• Transactions of Materials Processing
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• v.13 no.2
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• pp.180-187
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• 2004

A computer code was developed to simulate the filling stage of the injection/compression molding process by a finite element method. The constitutive equation used here was the compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Simulations of a disk part under different process conditions including the variation of compression stroke and compression speed were carried out to understand their effects on birefringence variation. The simulated results were also compared with those by conventional injection molding.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.2
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• pp.302-310
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• 1998

In the accompanying paper, part I, we have presented the physical modeling and the associated numerical analysis of injection molding process with a compressible viscoelastic fluid model. In part II, the effects of compression stage in the injection/compression molding process are presented. Numerical results showed that the injection/compression molding process reduced birefringence as compared with the injection molding process. In this respect, one can conclude that the injection/compression molding process is more suitable for manufacturing the precise optical products than the injection molding process. In the distribution of birefringence, the effect of packing procedure in injection/compression molding process was found to be similar to that in injection molding process. From the numerical results, we found that birefringence becomes smaller as the melt temperature gets higher and the closing velocity of the mold gets smaller with the flow rate and the mold temperature affecting the birefringence insignificantly. As far as the distribution of density is concerned, the flow rate, the melt temperature, and the closing velocity of the mold had insignificant effect on the distribution of density in comparison with the mold temperature.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.5
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• pp.28-33
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• 2010

A computer code was developed to simulate all three stages of the injection molding process: filling, packing and cooling by finite element method. The constitutive equation used here was compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Based on the simulation, the Taguchi method was used to investigate the influences of injection molding conditions on the birefringence of a center gate disk. In addition, the optimal processing conditions were selected to minimize the birefringence and the birefringence difference along the positions of the disk.

• 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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• 2005.10a
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• pp.105-110
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• 2005

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 modified approximate approach that can analyze compressible packing process using the penalty parameter, which is an improvement on an earlier formulation (KSME, 2004B). 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.

• International Journal of Precision Engineering and Manufacturing
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• v.8 no.1
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• pp.66-72
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• 2007

A computer code was developed to simulate the filling stage of an injection/compression molding process using a finite element method. The constitutive equation was the compressible Leonov model and the PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Simulations of a disk under different processing conditions, including variations of the compression stroke and compression speed, were performed to determine their effects on the flow-induced birefringence. Simulated pressure traces were also compared to those obtained in conventional injection molding and with experimental data from the literature.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.65-69
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• 2004

A computer code was developed to simulate the filling stage of the injection/compression molding process by a finite element method. The constitutive equation used here was the compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Simulations of a disk part under different processing conditions including the variation of compression stroke and compression speed were carried out to understand their effects on flow-induced birefringence. The simulated results were also compared with those by conventional injection molding and with experimental data from literature.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.305-309
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• 2005

A computer code was developed to simulate all three stages of the injection molding process ? filling, packing and cooling by finite element method. The constitutive equation used here was compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Based on the simulation, the Taguchi method was used to investigate the influences of injection molding conditions on the birefringence of a center gate disk. In addition, the optimal processing conditions were selected to minimize the birefringence and the birefringence difference along the positions of the disk.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.2
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• pp.289-301
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• 1998

The present study attempted to numerically simulate the process in detail by developing an appropriate physical modeling and the corresponding numerical analysis for precision injection and injection/compression molding process of center-gated disk. In part I, a physical modeling and associated numerical analysis of injection molding with a compressible viscoelastic fluid model are presented. In the distribution of birefringence, the packing procedure results in the inner peaks in addition to the outer peaks near the mold surface, and values of the inner peaks increase with the packing time. Also, values of the density in the core region increase with the packing time. From the numerical results, we also found that birefringence becomes smaller as the melt temperature gets higher and that it is insignificantly affected by the flow rate and the mold temperature. As far as the density distribution is concerned, mold temperature affected the distribution of density especially near the wall. But it was not significantly affected by flow rate and melt temperature. Numerical results of birefringence coincided with experimental data qualitatively but didn't quantitatively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.04a
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• pp.41-47
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• 2003

This study is an attempt to understand the birefringence and stress development in an injection molded disk. A computer code was developed to simulate all three stages of the injection molding process - filling, packing and cooling by finite element method. The constitutive equation used here was compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. The predicted birefringence was in good agreement with the experimental results.