• Journal of the Korea Academia-Industrial cooperation Society
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• 제2권2호
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• pp.115-119
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• 2001

The design and manufacture of injection molded polymeric parts with desired properties is a costly process dominated by empiricism, including the repeated modification of actual tooling. This paper presents an knowledge-based synthesis system which can predict the mechanical performance of a molded product and diagnose the design before the actual mold is machined. The knowledge-based system synergistically combines a rule-based system with CAE programs. Hueristic know]edge of injection molding. flow simulation, and mechanical performance prediction is formalized as rules of an expert consultation system. The expert system interprets the analytical results of the process simulation, predicts the performance, evaluates the design and generates recommendation for optimal design alternatives.

• Transactions of Materials Processing
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• 제27권4호
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• pp.211-221
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• 2018

To estimate the recycling feasibility of high melt-indexed polycarbonate, 3.5 inch LGP, tensile, flexural and impact specimens were injection-molded and the LGP was shredded into scraps. The scraps were injection-molded again and this process was repeated for 4 times. Properties of the sample, i.e., optical properties, mechanical properties and number average molecular weight were measured at each cycle. Based on the results, as the number of reprocessing increased, transmittance decreased at low wavelength and color coordinate was changed systematically to yellow. Yellow index increased more than twofold during 4 recycling processes. On the other hand, the number average molecular weight decreased during recycling processes. Flexural and impact strength showed no tendency according to the number of recycling, but tensile strength decreased sharply after the third recycling process. Based on these properties, it was concluded that the number of recycling for high melt-indexed polycarbonate allowed in this study was one.

• Transactions of Materials Processing
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• 제14권4호
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• pp.360-367
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• 2005

The injection-molded plastic parts have many surface defects: warpage, weldline, flowmark, zetting, scratching, shading and so on. As weldline was one of the major surface defects in the case of desktop monitor, warpage and surface shrinkage are the bigger problems of LCD monitor in the pursuit of light weight and thinner thickness of parts. Some measures to improve these defects were introduced in this paper. Based on these, the laboratory work to find out the optimum processing conditions and to get the best parts was repeated injection moulding try-out after reflecting these improvements. The defects of warpage and surface shrinkage was significantly improved after the improvements in the case of the 20.1 inch even if in the 15 and 17inch case the warpage size was a lttle over the allowed specification because of not taking the measure for parts design within the allowable limits from the required specification in the cause of cost down.

• Korea-Australia Rheology Journal
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• 제19권4호
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• pp.183-190
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• 2007

Injection molding is one of the most common operations in polymer processing. Good quality products are usually obtained and major post-processing treatment is not required. However, residual stresses which exist in plastic parts affect the final shape and mechanical properties after ejection. Residual stresses are caused by polymer melt flow, pressure distribution, non-uniform temperature field, and density distribution. Residual stresses are predicted in this study by numerical methods using commercially available softwares, $Hypermesh^{TM},\;Moldflow^{TM}\;and\;ABAQUS^{TM}$. Cavity filling, packing, and cooling stages are simulated to predict residual stress field right after ejection by assuming an isotropic elastic solid. Thermo-viscoelastic stress analysis is carried out to predict deformation and residual stress distribution after annealing of the part. Residual stresses are measured by the hole drilling method because the automotive part selected in this study has a complex shape. Residual stress distribution predicted by the thermal stress analysis is compared with the measurement results obtained by the hole drilling method. The molded specimen has residual stress distribution in tension, compression, and tension from the surface to the center of the part. Viscoelastic deformation of the part is predicted during annealing and the deformed geometry is compared with that measured by a three dimensional scanner. The viscoelastic stress analysis with a thermal cycle will enable us to predict long term behavior of the injection molded polymeric parts.

• Design & Manufacturing
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• 제13권2호
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• pp.1-5
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• 2019

In this study, micro cellular injection molding of automobile head lamp housing with uneven thickness structure was performed to obtain improvement on deformation and light-weight of the part. The thickness of the presented model was uniformly modified to control the deformation of the molded part. In order to maximize the lightweight ratio, the model having an average thickness of 2.0 mm were thinly molded to an average thickness of 1.6 mm. GFM(Gas Free Molding) and CBM(Core Back Molding) technology were applied to improve the problems of the conventional foam molding method. Equal Heat & Cool system was also applied by 3D cooling core and individual flow control system. Warpage of the molded parts with even cooling was minimized. To improve the mechanical properties of foamed products, complex resin containing nano-filler was used and variation of mechanical properties was evaluated. It was shown that the weight reduction ratio of products with light-weighted injection molding was 8.9 % and the deformation of the products was improved from the maximum of 3.6 mm to 2.0 mm by applying Equal Heat & Cool mold cooling system. Also the mechanical strength reduction of foamed product was less than 12% at maximum.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• 제20권4호
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• pp.490-494
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• 2011

In this paper, using by rapid heating and cooling systems for injection molding and temperatures to changes. In the process of molding temperature and pressure inside the mold was found. In addition, the tensile strength of test specimens were molded, mechanical properties of injection molded parts were identified on mold temperature. Copper could withstand more tensile force than NAK. Therefore, it can be concluded that materials with high heat conductivity must be used in thin walled products.

• Transactions of Materials Processing
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• 제17권6호
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• pp.443-448
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• 2008

Fiber reinforced injection molded parts are widely used in recent years because of their improved properties of materials such as specific stiffness, specific strength, and specific toughness. The demand for products with high precision is increasing and it is important to minimize the warpage of the products. The warpage of short-fiber reinforced product is caused by anisotropy induced by fiber orientation as well as the residual stresses induced during the molding process. In order to reduce the warpage of the part, it is important to achieve successful mold design, processing control, and part design. In the present study, the design of gating system, molding condition, and part structure were carried out and verified with numerical analysis using a commercial CAE code Moldflow. The numbers and locations of gates were iteratively determined, and the molding conditions which can decrease the warpage of the part were investigated. Finally, slight structural modification of the part was conducted to reduce the locally concentrated warpage.

• Proceedings of the KAIS Fall Conference
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• 한국산학기술학회 2001년도 추계산학기술 심포지엄 및 학술대회 발표논문집
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• pp.144-146
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• 2001

The synthesis of injection-molded parts has been done empirically, since it requires profound knowledge about injection molding which is not available to designers through current CAD systems. Appropriate U3 programs for mold design analysis to an existing geometric modeler is used to provide designers, at the initial stage, with comprehensive process knowledge for synthesis, performance analysis and feature-based geometric modeling.

• Journal of the Korean Society of Manufacturing Process Engineers
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• 제5권1호
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• pp.27-32
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• 2006

Thermoplastic elastomer(TPE) has many advantages such as high flexibility, high elasticity and high elongation, etc. TPE is easily molded as plastic materials, therefore, many TPE parts are applied as home appliances and mechanical parts. However, its mechanical properties would be changed by injection molding conditions such as melt temperature, mold temperature, injection pressure and holding pressure, etc. In this study, the influences of the injection molding condition on the mechanical properties as tensile strength, hardness of thermoplastic vulcanizates(TPVs), which is one of the TPE, were investigated. By the injection molding experiment, the molding's tensile strength and hardness was influenced on the melt temperature and composition ratio of PP and EPDM. The morphology of moldings were shown by the scanning electron microscope.

• IE interfaces
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• 제15권3호
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• pp.263-269
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• 2002

The injection molding process is a one of the most efficient techniques for manufacturing plastic parts of complex shape at low cost. In injection molding, molten plastic material is injected into the mold and cooled. Selection of molding conditions greatly affects the quality of molded parts. In this case study, we attempted to optimize the injection molding condition for a cooling filter using Taguchi experimental design methodology. The injection molding experiments were carried out using the Moldflow simulation software.