• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.129-135
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• 2021

Injection molding is a manufacturing method of melting the polymer resin and injecting it into a mold to molding it into the desired form. Due to the short molding time and outstanding formability, complex products can be shaped with high precision and it is the most widely used polymer molding method. However, there may be areas that are not filled depending on the location of the injection gate where polymer resin is injected. Formability is determined by deformation and surface precision due to the impact of residual stress after molding. Hence, choosing the location of the injection gate is very important and molding analysis of injection molding is essential to reduce the cost of the mold. This study evaluated the injection formability based on the location of the injection gate of the vertical machining center ATC tool port using injection molding analysis and the results were compared and analyzed. Injection molding analysis was conducted on filling, packing, and deformation according to the location of the gate of the ATC tool port. From each injection gate location, filling time, pressure, and maximum deformation were compared. At gate 2, conditions of molding time and the location of the gate were far superior in production and quality. Gate 2 produced the smallest deformation of 0.779mm with the best quality.

• Transactions of Materials Processing
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• v.15 no.8 s.89
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• pp.628-632
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• 2006

The gate mark in injection molded part is a kind of surface defects. The formation of gate mark has been investigated in this study. SEM photographs and surface roughness have been examined to study gate mark. The specimens were molded for various injection conditions, such as injection temperature, mold temperature, and injection speed. Gate diameter and mold surface condition were also molding variables. Gate marks were reduced as injection speed and mold temperature increased. Gate diameter and injection temperature did not affect the gate marks. No etching of mold surface showed no gate marks for any molding conditions.

• Design & Manufacturing
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• v.15 no.1
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• pp.1-7
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• 2021

The position of the gate is one of the important factors for optimal injection molding. This is because inappropriate gate positions cannot fill the cavity uniformly, which can lead to defects such as contraction. In this study, CAE was performed on hot runner injection molding of the washing machine base and plasticity was compared by changing gate position from existing gate position. A total of two alternatives have been applied to compare the plasticity of the washing machine base according to its optimal gate position. The gate position of the improved molds and the gate position of the current mold is analyzed by injection molding analysis. The results of the fill time, the pressure at V/P switchover, clamping force, and deflection were compared. In washing machine base injection molding, the deflection was reduced by about 3.76% in the improved mold 2. In improved mold 1, the fill time during injection molding was reduced by 3.32% to enable uniform charging, and the clamping force was reduced by 31.24%. We have confirmed that the position of the gate can change the charging pressure and the clamping force and affect the quality and cost savings of the molded product.

• Transactions of Materials Processing
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• v.16 no.1 s.91
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• pp.3-8
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• 2007

Novel compression molding system for preform has been developed in this study. The preforms for injection blow molding and injection stretch blow molding are being manufactured by injection molding. However it contains gate mark that affects the bottom crack in the PET bottle. The compression molded preform does not contain gate mark, thus the appearance quality of bottle has been increased and the residual stress near gate(bottom of the bottle) has been reduced. The thickness distributions, haze, and transmittance are well accepted for the preform. Also, flow characteristics of the resin between a core and cavity could be analyzed through computer simulation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.04a
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• pp.33-39
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• 2003

Injection molding is widely used in producing various plastic parts due to its high productivity and the demand for high precision injection molded products is ever increasing. To achieve successful product quality and precision, the design of gating and runner systems in the injection mold is very important since it directly influences melt flow into the cavity. Some defects such as weld lines and overpacking can be effectively controlled with proper selection of gate locations. In the present study, the design of gate locations in injection molding of a dashboard for automobiles was carried out with CAMPmold, a PC-based simulation system for injection molding. A dummy runner was developed to simulate a runner system in order to increase the efficiency of the analysis. The numbers and locations of gates were varied in the present investigation as that an acceptable design was obtained in terms of reduced maximum pressure and clamping force.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2005.05a
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• pp.252-257
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• 2005

Injection molding is a very important industrial process for the manufacturing of plastics objects. During an injection molding process of composites, the fiber-matrix separation and fiber orientation are caused by the flow of molten polymer/fiber mixture. As a result, the product tends to be nonhomogeneous and anisotropic. Hence, it is very important to clarify the relations between separation' orientation and injection molding conditions. So far, there is no research on the measurement of fiber orientation using image processing. In this study, the effects of fiber content ratio and molding condition on the fiber orientation-angle distributions are studied experimentally. Using the image processing method, the fiber orientation distribution of weld-line in injection-molded products is assessed. And the effects of fiber content and injection mold-gate conditions on the fiber orientation are also discussed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.7
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• pp.4411-4417
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• 2015

The proper design of the gate location for injection molding of plastic goods is obtained from three-dimensional injection molding analysis for various design alternatives. This paper is study on effect of gate location in injection molding. It have a decisive impact on productivity and quality of plastic goods. This objectives of this paper is to analysis effect of hot runner gate location for resin filling, weld line, injection pressure to manufacture of automobile air cleaner upper case with injection molding machine. Thus, to analysis these problems in this paper, location of gate are gave variety in 4 CASEs. In this paper, the CAE simulation considering each variations in location of gate is performed to predict the cause of faulty which appears in the injection molding process.

• Design & Manufacturing
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• v.2 no.6
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• pp.7-10
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• 2008

Injection-stretch blowing system for preform has been developed in this study. The preforms for injection blow molding and injection stretch blow molding are being manufactured by injection molding. However it contains gate mark that affects the bottom crack in the PET bottle. The compression molded preform does not contain gate mark, thus the appearance quality of bottle has been increased and the residual stress near gate(bottom of the bottle) has been reduced. The thickness distributions, haze, and transmittance are well accepted for the preform. Also, flow characteristics of the resin between a core and cavity could be analyzed through computer simulation.

• Design & Manufacturing
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• v.12 no.3
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• pp.55-59
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• 2018

In a multi-cavity mold having a runner layout of a fish bone structure, problems of unbalanced filling between cavities occur constantly. Unbalanced charging lowers the dimensional accuracy of a molded article and causes deformation after molding. To solve this problem, the gate size connected to each cavity is adjusted using the BGV (Balanced Gate Value) equation. In this paper, in order to solve the filling imbalance problem of the runner layout mold of fish bone structure through injection molding analysis study, we compared the charging imbalance phenomenon before and after improvement after adjusting the gate size by applying BGV equation. From the results of the molding analysis, the shrinkage ratio before and after the improvement of the molded article was improved by only about 0.08%. Based on these results, it was confirmed that the charging imbalance problem was not significantly improved even when the BGV equation was applied.

• Transactions of Materials Processing
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• v.12 no.2
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• pp.134-140
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• 2003

Polymers such as polypropylene or polyethylene offer a unique feature of producing an integral hinge, which can flex over a million times without causing a failure. With such advantage manufacturing, time and cost required at the assembly stage can be eliminated by injecting the whole part as one piece. However, due to increased fluidity resistance at hinges during molding, several defects such as short shot or premature hinge failure can occur with the improper selection of gate locations. Therefore, it is necessary to optimize flow balancer in injection molding of part with hinges before actually producing molds. In this paper, resin flow patterns depending on several gate positions were investigated by numerical analyses of a simple strip part with a hinge. As a result, we found that the properly determined gate location leads to better resin flow and shorter hesitation time. Finally, injection molding tryouts using a mold that was designed one of the proposed gate systems were conducted using polypropylene that contained 20% talc. The experiment showed that hinges without defects could be produced by using the designed gate location.