• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.6
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• pp.1465-1477
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• 1993

Powder Injection Molding(PM) is an advanced and complicated technology for manufacturing ceramic or metal products making use of a conventional injection molding process, which is generally used for plastic products. Among many technologies involved in the successful PIM, injection molding process is one of the key steps to form a desired shape out of powder/binder mixtures. Thus, it is of great importance to have a numerical tool to predict the powder injection molding filling process. In this regard, a finite element analysis system has been developed for numerical simulations of filling process of powder injection molding. Powder/polymer mixtures during the filling pro cess of injection molding can be rheologically characterized as Non-Newtonian fluids with a so called yield phenomena and have a peculiar feature of apparent slip phenomena on the wall boundaries surrounding mold cavity. Therefore, in the present study, a physical modeling of the filling process of powder/polymer mixtures was developed to take into account both the yield stress and slip phenomena and a finite element formulation was developed accordingly. The numerical analysis scheme for filling simulation is accomplished by combining a finite element method with control volume technique to simulate the movement of flow front and a finite difference method to calculate the temperature distribution. The present study presents the modeling, numerical scheme and some numerical analysis results showing the effect of the yield stress and slip phenomena.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.18 no.2
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• pp.144-153
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• 2009

It is widely known that no-slip assumptions are often violated on regular basis in micrometer- or nanometer-scale fluid flow. In the case of cavity-filling process of nanoimprint lithography(NIL), slip phenomena take place naturally at the solid-to-liquid boundaries, that is, at the mold-to-polymer or polymer-to-substrate boundaries. If the slip or partial slip phenomena are promoted at the boundaries, the processing time of NIL, especially of thermal-NIL which consumes more tact time than that of UV-NIL, can be significantly improved. In this paper it is aimed to elucidate how the cavity-filling process of NIL can be influenced by the slip phenomena at boundaries and to what degree those phenomena increase the process rate. To do so, computational fluid dynamics(CFD) analysis of cavity filling process has been carried out. Also, the effect of mold pattern shape and initial thickness of polymer resist were considered in the analysis, as well.

• Journal of Powder Materials
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• v.9 no.4
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• pp.245-250
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• 2002

In this paper we presented numerical method for the simulation of powder injection molding filling process, which is one of the key processes in powder injection molding. Rheological properties of powder binder mixture such as slip phenomena and yield stress were introduced into the numerical analysis model of powder injection molding filling simulation. Numerical model can be classified into two types. One is 2.5D model which can be introduced to a arbitrary thin geometry and the other is full 3D model which can be applied to a general 3D shape. For 2.5D model we showed the validity of our CAE system with several verification examples. Finally we suggested flow analysis model for 3D powder injection molding filling simulation.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.24 no.1
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• pp.102-113
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• 2000

In this study, a three-dimensional gravity casting problem has been examined to investigate a coupled phenomenon of the filling and solidification process. This work simultaneously considers the two key phenomena of metal casting : the fluid flow during mold filling, and solidification process. The VOF method is used to analyze the free surface flow during filling and the equivalent specific heat method is employed to model the latent heat release during solidification. The time-implicit filling algorithm is applied to save the computational time for analyzing the mold filling process. The three-dimensional benchmark problem used in the MCWASP VII has been solved using both the implicit and explicit algorithm, and the present results are compared with the benchmark experimental results and the other numerical results.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.5
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• pp.657-665
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• 2003

Several interesting results were obtained from the flow visualization experiment in the accompanying paper, Part I. in the present study, Part II, a numerical study has been carried out to explain the detailed flow phenomena in micro-channel filling process. Hele-Shaw flow approximation was applied to the micro-channel geometry based on the small characteristic length. And surface tension effect has been introduced on the flow front as the boundary condition with the help of a dynamic contact angle concept between the melt front and the wall. A dimensional analysis for numerical results was carried out and a strong relationship between dimensionless pressure and Capillary number is obtained. The numerical analysis results are compared with the flow visualization experimental observations. And the numerical system developed in the present study seems to be able to predict the interesting micro-channel filling flow characteristics observed from experiments.

• Journal of Advanced Marine Engineering and Technology
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• v.28 no.6
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• pp.931-937
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• 2004

Simultaneous filling is a goal in plastic injection mold that has multi cavities. The moldings which have not been filled at the same time have undesired faults such as dimension inaccuracy, residual stress, law mechanical strength, etc. The best way to simultaneous fill is to be injected in a geometrically balanced runner system. In a general processing, however, in balanced runner system mold, filling imbalance would be observed in cavities. These phenomena result from molten polymer's characteristics and circumstances in balanced runner. In this study, the degree of filling imbalance (DFI) was defined for showing rate of filling imbalance in geometrically balanced injection mold that has 8 cavities. Before the main experiment, an injection molding simulation was conducted to know a pattern of filling imbalance with Moldflow software. There were somewhat differences between results of experiment and simulation about the filling imbalance. The reason for the difference was that the software have not concerned about a situation in a real flow channel. It was also investigated how the injection speed affected on filling imbalance in the experiment.

• Transactions of Materials Processing
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• v.5 no.3
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• pp.239-255
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• 1996

A new forming technology has been developed to fabricate near-net shape products using light metal. A semi-solid forming technology has some advantages compared with the conventional forming processes such as die casting squeeze casting and hot/cold forging. In this study the numerical analysis of semi-solid filling for a straight die shape and orifice die shape in gate pattern is studied on semi-solid materials(SSM) of solid fraction fs =30% in A356 aluminum alloy. The finite difference program of Navier-Stokes equation coupled with heat transfer and solidification has been developed to predict a filling pattern and the temperature distribution of SSM. The programdeveloped in this study gives die filling patterns of SSM and final solidifica-tion region.

• Journal of Hydrogen and New Energy
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• v.34 no.6
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• pp.608-614
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• 2023

The fast filling process of high-pressure hydrogen has an important impact on the filling efficiency and safety. In this paper, a specific study is carried out on the thermophysical phenomena during the fast filling process. Starting from the gas state equation of hydrogen, the change law of the hydrogen storage temperature is obtained, and then the temperature rise prediction is constructed. The model can clarify the relationship between the filling parameters and the temperature rise during the fast filling process, thereby revealing the flow and heat transfer laws of the fast charging process. To improve the theoretical research basis for the evaluation of vehicle-mounted hydrogen fast charging capacity, temperature prediction and optimization of hydrogenation methods.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.10
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• pp.1982-1988
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• 2002

Micro-injection molding and microfluidic devices with the help of MEMS technologies including the LIGA process are expected to play important roles in micro-system industries, in particular the bio-application industry, in the near future. Understanding fluid flows in micro-channels is important since micro-channels are typical geometry in various microfluidic devices and mold inserts for micro-injection molding. In the present study, Part 1, an experimental investigation has been carried out to understand the detailed flow phenomena in micro-channel filling process. Three sets of micro-channels of different thickness (40um,30um and 2011m) were fabricated using SU-8 on silicon wafer substrate. And a flow visualization system was developed to observe the filling flow into the micro-channels. Experimental flow observations are extensively made to find the effects of pressure, inertia force, viscous force and surface tension. A dimensional analysis for experimental results was carried out and several relationships A dimensionless parameters are obtained.

• Journal of Korea Foundry Society
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• v.24 no.4
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• pp.225-230
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• 2004

Computer simulation of mold filling and solidification has been performed in order to analyze the flow and solidification phenomena for the casting process of cylinder liner. The simulation result of mold filling shows that the molten metal flows into the mold in stable without scattering. The simulation results of solidification indicate that the last solidified area is located in the feeder. The temperature variation in casting is measured in actual casting and the result is compared with calculation result.