• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1191-1192
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• 2010

• Journal of the Korean Society for Precision Engineering
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• v.17 no.9
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• pp.210-221
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• 2000

Plastic mold designers and frequently faced with optimizing multi-quality issues in injection molded parts. These issues are usually in conflict with each other and thus tradeoff needs to be made to reach a final compromised solution. in this study an automated injection molding design methodology has been developed to optimize multi-quality characteristics of injection molded parts. The features of the proposed methodology are as follows : first utility theory is applied to transform the original multi-objective problem into single-objective problem. Second is an implementation of a direct search-based injection molding optimization procedure with automated consideration of robustness against process variation. The modified complex method is used as a general optimization tool in this study. The developed methodology was applied to an actual mold 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 companies in reducing the product development time and enhancing the product quality.

• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.368-374
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• 2005

In the present study we used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design and molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors. The contributing factors for the final cycle time could be enumerated as follows; the thickness of hot spot, main nominal part thickness, coolant inlet temperature, melt temperature and cooling line layout, etc.. As a first step, all the critical factors of design process applied to the current monitor housing were investigated through 6 sigma process. Thereafter, the optimal and better critical factors found in the first step were applied to new product design to prove that our process was correct. The Moldflow was used for injection molding simulation, and Minitab software for the statistical analysis, respectively. Finally, the productivity of new design was increased about 33 percents for our specific case.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.269-272
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• 2004

The present study used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding process of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design & molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors, as critical ones influencing on the quality and productivity, of which is summarized as design guidance. The main contribution factors for cycle time can be sequentially enumerated as follows; hot spot, part thickness, coolant inlet temperature, melt temperature cooling line layout, etc.. As a first step critical factors of the design process of current monitor housing were investigated. And the optimal and better critical factors found in the first step were applied to a new product proving our process was correct. Moldflow software was used for injection molding simulation, and Minitab software for the statistical analysis. Finally, the productivity was increased by about 33 percents for our specific case.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.269-274
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• 2001

This research covers the development of new technique for composite injection molding of high stiffness Sabot. An analysis of polymer resin is performed by means of making test specimen mold and doing test with accordance of ASTM test guidelines. Structural analysis and simulation of injection molding process are carried out in order not only to estimate but also to predict the characteristics of molding stresses what both product and structure of mold may have. For structural analysis software, Moldflow and LS-dyna are used and universal test machine is utilized for evaluating performance of sabot. Cases of adopting this material to sabot are not announced yet in domestic academic world. In addition to that, materials for polymer-metal mixed injection molding are imported on the whole due to deficient level of domestic technology. Therefore, this new developed injection molding technique using PEI material can make it available to ensure the technology of making mold, injection and design. Finally, this technique may be applicable to another sabot having different radius of warheads from now on.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.10
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• pp.1575-1582
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• 2001

Injection molding is widely used in producing various plastic parts due to its high productivity, and the demand for injection molded products with high precision is increasing. To achieve successful product quality and precision, the design of gating and runner system in injection mold is very important because it influences the melt flow into the cavity. Some deflects, 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 fur automobiles was carried out with CAMP mold, a PC-based simulation system for injection molding. A dummy runner system was developed to simulate a runner system in order to increase the efficiency of the analysis procedure. The numbers and locations of gates were iteratively determined in the present investigation. In this procedure, an acceptable design was obtained in terms of reducing the maximum pressure and clamping force.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.60-65
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• 2012

This paper deals with an CAE analysis and optimization of injection molding for a mobile phone cover. Two design goals are established in the optimization; one is to switch over the feed system from cold runner to hot runner for the purpose of reducing material costs, and the other is to minimize the warpage in order to improve product quality. By the full-factorial experiments for design parameters, we showed that the cold runner design could be changed to the hot runner design by replacing the current resin with a new resin of higher fluidity. In addition, we could significantly reduce the warpage of the cover product under the hot runner system by optimizing packing pressure and packing time.

• Design & Manufacturing
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• v.17 no.1
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• pp.64-69
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• 2023

This paper explores the impact of gate shape changes on the size and density of foamed cells in microcellular foam injection molding. Five different gate shapes were examined while varying the amount of nitrogen gas(N2) injected for foaming. Analysis of the results showed that while average values did not change significantly, deviation values decreased by approximately 65% for cell size and 56% for density when 3.5wt% of nitrogen gas was injected in the film gate. Further analysis was conducted to verify this phenomenon, revealing that the contact area between the gate and product had the greatest impact. Our findings indicate that to ensure uniform generation of foamed cells in microcellular foaming product design, a gate with a wide contact area should be secured.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.4 no.3
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• pp.183-188
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• 2003

Non-molding and welding line happen by the assembly of gas at the connector terminal. There is not good phenomenon of burr by increasing the over injection pressure, the temperatures of die and resin to prevent from them. Therefore, the connector mold to apply the vacuum molding system is developed in this study. The vacuum pressure is controlled systematically with the optimum conditions in the important ingredients of injection molding that are the temperatures of melting resin and die and cooling condition. The badness in charging is cleared by making a vacuum to non-charging part of the deep bottom part of each cavity. And the vacuum system to reduce the cycle time is applied as the study envelopment of molding work. So, the good product and the productivity improvement can be obtained in this study.

• Design & Manufacturing
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• v.11 no.3
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• pp.25-28
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• 2017

The production of carbon fiber reinforced thermoplastics(CFRTP) parts using an injection/compression molding process that differs from the conventionally used fabrication methods was investigated Before the application of composite molding in the injection/compression molding process, a simple compression molding experiment was performed using a hydraulic press machine to determine the characteristics of resin impregnation and to obtain a basic physical property data for the CFRTP. Based on these results, injection/compression molded specimens were manufactured and an additional insert/over molding process was applied to improve the impregnation rate of the molded specimens. The results demonstrated that the tensile strength of the molded parts using the faster injection/compression process was similar to that of a hydraulic press molded product.