• International Journal of Precision Engineering and Manufacturing
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• v.2 no.2
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• pp.17-25
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• 2001

In this paper, a theoretical study has been made to reduce the residual stress and birefringence in the injection-molded parts. An optimization program has been used to minimize the residual stresses and birefringence calculated from a simulation program. The thermally induced stress has been calculated using a linear viscoelasticity model. The flow stress and birefringence has been calculated using the Leonov's viscoelasticity model. This has been applied to the injection molding of a circular disc and a plate. the optimization has been done either by changing process variables while maintaining the mold temperature constant or by varying the mold-wall temperature with time. This study shows the significant reduction in residual stress and birefringence is possible through the optimization of processing conditions.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.2 no.2
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• pp.33-37
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• 2001

The synthesis of gates of injection-molded parts has been done empirically, since it requires profound knowledge about the gate design,. which is not available to designers through current CAD systems. GATEWAY is a knowledge module which contains knowledge to Permit non-experts as well as mold design experts to generate acceptable gate design of injection-molded parts. A knowledge-based CAD system is constructed by adding the knowledge module, GATEWAY, for gate synthesis and appropriate CAE programs for mold design analysis to an existing geometric modeler to provide designers, at the initial stage, with comprehensive process knowledge for gate synthesis. Performance analysis and feature-based geometric modeling.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.131.2-135
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• 1999

This study focuses on part quality and cycle times under gas-assisted injection molding(GIM) of housing molded parts. The position of the gas channel was estabished near to parting line at the end of last locations to fill. Applied hot runner and valve gates the gas was introduced directly into the mold cavity via gas pin. As GIM was applied the introduced directly into the mold cavity via gas pin. As GIM was applied the conclusion reached as follows. I) The quality of appearance was improved by reducing sink marks and scratches of texture ii) The realibility was improved by preventing warpages and reinforcing rigidity through optimum gas channel layout iii)It is enable to use small size of injection molding machine step by step as GIM was accomplished low pressure and reduced clamp forces against CIM iv)The productivity were improved by reducing cycle times.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.6 s.237
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• pp.828-834
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• 2005

Recently, injection molded plastic optical products are widely used in many fields, because injection molding process has advantages of low cost and high productivity. However, there remains residual birefringence and residual stresses originated from flow history and differential cooling. The present study focused on developing a technique to measure the birefringence in optical plastic parts using R-G-B separation of white light. The main idea of an analysis comes from the fact that more information can be obtained from the distribution of retardation caused by different wavelengths. A complete system to give the quantitative values of retardation covering high order 2-D birefringence will be demonstrated. Further investigation is under way to improve the accuracy of the system using diodes as light sources.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.290-293
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• 2004

Recently, injection molded plastic optical products are widely used, because injection molding process has advantages of low cost and high productivity. However, there remains residual birefringence and residual stresses originated from flow history and differential cooling. The present study focused on developing a technique measuring birefringence in optical plastic parts using R-G-B separation of white light. The main idea of an analysis comes from the fact that more information can be obtained from the distribution of retardation caused by different wavelengths. A complete system to give the quantitative values of retardation covering high order 2-D birefringence will be demonstrated. Further investigation is under way to improve the accuracy of the system using diodes as light sources.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.8
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• pp.71-78
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• 1999

The application range of injection molded parts is expanding by the development of engineering plastics with good mechanical properties. Plastic gears are specially used as automotive parts due to an excellent performance in the characteristics of a strength vs. weight, and the study of injection molding process of plastic gear using Nylon66 is performed in this study. Filling, packing and cooling analyses were done by using the simulation software like Moldflow, and a mold was designed by following the simulation results. Pin-point gates with three points were taken to satisfy the design guides like a full-shot, and lower clamping force and uniform shrinkage. Characteristics of shrinkage of molded gear and temperature difference between cavity and core sides of a mold were shown.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.10
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• pp.32-39
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• 1995

The design of injection molded polymeric parts has been done empirically, since it requires profound knowledge about the moldability and causal effects on the properties of the part, which are not available to designers through current CAD systems. An interactive computer-based design system is developed in order to realize the concept of rational design for the productivity and quality of mold making. The knowledge-based CAD system is constructed by adding the knowledge -base module for mold feature synthesis and appropriate CAE programs for mold design analysis in order to provide designers, at the initial design stage, with comprehensive process knowledge for feature synthesis, performance analysis and feature-based geometric modeling. A knowledge-based CAD system is a new tool which enables the concurrent design with integrated and balanced design decisions at the initial design stage of injection molding.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.1
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• pp.62-75
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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 repeated modification of actual tooling. This paper presents and expert design evaluation 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 expert system with CAE programs. An iterative boundary pressure reflection method(IBPR) is developed to automate the cavity filling simulation program and to predict thermo-mechanical properties of a molded part precisely. Mathematical models of weldline and frozen-in molecular orientation are established to determine the spatial variation of microstructural anisotropies of a molded part from the result of cavity filling simulation. The strength ellipse is devised as and index which represents th spatial distribution of the microstructural anisotropies of a molded part, Heuristic knowledge 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 recommendations for optimal design alternative.

• Korean Journal of Computational Design and Engineering
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• v.7 no.2
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• pp.96-101
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• 2002

Rapid Prototyping (RP) technology has been advanced to fabricate initial prototypes from various materials. Stratasys′ Fused Deposition Modeling (FDM) is one of the typical RP processes that provide functional prototypes of ABS plastic. In order to predict the behavior of final ABS parts, it is critical to understand the material properties of the raw FDM process material, and the effect that FDM build parameters have on the FDM part. In this paper, we seek to characterize the properties of ABS parts fabricated by the FDM 1650. Using the Design of Experiment (DOE) approach, the process parameters of FDM, such as raster orientation, air gap, bead width, color, and model temperature were examined. Tensile strengths of crisscross specimens, 〔45°/-45°〕, cross specimens, 〔0°/90°〕, and directionally fabricated tensile specimens (〔0°〕 and 〔90°〕) were measured and compared with the injection molded FDM-ABS P400 material. For the FDM parts made with a -0.003"air gap, the typical tensile strength ranged between 50 percent and 83 percent of the strength of injection molded ABS P400. From the experiments, a couple of build rules for designing FDM parts were obtained.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.15-16
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• 2009