this study, data was generated using Autodesk Moldflow 2018, an injection molding analysis software. Several Machine Learning Algorithms models were developed using RapidMiner version 9.5, a machine learning platform software, and the root mean square error was compared. The decision-tree showed better prediction performance than other machine learning techniques with the RMSE values. The classification criterion can be increased according to the Maximal Depth that determines the size of the Decision-tree, but the complexity also increases. The simulation showed that by selecting an intermediate value that satisfies the constraint based on the changed position, there was 7.7% improvement compared to the previous simulation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.3
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• pp.375-382
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• 2010

In this study, we developed a method to predict the residual stress distribution and thermal deformation caused by in-mold labeling (IML) processes. IML is one of the injection molding processes for injecting a material into a cavity and subsequently inserting a decorated film. The IML process can yield products with decorations of outstanding excellent quality in only one working step. Although the IML process has various advantages, it causes defects such as film delamination, wash-out, and flow marks. In particular, deformation is considered to be a major concern in terms of delamination. To validate the model, the deformation predicted by using a numerical model was compared with experimental results, and both results showed good agreement. We verified that the developed method can be used to obtain the design guidelines for preventing delamination in the initial design stage of the IML process.

• Transactions of The Korea Fluid Power Systems Society
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• v.8 no.4
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• pp.24-31
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• 2011

Double-color Injection molding machine is the assembly of many kinds of mechanical, fluid power part and electric electronic control system. From in these, fluid power is a part where becomes the first core of this machine. Fluid power systems of double-color injection molding machine are modelled and analyzed using a commercial program AMESim. Partial system models which is divided according to functional operation are made and its analysis results shows how design parameters work on operational characteristics like pressure, flow rates, displacement at each node and so on. Analysis modeling and compared the data which gets from experiment and the analysis result which has a reliability got data. The results made by analysis will be used design of fluid power circuit for developing a double-color injection molding machine.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.251-256
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• 2001

Deformation analysis of injection molded articles whose geometry is considered as the assembly of the thin flat plates has been conducted. For the in-mold analysis, thermo-viscoelastic stress calculation of rheologically simple amorphous polymer and in-mold deformation calculation considering the in-plane mold constraint has been done. Free volume theory has been used for the non-equilibrium density state by the fast cooling. At ejection, the redistribution of stress together with instantaneous deformation has been considered. During out-of-mold cooling after ejection, thermoelastic model based on the effective temperature has been adopted for the calculation of deformation. Two typical mold geometries are used to test the numerical simulation.

• Proceedings of the KAIS Fall Conference
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• 2010.11a
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• pp.301-304
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• 2010

본 논문에서는 다수 캐비티 금형의 러너 내 불균일한 전단분포로 인해 발생되는 충전불균형에 따른 치수정밀도, 기계적 강도 등 물성의 차이가 발생되는 문제점을 해소하기 위해서 수지가 처음 분기되는 2차 러너의 구조에 변화를 주어 다수 캐비티 사출성형에서 충전균형을 위한 러너시스템을 제시하였다. 이 러너시스템은 전단률차이에 의한 즉, 온도가 불균일한 수지의 흐름을 혼합함으로써 수지의 흐름을 균일하게 하여 충전균형을 이루도록 하였다. PP수지를 대상으로 각 캐비티 간 균형충전에 대해 이 러너시스템이 효과가 있는지 검증하기 위해 CAE프로그램(Moldflow)을 이용한 유동해석을 통해 그 효과를 나타내 보았다.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1724-1727
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• 2005

Injection molding process is one of the processes that can mold plastic product as low cost. However, manufacturing process of automobile bumper mold has lots of trial and error. Especially, desiging of a huge mold such as bumper mold is needed to establish a design standard for runner system. In this study, CAE was conducted to observe the variation of melt-flow by changing runner and gate type in automobile bumper mold as preceding study for a standard design of runner system.