• Title/Summary/Keyword: Die and Mold Material

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A study on press plasticity of A3003-O aluminum material (A3003-O 알루미늄 소재의 프레스 성형성에 대한 연구)

  • Kim, Hyeok-Jin;Han, Seong-Ryeol;Kim, Kyung-A
    • Design & Manufacturing
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    • v.13 no.4
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    • pp.23-27
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    • 2019
  • People's interest in the environmental problems of the Earth is growing as they come to the modern world, and research is being actively conducted on how to protect the environment. As a result, the automobile industry, one of the causes of environmental pollution, is also affected. Therefore, research is being conducted to improve the fuel economy and light weight of cars, development of pollution-free cars such as electric cars, and aluminium materials that are lighter than ordinary steel sheets and easier to recycle are gaining attention. In this experiment, the material was formed to form a form of aluminium and the material reduction rate of the side wall of the foam was tested according to the amount of side wall. The material used in the experiment was A3003-O, which is less plastic than normal steel plates, but has excellent corrosion resistance, plasticity and weldability compared to aluminium materials, but has poor tensile strength. For tensile testing, a certain array of Forming Shapes was molded and the height of the Forming was set to 5mm, and the height of the Forming was 4.7mm, indicating that the difference between the first 5mm Forming and the height was not large. In addition, the material reduction rate was tested by giving 15, 0, and -0.15 teas, respectively, and was found to be valuable as a product only for -0.15.

Replication of concave and convex microlens array of light guide plate for liquid crystal display in injection molding (음각, 양각 광학패턴 적용 휴대폰용 도광판 금형 제작 및 광특성 연구)

  • Hwang, Chul Jin;Kim, Jong Sun;Kang, Jeong Jin;Hong, Seokkwan;Yoon, Kyung Hwan
    • Design & Manufacturing
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    • v.2 no.2
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    • pp.29-32
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    • 2008
  • A back light unit (BLU) is a key module of a thin film transistor liquid crystal display (TFT-LCD), frequently utilized in various mobile displays. In this study, we experimentally characterize transcription and optical properties of concave and convex microlens arrays (MLAs) of light guide plate (LGP) fabricated by injection molding with polycarbonate as a LGP substrate material. Nickel mold inserts were manufactured by electroforming on the MLA which was fabricated by the thermal reflow of photoresist microstructures patterned by UV-photolithography. For the case of convex microlens, the height of replicated microlens was less than that of the mold insert while maintaining almost the same microlens diameter of the mold insert as the location of the microlens is far from the gate. In contrast, for the concave microlens, the diameter of replicated microlens was larger than that of mold insert, while showing almost the same microlens height as the mold insert. From the optical examination of replicated convex and concave MLAs, it was found that a higher luminance of the LGP was achieved by the concave MLAs compared to the convex MLAs (about 30% enhancement in this case)due to the utilization of a larger amount of light provided by the light sources.

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A development of creative capstone design process by product and mold design (제품 및 금형 연계 창의 캡스톤 디자인 교육과정에 관한 연구)

  • Kim, Kyung-A;Han, Seong-Ryeol
    • Design & Manufacturing
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    • v.13 no.4
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    • pp.45-50
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    • 2019
  • The fourth industrial revolution calls for an integrated talent by improving working-level skills within the big framework of creativity and convergence. Therefore, university education focuses on solving the problem of practical ability education by improving employment ability. Based on this improvement in practical skills, this study is based on the field-based design curriculum of Capstone. Currently, the Capstone Design Course is being implemented at most universities, extending its scope to the fields of engineering, humanities, social studies and arts. However, there is a limit to the core concept of Capstone design education and capacity education developed in line with the foreign educational environment and applied directly to our nation's university education. In terms of overseas cases, the core focus is to develop practical, design, and prototype capabilities by forming a team among all grades and multidisciplinary institutions to support the capital and manpower of the industry. However, the nation's industrial linkage and curriculum have difficulties in carrying out multi-disciplinary education. In this study, students were asked to team up and solve the challenges that the industry needs based on the expertise acquired in the lower grade curriculum by applying majors and 3D printing through the first and second semester courses of the fourth grade to address these limitations. In addition, business skills for the process of creativity and leadership experience in our country through a suitable design capstone class to review the efficiency of education by applying a model. In order to achieve the purpose of Capstone design subject, the goal setting, class model composition, class model application, verification and evaluation, and final class model development procedures were carried out. Through this process, it will be used as a basic material for educating design class capstone design.

Finite Element Analysis of Shrink Fitting Tolerance and Force of Tile Mold Liner and Fitting Material (타일 금형 라이너 및 끼움재의 열박음 공차 및 결합력에 대한 해석적 연구)

  • Lim, Dong Wook;Lee, Jeong Sik;Jeong, Young Ho;Choi, Doo Sun;Ko, Kang-Ho;Lee, Jeong-woo;Kim, Ji-Hun
    • Design & Manufacturing
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    • v.14 no.3
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    • pp.50-56
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    • 2020
  • Ceramic tile is widely used as a floor or interior decoration of buildings. The main processes are raw material blending, molding, drying, firing, etc., and since dimensional and quality stability are very important, they are generally molded by a dry press method. In ceramic tile molds, there is a liner that can be easily replaced in case of wear. The liner is constantly abrasion due to a continuous pressing process during tile forming, and it is required to be replaced every certain period. Even in the liner, use a wear-resistant fitting material only in areas where wear is concentrated. However, there was a risk that the fitting material was applied to large-sized tile molding due to problems such as damage to the molding machine and decrease in productivity when detached during the actual tile molding process due to weak fitting strength with the liner. Therefore, in this study, thermal-structural analysis for fitting tolerance analysis and structural analysis for fitting force analysis were performed for the shrink fit process of the fitting material.

Numerical Analysis of CO2-Based Rapid Mold Cooling Technology (CO2 기반 금형 급속 냉각기술의 수치해석적 연구 )

  • Jae Hyuk Choi
    • Design & Manufacturing
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    • v.17 no.3
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    • pp.61-66
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    • 2023
  • In this study, we developed a simulation methodology for a technology that rapidly cools molds by directly spraying them with CO2 in its liquefied gaseous state. Initially, a simulation verification process was conducted using ANSYS Fluent's heat transfer analysis based on temperature values measured in prior research experiments, ensuring a comparable temperature could be calculated. Subsequently, the validated analysis method was employed to evaluate design factors that exert the most significant influence on cooling. An evaluation was conducted based on three factors: part thickness, mold thickness, and the melting temperature of material. Using a full factorial design approach, a total of 27 analyses were completed and subsequently calculated through analysis of means. The impact assessment was carried out based on the temperature values at the product's core. The results indicated that the thickness of the mold had the highest influence, while the melting temperature of material had the least.

Injection molding analysis for LED outdoor lighting top cover of one heat sink body type structure (방열체 일체형 구조의 LED 아웃도어 등기구 상부커버에 관한 사출성형해석)

  • Lee, Kwan-Young
    • Design & Manufacturing
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    • v.14 no.2
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    • pp.42-48
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    • 2020
  • This study is on the injection molding analysis for the LED outdoor lighting top cover of one heat sink body type structure. Thermoplastic and thermosetting resins were applied to compare the thermal properties during the injection molding process. The thermoplastic resin is used in this study due to special characteristics that it is light, good strength and dose long not transmute quality even if pass long time. The thermosetting resin is applied to this study due to good in strength, lightweight and excellent etc, thermal conductivity. This study presented a preliminary analysis of fill time, weld line, air trap etc. for the injection molding process of LED lamp cover and body through simulation using Moldflow. As a result of the study, it was selected HTM-102 material because the thermosetting resin has excellent strength and heat conductivity.

Injection molding and structure analysis for design of glass insert injection mold (유리인서트 사출금형 설계를 위한 사출성형 및 구조해석)

  • Moon, Young-Bae;Go, Bo-Sun;Jeong, Yeong-Deug
    • Design & Manufacturing
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    • v.2 no.3
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    • pp.6-9
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    • 2008
  • This paper describes the process of structure analysis and injection molding analysis to manufacture the forming injection dies for huge glass insert. Factors such as filling time, filling pressure, material temperature, shrinkage, warpage were investigated by using the analysis software, Moldflow. Runner system and cavity structure were designed and manufactured through the results of deformation analysis data for glass insert. Filling time and filling pressure were analyzed in 3.756sec and 43.37MPa.

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A study on the change of thickness according to material change of water purifier cold and hot water tank cylindrical drawing products (정수기 냉온수 탱크 원통형 드로잉 제품의 재질 변화에 따른 두께 변화에 관한 연구)

  • Jang, Eun-Jeong;Lee, Chun-Kyu
    • Design & Manufacturing
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    • v.15 no.3
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    • pp.13-18
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    • 2021
  • In plate forming technology, cylindrical drawing process is widely used in industry due to technological development. In this study, we used stainless steel 3042B and stainless steel 304J1, which are the most commonly used materials in the production of cold and hot water tanks for water purifiers, among cylindrical drawing products. Under the same conditions, the thickness of the sidewall of the product formed by drawn experiment was studied. As a result of the experiment, the bottom thickness of stainless steel 304J1 was considered to be thick. It is judged that the defect rate can be reduced by changing the breaking phenomenon of the floor surface of the cold and hot water bottles to the material of stainless steel 304j1. Stainless steel 304 2B material shows a sharp change in thickness from punch corner R to sidewall position, while stainless steel 304J1 material showed a uniform change from punch corner R to sidewall position. Stainless steel 304J1 material is considered to improve the clamping of the product in the process of extracting the product after hand drawing. The appearance of stainless steel 3042B products is considered to produce more wrinkles in the flange, which exerts greater tensile force on the sidewall during molding, resulting in uneven sidewall thickness.

The Fluidity and Hardness of the Recycled Thermoplastic Elastomer in the Injection Molding process (엘라스토머 재생재의 사출성형시 유동성과 경도)

  • Noh, Byeong-Su;Jeong, Yeong-Deug
    • Design & Manufacturing
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    • v.1 no.1
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    • pp.39-44
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    • 2007
  • In recent, recycling of plastic material has became a major issue due to the landfills and environmental problem. This study investigated fluidity and hardness of thermoplastic vulcanizate(TPV), which is used for automobile component parts such as weather strip in order to replace ethylene propylene rubber (EPDM). So, using the spiral flow test mold, we conducted an experiment on fluidity and hardness of TPV according to injection molding conditions. As results of injection molding experiment, the recycled TPV's flow length was a little bit longer than virgin TPV and the hardness was decreased in case of using the recycled resin. Also, we investigated the morphology study by SEM photo.

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A study on the flatness of automotive torque-angle sensors (자동차 토크앵글센서(TAS)의 평면 정밀도에 관한 연구)

  • Yoon, Sean-Jhin;Cho, Yong-Moo
    • Design & Manufacturing
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    • v.12 no.2
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    • pp.11-15
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    • 2018
  • In this study, we proposed three analysis methods to calculate the flatness of torque-angle sensors (TAS). We introduced two statistical and one geometrical methods in evaluating the precision of the flat plane in the axis direction for TAS. To verified the results, we fabricated TAS and a reference sample using a injection molding machine, mold, polyester as a raw material. We measured ($x_i$, $y_i$) position using 3D contact automated system and applied three analysis methods developed for TAS and a reference sample to see the feasibility. While each analysis method has its own pros and cons, the analysis using the shortest optimal distance was the most precise technique for the flatness evaluation of TAS components.