• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.163-166
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• 2008

Injection molding operation consists of filling, packing, and cooling phase. The highest pressure is involved during the packing phase among the operation phases. Cavity pressure depends upon velocity to pressure switchover time and magnitude of packing pressure. The cavity pressure is directly related to stress concentration in the cavity of mold. Thus the observation and control of cavity pressure is very important to prevent mold cracking. In this study, cavity pressures were observed for operational conditions using the commercial CAE software,Moldflow. Operational conditions were velocity to pressure switchover time and packing pressure. Cavity pressures were also measured directly during injection molding. Simulation and experimental results showed good agreement.

• Transactions of Materials Processing
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• v.20 no.5
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• pp.333-338
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• 2011

Rapidly developing IT technologies in recent years have raised the demands for high-precision optical lenses used for sensors, digital cameras, cell phones and optical storage media. Many techniques are required to manufacturing high-precision optical lenses, including multi-beam sensing lenses investigated in the current study. In the case of injection molding for thick lenses, a shrinkage phenomenon often occurs during the process. This shrinkage is known to be the main reason for the lower optical quality of the lenses. In the present work, a CAE analysis was conducted simultaneously with experiments to understand and minimize this phenomenon. In particular, the sectional area of a gate was varied in order to understand the effects of packing and cooling processes on the final shrinkage pattern. As a result of this study, it was demonstrated that a dramatic reduction of the shrinkage could be obtained by increasing the width of the gate.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.46-51
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• 2012

Injection pressure, an important factor in filling process, should be minimized to enhance injection molding quality. Injection pressure can be controlled by valve gate open timing. In this work, we decided the valve gate open timing to minimize the injection pressure. To solve this design problem, we integrated MAPS-3D (Mold Analysis and Plastic Solution-3Dimension), a commercial injection molding CAE tool, to PIAnO (Process Integration, Automation and Optimization), a commercial PIDO (Process Integration, and Design Optimization) tool using the file parsing method. In order to reduce computational cost, we performed an approximate optimization using meta-models that replaced expensive computer simulations. At first, we carried out DOE (Design of Experiments) using OLHD (Optimal Latin Hypercube Design) available in PIAnO. Then, we built Kriging models using the simulation results at the sampling points. Finally, we used micro GA (Genetic Algorithm) available in PIAnO. Using the proposed design approach, the injection pressure has been reduced by 13.7% compared to the initial one. This design result clearly shows the validity of the proposed design approach.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.10a
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• pp.46-50
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• 2001

Due to its ability in producing a net-shape product to high precision in a very shot cycle time, injection molding has become one of the most important polymer-processings in the industry today. Recently the CAE applications in the field of injection molding have provided significant contributions to the mold design and process optimization. As a part of such an application the packing process has been studied using C-PARK. The prediction of pressure variations during post-filling stage for amorphous material has been compared with an experimental observation for a simple rectangular geometry of uniform thickness. And the optimal packing processes were calculated using the cavity pressure curve near the gate. As a case study, a warpage simulation was carried out for a DY-HOLDER with the variable number of gates.

• Transactions of Materials Processing
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• v.15 no.9 s.90
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• pp.641-647
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• 2006

During the injection molding process an excessive packing can occur in the smaller volume cavity because of volumetric difference of the family-mold. It causes warpage by increased residual stress in the product and flesh by over packing. In this study, we used a variable-runner system for the filling balance of the cavities by changing the cross-sectional area of a runner, and confirmed the filling imbalance by temperature and pressure sensors. We carried out experiments to examine the influence of types of resins such as LDPE/ABS/PA6,6 on the filling balancing of the system, in order to help mold designers, who can easily adopt the variable-runner system to their design. We also examined filling imbalance in the system with CAE analysis.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.361-364
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• 2009

The cooling system optimization for injection molds was studied with a response surface method in the previous research. It took so much time to find an optimum solution for a large product due to an extensive amount of calculation time for the CAE analysis. In order to use the optimization technique in the actual design process, the calculation time should be much reduced. In this study, we tried to reduce the number of design variables with the concept of the close relationship between the depth and the distance of cooling channels. The optimum ratio of the distance to the depth of cooling channels for a 2-dimensional problem was 2.0 so that the optimum ratio was again sought out for 4 industrial products. The major cooling effect of the injection molds for large products rely on baffle tubes. The optimum ratio of the distance to the depth for baffle tubes was 2.0 for the large products. The result enables us to reduce the number of the design variables by half in the cooling system optimization problem.

• Composites Research
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• v.37 no.2
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• pp.59-67
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• 2024

Research was conducted on a PA material-based composite material manufacturing method for application to engine mount brackets. Engine mount brackets must have heat resistance, impact resistance, and damping performance. PA66 resin was used as the base material for the composite material. The glass fiber was used as the reinforcement material. The composite material was manufactured using the injection molding method. The thermal, mechanical, and morphological characteristics were analyzed depending on the content of glass fiber. 3D model was created using the property evaluation database of composite materials(input data). The damping performance of the generated 3D model was extracted as out-put data. The reason for evaluating the characteristics of PA-based composite materials and conducting simulations on the damping performance of 3D models of engine brackets is because product performance can be predicted without manufacturing actual automobile parts and conducting damping performance tests. As a result of the damping simulation, damping performance tended to increase proportionally as the mass fraction of the reinforcement increased. But above a certain level, it no longer increased and slightly decreased. As a result of comparing the actual experimental values a nd the simulated values, the approximate value was within ±5%.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.2 no.2
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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.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.12
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• pp.116-123
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• 2001

An automated injection molding design methodology has been developed to optimize multiple quality attributes, which are usually in conflict with each other, in injection molded parts. For the optimization, commercial CAE simulation tools and optimization techniques are integrated into the methodology. To decal with the multiple objective problem the relative closeness computed in TOPSIS(Technique for Order Preference by Similarity to Ideal Solution) is used as a performance measurement index for optimization multiple part defects. To attain robustness against process variation, Taguchi's quadratic loss function is introduced in the TOPSIS. Also, the modified complex method is used as an optimization tool to optimize objective function. The verification of the developed design methodology was carried out on simulation software with an actual model. Applied to production this methodology will be useful to companies in reducing their product development time and enhancing their product quality.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.6
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• pp.648-653
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• 2012

Cavity pressure, an important factor in injection molding process, should be minimized to enhance injection molding quality. In this study, we decided the locations of valve gates to minimize the maximum cavity pressure. To solve this problem, we integrated MAPS-3D (Mold Analysis and Plastic Solution-3Dimension), a commercial injection molding analysis CAE tool, using the file parsing method of PIAnO (Process Integration, Automation and Optimization) as a commercial process integration and design optimization tool. In order to reduce the computational time for obtaining the optimal design solution, we performed an approximate optimization using a meta-model that replaced expensive computer simulations. To generate the meta-model, computer simulations were performed at the design points selected using the optimal Latin hypercube design as an experimental design. Then, we used micro genetic algorithm equipped in PIAnO to obtain the optimal design solution. Using the proposed design approach, the maximum cavity pressure was reduced by 17.3% compared to the initial one, which clearly showed the validity of the proposed design approach.