• Design & Manufacturing
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• 제1권1호
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• pp.17-21
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• 2007

In the manufacture and processing of large plastic materials, product quality is tested and verified through several techniques such as injection processing, residual stress through injection molding and shrinkage. With regards to the injection molding process, common problems such as inconsistent density is seen when different points of the product are discovered to have varying thickness levels. Sink marks in product are then evident. This occurs when there is poor molding conditions caused about by poor runner and packaging systems incorporated into the process. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique.

• 소성∙가공
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• 제14권3호
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• pp.269-276
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• 2005

The purpose of this research is the warpage reduction for intake-manifold which is made to the injection molding. Intake-manifold is assembling to ultra sonic welding after forming. Therefore deformation is influence on the performance and manufacture to intake-manifold product. Location and number of gates, filling time, mold temperature, packing time, packing pressure and cooling time are factors that affect the deformation of injection molding product. Therefore, the injection molding characteristics of intake-manifold and the estimated deformation are detected by CAE analysis and compare measuring data in this study.

• Design & Manufacturing
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• 제11권1호
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• pp.34-38
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• 2017

Deformation frequently occurring in injection molded products is a phenomenon displayed due to uneven shrinkage distribution and orientation of the whole molded product. Shrinkage deformation is a very serious problem because it causes deformation of the molded article and shortens the performance of the product. In this paper, we are focusing on the warpage of keypad in mobile phone. In other words, we focused on minimizing keypad deformation. In the study, the Taguchi method was applied to find the injection molding conditions that minimize the deformation of the keypad. In the case of this keypad, the main factors influencing the shrinkage deformation were predicted as the melting temperature, coolant temperature and cooling time. In addition, the optimum molding conditions were obtained and the shrinkage strain was minimized. Experiments for the Taguchi method and verification of optimal molding conditions were performed using an injection molding analysis program.

• International Journal of Precision Engineering and Manufacturing
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• 제1권1호
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• pp.133-145
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• 2000

Plastic molding designers are frequently faced with optimizing multiple defects in injection molded parts. these defects are usually in conflict with each other, and thus a tradeoff needs to be made reach a final compromised solution. In this study, an automated injection molding design methodology has been developed to optimize multiple defects of injection molded parts. Two features of the proposed methodology are as follows: one is to apply the utility theory to transform the original multiple objective optimization problem into single objective optimization problem with utility as objective function, the other is an implementation of a direct search-based injection molding optimization procedure with automated consideration of process variation. The modified complex method is used as a general optimization tool in this research. The developed methodology was applied to an actual molding design and the results showed that the methodology was useful through the CAE simulation using a commercial injection molding software package. Applied to production, this study will be of immense value to industry in reducing the product development time and enhancing the product quality.

• Design & Manufacturing
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• 제17권2호
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• pp.62-69
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• 2023

In this study, we conducted a study on the optimization of injection molding conditions to minimize deformation of plastic product. The charging management system housing of the vehicle was selected as the research subject. Melting temperature, cooling temperature, packing time, and packing pressure were selected as the main factors expected to affect the deformation of molded products. Each main factor was divided into 5 levels. Optimization of injection molding conditions to minimize deformation was performed using the Taguchi Method. We performed an analysis of variance (ANOVA) to identify significant factors affecting the deformation of plastic product. In order to select injection molding conditions that minimize deformation of plastic products, injection molding analysis was additionally performed for insignificant factors. We then compared the deformation of the molded part before and after optimization. As a result of comparing the injection analysis results of the basic conditions and the injection analysis results of the optimal conditions, it was confirmed that the amount of deformation after optimization was improved by about 10.9%.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 추계학술대회 논문집
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• pp.100-104
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• 2005

The injection molding is very effective process for various plastic products due to its high productivity. It is also good fur precise products like optical parts. Various thermoplastic materials are also available with this injection molding process. In recent, however, as the overall size of the product increases and micro or nano scale of patterns are applied to the products, we now have some problems such as low fidelity of the replication of the pattern, high molding pressure, or warpage from the in-mold stress. Injection/compression molding is studied to overcome those problems in molding large thin plate with micro pattern array on its surface. An injection compression mold is designed to 3 pieces mold for side gate. We install 4 pressure transducers and 9 thermocouples to measure the melt pressure and surface temperature in the cavity during the process. As a result, the maximum molding pressure for injection compression molding is reduced to 1/3 compared to injection molding and the uniformity of the pressure in the cavity is enhanced by about 15%.

• Design & Manufacturing
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• 제15권1호
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• pp.48-56
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• 2021

The quality of products produced by injection molding process is greatly influenced by the process variables set on the injection molding machine during manufacturing. It is very difficult to predict the quality of injection molded product considering the stochastic nature of manufacturing process, because the process variables complexly affect the quality of the injection molded product. In the present study we predicted the quality of injection molded product using Artificial Neural Network (ANN) method specifically from Multiple Input Single Output (MISO) and Multiple Input Multiple Output (MIMO) perspectives. In order to train the ANN model a systematic plan was prepared based on a combination of orthogonal sampling and random sampling methods to represent various and robust patterns with small number of experiments. According to the plan the injection molding experiments were conducted to generate data that was separated into training, validation and test data groups to optimize the parameters of the ANN model and evaluate predicting performance of 4 structures (MISO1-2, MIMO1-2). Based on the predicting performance test, it was confirmed that as the number of output variables were decreased, the predicting performance was improved. The results indicated that it is effective to use single output model when we need to predict the quality of injection molded product with high accuracy.

• Design & Manufacturing
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• 제8권1호
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• pp.1-4
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• 2014

Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

• 한국금형공학회:학술대회논문집
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• 한국금형공학회 2008년도 하계 학술대회
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• pp.99-102
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• 2008

Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2005년도 춘계학술대회 논문집
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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.