• The Korean Journal of Rheology
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• v.5 no.2
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• pp.109-124
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• 1993

본 연구의 목표는 임의의 3차원 사출성형 금형 공간내에서 단섬유 강화 플라스틱의 충전 공정에서의 과도기적 섬유방향성을 예측하는 수치해석 프로그램의 개발에 있다. Hele-Shaw 방정식에 단섬유에 의해서 추가된 응력을 고려한 Dinh-Armstrong의 모델을 도 입함으로써 새로운 충전과정의 압력 지배 방정식이 유도되었다. 새로운 압력지배 방정식은 단섬유에 의한 응력 때문에 몇 개의 새로운 항들을 포함하고 있다. 충전 과정의 해석은 새 로운 압력지배방정식과 에너지 방정식을 유한효소법과 유한 차분법을 이용하여 풀고 동시에 배향텐서(roientation tensor)의 변화 방정식을 4차 Runge-Kutta 방법을 이용하여 풀었다. 단섬유 배향 텐서를 텐서의 변환 법칙을 이용하여 임의의 3차원 금형 공간내의 모든유한요 소의 중심에서 두께방향의 모든유한 차분 격자를 따라 계산하였다. 이러한 방법으로 임의의 3차원 사출성형 금형 공간내에서 비등온 충전유동과 과도기적 3차원 섬유배향상태를 서로의 상호작용을 고려하여 수치 모사하여 다양한 유동 형태에 따른 단섬유 배향 상태의 변화에 대하여 알아보고자 한다.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.12
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• pp.6047-6052
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• 2013

A cosmetic manufacturing process requires a mold that is inevitable for mass production. Cosmetic containers are one of major factors affecting the customer's purchase decision. In addition, the manufacturing cost in cosmetic container comprises a large portion of the entire product cost. Therefore, a mold satisfying the economical feasibility, aesthetics and functionality is necessary. Among the cosmetic containers, square shape containers have a tendency of having a short shot defect product. The square shaped cosmetic containers are mostly produced as a side gate shape on the two-plate molds. On the other hand, there are two disadvantages, such as gate trace and post processing requirement. The overlap-gateproposed in this study has the characteristics of intaglio gate cutting and no need for post processing. The delivery system of the overlap gate was simulated and compared with the side gate via Moldflow. The improvement in flow, frozen rate, density, and Air trap was confirmed. Based on the simulation results, the mold and performed injection molding was fabricated. In this study, the possibility of the mass production of high aesthetic and functionality cosmetic containers was verified.

• Proceedings of the KAIS Fall Conference
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• 2009.12a
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• pp.678-681
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• 2009

사출성형은 열가소성수지의 가공법으로써 정밀도나 고품질의 제품을 효과적으로 생산하는데 널리 이용되며 플라스틱은 현재 광범위하게 사용되고 있는 공업재료 중의 하나이다. 과거에는 플라스틱을 일회용품 및 외장재로 사용하였다. 그러나 산업기술이 발전하며 플라스틱은 금속을 대체 할 수 있는 재료로서 사용할 수 있다는 인식의 변화로 점차 기계요소용 재료로 사용되고 있으며 기계요소용 재료로 사용됨에 따라 플라스틱 제품이 정밀한 부품으로 사용되기 위해서는 금형의 가공뿐만 아니라 사출성형 시 용융수지가 금형의 각 캐비티에 균형적으로 충전되는것이 요구된다. 이러한 요구조건을 만족하기 위해서는 각 캐비티의 가공치수는 매우 높은 정밀도를 유지해야 하며, 각 캐비티에서의 충전과 냉각도 동일한 상태를 유지해야 한다. 충전 불균형은 성형품의 품질에 큰 저해 요인으로서 플라스틱 제품의 치수성, 밀도, 외관품질, 강도 등에 불균일한 결과를 가져오는 요인으로 지적되고 있다. 실제로 충전 불균형은 충전 단계에서 런너 내에서 발생하는 불균일한 전단분포에 기인하여 발생되므로 점도변화에 영향을 주는 수지의 물성, 런너의 배열과 같은 외부 요인과 사출압력, 사출속도, 수지온도, 금형온도와 같은 성형공정 조건에 의한 요인에 의한 충전 불균형의 양상이 달라지게 된다. 본 연구는 다수 캐비티 금형에서 충전 불균형 현상에 대한 원인을 검토하고 실제로 사출성형을 실시하기 전 사출성형해석 소프트웨어를 이용하여 시뮬레이션을 하여 다수 캐비티에 대한 충전 패턴을 미리 예측하여 보았다.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2012.04a
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• pp.196-199
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• 2012

Generally the piezo-composites have superior hydrostatic response characteristics than PZT ceramics due to both the stress amplification effect in axial direction and stress reduction effects in radial direction. This paper described material properties of a 1-3 type piezo-composite that fabricated with ceramic injection molding (CIM) technology. The electro-mechanical performances of the composite have been analyzed using FEM and the physical properties of the composite have been measured with the vol. % of the PZT ceramics. Based on the results, the $k_t$ increased rapidly as the vol. % of the PZT ceramics increased up to 30 vol. % and saturated the constant value in the above region. Also the experimental results have good agreement with the simulation values of the composite. Finally we developed the composites having high piezoelectric properties than the PZT ceramics with the CIM technology.

• Transactions of Materials Processing
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• v.16 no.1 s.91
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• pp.42-47
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• 2007

LCD-BLU is one of kernel parts of LCD and it consists of several optical sheets: LGP, light source and mold frame. The LGP of LCD-BLU is usually manufactured by etching process and forming numerous dots with $50\sim300{\mu}m$ diameter on the surface. But the surface of the etched dots of LGP is very rough due to the characteristics of the etching process during the mold fabrication, so that its light loss is high along with the dispersion of light into the surface. Accordingly, there is a limit in raising the luminance of LCD-BLU. In order to overcome the limit of current etched dot patterned LGP, optical pattern with continuous microlens was designed using optical simulation CAE. Also, a mold with continuous micro-lens was fabricated by UV-LiGA reflow process and applied to 7 inch size of navigator LCD-BLU in the present study.

• Transactions of Materials Processing
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• v.16 no.1 s.91
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• pp.48-53
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• 2007

LCD-BLU(Liquid Crystal Display - Back Light Unit) consists of several optical sheets: LGP(Light Guiding Plate), light source and mold frame. The LGP of LCD-BLU is usually manufactured by etching process and forming numerous dots with $50{\mu}m$ in diameter on the surface. But the surface roughness of LGP with etched dots is very high, so there is much loss of light. In order to overcome the limit of current etched dot patterned LGP, optical pattern design with microlens of $50{\mu}m$ diameter was applied in the present study. The microlens pattern fabricated by modified LiGA with thermal reflow process was applied to the optical design of LGP and optical simulation was carried out to know tendency of microlens patterned LGP simultaneously. The attention was paid to the effects of different aspect ratio(i.e. $0.2\sim0.5$) of optical pattern conditions to the brightness distribution of BLU with microlens patterned LGP. Finally, high aspect ratio microlens patterned LGP showed superior results to the one made by low aspect ratio in average luminance.

• Polymer(Korea)
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• v.25 no.6
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• pp.855-865
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• 2001

The optimization condition of injection molding for a commercial product of TV speaker grille of A Company was induced using a CAE software of Moldflow. The flow and packing phase analysis was performed by using flow balance, runner balance, and the intermediate one by using the above two balances, which were used for controlling the amount of packing resins into the cavity, Later, the analysis performed by using the measured viscosity (local database) at various shear rates and the results were compared with the computer simulation using the standard database. Flow balance induced minimized weld line resulted in a better appearance and physical properties of the were line, but exhibited a disadvantage of large deformation and gas formation due to over-packing of the molten resin in the center of the speaker grille. Runner balance improved the disadvantage of the flow balance by controlling the amount of molten resin injected from the gate, however resulted reduced mechanical properties and poor appearance of the weld line. However, the modified method induced from the flow and runner balance improved the disadvantages by changing the runner size. In addition, the analyses based on the local database and the standard database were compared. Although the measured viscosity was slightly higher and the temperature distribution was broader than the standard database, no distinct difference was obtained from the analysis using the two different databases.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.9 s.186
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• pp.174-178
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• 2006

Pyramid shape of micro pattern is applied to the light guide panel (LGP) to enhance the uniformity of the brightness of the LCD. The micro pyramids are molded in intaglio on the surface of the LGP. The size of each pyramid is 5$\mu$m $\times$ 5$\mu$m on bottom and the height is about 3.5$\mu$m. The pyramids are distributed on the LGP surface randomly to be sparser where the light comes in and denser at the opposite side as a result of a simulation using lightools$^{TM}$ Based on this design, a silicon pattern master and a nickel stamper are fabricated by MEMS process and electro plating process. Intaglio micro pyramids are fabricated on the 6' of silicon wafer from the anisotropic etching using KOH and the process time, temperature of the KOH solution, etc are optimized to obtain precise shape of the pattern. A Wi stamper is fabricated from this pattern master by electro plating process and the embossed pyramid patterns turns out to be well defined on the stamper. Adopting this stamper to the mold base with two cavities, 1.8' and 3.6' LGPs are injection molded.

• Proceedings of the Materials Research Society of Korea Conference
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• 2012.05a
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• pp.81.2-81.2
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• 2012

To fabricate a metal mold for injection molding, hot-embossing and imprinting process, mechanical machining, electro discharge machining (EDM), electrochemical machining (ECM), laser process and wet etching ($FeCl_3$ process) have been widely used. However it is hard to get precise structure with these processes. Electrochemical etching has been also employed to fabricate a micro structure in metal mold. A through mask electrochemical micro machining (TMEMM) is one of the electrochemical etching processes which can obtain finely precise structure. In this process, many parameters such as current density, process time, temperature of electrolyte and distance between electrodes should be controlled. Therefore, it is difficult to predict the result because it has low reliability and reproducibility. To improve it, we investigated this process numerically and experimentally. To search the relation between processing parameters and the results, we used finite element simulation and the commercial finite element method (FEM) software ANSYS was used to analyze the electric field. In this study, it was supposed that the anodic dissolution process is predicted depending on the current density which is one of major parameters with finite element method. In experiment, we used stainless steel (SS304) substrate with various sized square and circular array patterns as an anode and copper (Cu) plate as a cathode. A mixture of $H_2SO_4$, $H_3PO_4$ and DIW was used as an electrolyte. After electrochemical etching process, we compared the results of experiment and simulation. As a result, we got the current distribution in the electrolyte and line profile of current density of the patterns from simulation. And etching profile and surface morphologies were characterized by 3D-profiler(${\mu}$-surf, Nanofocus, Germany) and FE-SEM(S-4800, Hitachi, Japan) measurement. From comparison of these data, it was confirmed that current distribution and line profile of the patterns from simulation are similar to surface morphology and etching profile of the sample from the process, respectively. Then we concluded that current density is more concentrated at the edge of pattern and the depth of etched area is proportional to current density.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.28 no.8
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• pp.544-549
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• 2015

Since LEDs (light emitting diodes) have many advantages as a light source in vehicle headlamp, such as good reliability, energy and space saving, and flexible headlamp design. On the other hand, the dependence of its performance and life on temperature have great influence on its practical use. In this study, design and fabrication of heat sink for vehicle LED headlamp were performed using thermally-conductive plastics. This study focused on the effective heat sink structure with limited space in the vehicle LED headlamp. We designed two different prototype of heat sink by thermal simulation using SolidWorks program, which had excellent temperature characteristics. The two different prototype of heat sink were fabricated by injection molding with thermally-conductive plastics. The results showed that LED $T_j$ (junction temperature) of sample B (model 1) and sample C (model 1, 2) was below then $165^{\circ}C$ when applying the thermally-conductive plastics in heat sink of vehicle LED headlamp.