• Journal of the Korean Society for Heat Treatment
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• v.34 no.1
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• pp.17-24
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• 2021

In this study, Ti-X (X=Mn, Fe, Mo) powder alloys were designed and manufactured by both powder metallurgy (PM) and metal powder injection molding (MIM) process to improve strength and formability compared to CP-Ti powder materials. It was found that the lamellar microstructure consisted of α and β phases was formed in PM-processed alloys. However, MIM-processed alloys showed not the lamellar microstucture but the equiaxed α + β microstructure. It was also revealed that the contents of X component and feedstock were not affected to microstructure evolution. The reason why different microstructure was appeared between PM-processed and MIM-processed alloys is not clear yet, but supposed to be the effect of intersticial elements such as C, H and N derived from feedstock during debinding process of MIM.

• The Journal of Korean Academy of Prosthodontics
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• v.41 no.3
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• pp.360-368
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• 2003

Statement of Problem: The residual monomer of denture base materials causes hypersensitivity on oral mucosa and intereferes with the mechanical properties of the cured resin. The amount of residual monomer is influenced by materials, curing cycle, processing method, and etc. Purpose: The aim of this study was to investigate the residual methyl methacrylate(MMA) content of injection molded denture base polymer, and to compare this with the self-cured resin and the conventional compression molded heat-cured resin. Materials and Methods: Disc shaped test specimens (50mm in diameter and 3mm thick) were prepared in a conventional flasking technique with gypsum molding. One autopolymerized denture base resins (Vertex Sc. Dentimex. Netherlands) and two heat-cured denture base resins (Vertex RS. Dentimex. Netherlands, Ivocap. Ivoclar Vivadent, USA) were used. The three types of specimens were processed according to the manufacturer's instruction. After polymerization, all specimens were stored in the dark at room temperature for 7 days. There were 10 specimens in each of the test groups. 3-mm twist drills were used to obtain the resin samples and 650mg of the drilled sample were collected for each estimation. Gas chromatography (Agillent 6890 Plus Gas Chromatograph, Agillent Co, USA) was used to determine the residual MMA content of 10 test specimens of each three types of polymer. Results: The residual monomer content of injection molded denture base resins was $1.057{\pm}0.141%$. The residual monomer content of injection molded denture base resins was higher than that of compression molded heat cured resin ($0.867{\pm}0.169%$). However, there was no statistical significant difference between two groups (p>0.01). The level of residual monomer in self cured resin($3.675{\pm}0.791$) was higher than those of injection molded and compression molded heat cured resins (p<0.01). Conclusion: With respect to ISO specification pass / fail test (2.2% mass fraction) of residual monomer, injection molding technique($1.057{\pm}0.141%$) is a clinically useful and safe technique in terms of residual monomer.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.5
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• pp.2092-2099
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• 2013

Through the data transfer race in industry since 1990s, the operational speed of optical disk drive(ODD) becomes commonly over 10,000 rpm. Such high speed operation inevitably causes the vibration, which is also the disturbances in the read-write process of pick-up servo-controller. Generally the vibration disturbance problem can be solved by the vibration isolation using the rubber mount and the increase of robustness of the pick-up servo-controller. Optical disk itself has not been targeted for the vibration reduction, because it is manufactured under the standardized format. In this paper we focused on the increase of critical speed of optical disk, that is, the improvement of dynamic characteristics, with the control of residual stresses which are come from the injection molding process. To do this, first, the residual stresses induced from the injection molding process are calculated using finite element method. The major design parameters of the process conditions are flow rate and melt temperature, which control the residual stresses in optical disk. Second, the critical speed of optical disk is calculated with modal analysis considering residual stress distributions. It was found out that the critical speed can be improved by the control of operational parameters in the injection molding process.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.6
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• pp.648-653
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• 2012

Cavity pressure, an important factor in injection molding process, should be minimized to enhance injection molding quality. In this study, we decided the locations of valve gates to minimize the maximum cavity pressure. To solve this problem, we integrated MAPS-3D (Mold Analysis and Plastic Solution-3Dimension), a commercial injection molding analysis CAE tool, using the file parsing method of PIAnO (Process Integration, Automation and Optimization) as a commercial process integration and design optimization tool. In order to reduce the computational time for obtaining the optimal design solution, we performed an approximate optimization using a meta-model that replaced expensive computer simulations. To generate the meta-model, computer simulations were performed at the design points selected using the optimal Latin hypercube design as an experimental design. Then, we used micro genetic algorithm equipped in PIAnO to obtain the optimal design solution. Using the proposed design approach, the maximum cavity pressure was reduced by 17.3% compared to the initial one, which clearly showed the validity of the proposed design approach.

• Design & Manufacturing
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• v.10 no.1
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• pp.7-11
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• 2016

Sinks occurring in the rib portion of the testing product for the unpainteds are fatal defects at surface quality. In this study, we carried out moldflow analyses for several factors that affect the sinks. The result tells us large important effective factors on sinks by analyzing sink marks estimate. We expect practical use as reference for performing analysis or manufacturing products with rib designs and injection moldings which minimize sink-marks surrounded ribs.

• Journal of Powder Materials
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• v.30 no.1
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• pp.1-6
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• 2023

High-entropy alloys (HEAs) are attracting attention because of their excellent properties and functions; however, they are relatively expensive compared with commercial alloys. Therefore, various efforts have been made to reduce the cost of raw materials. In this study, MIM is attempted using coarse equiatomic CoCrFeMnNi HEA powders. The mixing ratio (powder:binder) for HEA feedstock preparation is explored using torque rheometer. The block-shaped green parts are fabricated through a metal injection molding process using feedstock. The thermal debinding conditions are explored by thermogravimetric analysis, and solvent and thermal debinding are performed. It is densified under various sintering conditions considering the melting point of the HEA. The final product, which contains a small amount of non-FCC phase, is manufactured at a sintering temperature of 1250℃.

• Clean Technology
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• v.18 no.2
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• pp.155-161
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• 2012

The purpose of this study is to remove paraffin wax binder effectively from powder injection molded part using supercritical fluids in powder injection molding process. For a thin powder injection molded part about 1-2 mm thickness, paraffin wax binder can be removed rapidly without any defect by traditional supercritical extraction process which has fixed high temperature and pressure condition. But, for a thick powder injection molded part, there are limitations in removing paraffin wax binder by the fixed high process condition because crack occurs at the beginning step. Therefore, here we studied variable condition debinding process that starts with mild process condition at the beginning step and then increase the process conditions simultaneously at each step. To find out the initial process condition that has the highest extraction yield without any defect for each sample thickness, we investigated various supercritical debinding conditions using 1-4 mm thickness ceramic injection molded sample. By using the variable condition debinding process that starts with the initial process condition at the first step and then increasing process conditions simultaneously at each step (temperature from 333.15 to 343.15 K, pressure from 12 to 27 MPa, and $CO_2$ flow rate from 1.5 to 10 L/min), over 95% of paraffin wax binder was removed from the 4 mm thick (10 mm diameter) ceramic injection molded disk samples within 5 hours.

• Design & Manufacturing
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• v.7 no.1
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• pp.60-63
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• 2013

Recently, Silicone that one of the thermo-sets is used to making optical products such as LED lenses because of excellent thermal properties. LED lenses are required to keep the precise dimensions, so they must be molded to have the minimum deformation. Thermo-sets have the expansion characteristic on the part of thermal property, it is important to optimize the cure condition so that the deformation of the part become minimum. In this study, to investigate the relationship between the shrinkage by the curing and expansion by the thermal properties of the resin, reactive injection experiment was performed by setting the variables such as mold setting temperature, cure time. As a result, it was confirmed that there was a interval while the thermal properties were transferred to more active during the cure process. It is expected to help in determining the reactive injection molding conditions of the thermo-set parts as well as LED lens in order to reduce the amount of deformation.

• Proceedings of the KAIS Fall Conference
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• 2010.11b
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• pp.933-936
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• 2010

본 연구는 성형해석 및 실험적 방법을 통하여 페트 패키징 제품의 두께편차를 최소화 하기 위하여 프리폼 설계 및 블로우 성형공정 변수를 변화보았다. 블로우 성형과정을 정확하게 묘사하기 위하여 쉘(shell) 모델을 이용하여 블로우 성형해석을 수행하였으며, 이 결과를 토대로 프리폼 설계변수 및 공정 변수를 최적화 하였다. 제품 형상이 점점 복잡해지고 요구되는 제품의 품질이 높아질수록 실험적으로 최적의 결과를 도출하기가 어렵다. 이러한 문제점을 수치적 해석을 통하여 사전에 발생될 수 있는 파악함으로서 시행착오를 줄이고 최적의 금형을 제작함으로써 설계 불량, 제작시간 단축 및 비용 감소등 최적의 결과를 빠른 시간에 도출할 수 있음을 알 수가 있었다.

• Journal of Powder Materials
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• v.8 no.2
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• pp.91-97
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• 2001

The conventional debinding process in metal injection molding is very long time-consuming and unfriendly environmental method. Especially, in such a case of injection molded parts from hard and fine metal powder, such as WC-Co, an extremely long period of time is necessary in the conventional slow binder removal process. On the other hand, supercritical debinding is thought to be the effective method which is appropriate to eliminate the aforementioned inconvenience in the prior art. The supercritical fluid has high diffusivity and density, it can penetrate quickly into the inside of the green metal bodies, and extract the binder. In this paper, super-critical debinding is compared with wicking debinding process. Wax-based binder system is used in this study. The binder removal rate in supercritical $CO_2$ have been measured at $65^{\circ}C$, 75$^{\circ}C$ in the pressure range from 20 MPa to 28 MPa. Pores and cracks in silver bodies after sintering were observed using SEM When the super-critical $CO_2$ debinding was carried out at 75$^{\circ}C$, almost all the wax (about 70 wt% of binder) was removed in 2 hours under 28 MPa and 2.5 hours under 25 MPa.