• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1995.10a
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• pp.64-67
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• 1995

Transfer Molding is currently the most widely used process for encapsulation integrated circuits(;IC). Although the process has been introduced over 20 years ago, generating billions of parts each year, it is far from being optimized. With each new mold, epoxy mold, epoxy mold compound, and lead-frame, lengthy period and expensive qualification runs have to be performed to minimized defects ranging from wire sweep, incomplete fill, and internal voids etc. This studies describes how simulation can be applied to transfer molding to yield acceptable design and processing parameter. The non-isothermal filling of non-newtonian reactive epoxy molding compound(;EMC) in a multi-cavity mold is analyzed. Sensitivity analysis is conducted to investigate the influence of process deviations on the final molded profile. This study trend is carried out by following some heuristic process guidelines.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.5
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• pp.575-582
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• 2010

In recent years, several rapid-mold-heating techniques that can be used for the injection molding of thin-walled parts or micro/nano structures have been developed. High-frequency induction heating, which involves heating by electromagnetic induction, is an efficient method for the rapid heating of mold surfaces. The present study proposes an integrated numerical model of the high-frequency induction heating process and the resulting injection molding process. To take into account the effects of thermal boundary conditions in induction heating, we carry out a fully integrated numerical analysis that combines electromagnetic field calculation, heat transfer analysis, and injection molding simulation. The proposed integrated simulation is extended to the injection molding of a thin-wall part, and the simulation results are compared with the experimental findings. The validity of the proposed simulation is discussed according to the ways of the boundary condition imposition.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1992.03a
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• pp.177-200
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• 1992

A thermo-viscoplastic finite element program was developed to analyze the compression molding of SMC process. Deformation of the material was modelled by using the flow-rule. Heat balance during the process was coupled to the deformation. In the cure study, a kinetic model was adopted to describe the cure behavior. The numerical kinetic model was integrated with the thermo-viscoplastic numerical analysis by adding heat generation due to the chemical reaction of the workpiece in the heat transfer analysis. The integrated finite element program can simulate a whole sequential molding process including deformation, heat transfer, and chemical reaction. A practical SMC molding process with T-shaped substructure was simulated. The simulated results showed good agreements with experiments.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.840-843
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• 2004

UV molding is a process for integrating micro/nano polymeric optical components on optoelectronic modules. In the present study, a microlens array for vertical cavity surface emitting laser(VCSEL) to fiber coupling was designed, integrated and tested. At the design stage, design variables ware optimized to maximize the coupling efficiency, and tolerance analysis was carried out. At the integration stage, the UV transparent mold was fabricated and the microlens array on VCSEL array was integrated by UV molding process. Finally the coupling efficiency of VCSEL to fiber was measured and analyzed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.10
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• pp.34-41
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• 2019

Warpage and weld line are two major cosmetic defects in the injection molding process. These defects are very sensitive to uncontrollable parameters within the process. The optimization of the design variables can be treated with the use of robust designs. Therefore, in order to minimize the warpage and weld line, a special design method to diminish defects is required. In this study, a new robust design method using designer preference to achieve the optimal robust design conditions in the injection molding process is proposed. The effectiveness of the proposed method is shown with an example of the part of warpage and weld line.

• Design & Manufacturing
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• v.14 no.4
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• pp.71-77
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• 2020

Various manufacturing technologies, including over-molding and insert-injection molding, are used to produce hybrid plastics and metals. However, there are disadvantages to these technologies, as they require several steps in manufacturing and are limited to what can be reasonably achieved within the complexities of part geometry. This study aims to determine a practical approach for producing metal/plastic hybrid components by combining plastic injection molding and metal die casting to create a new hybrid metal/plastic molding process. The integrated metal/plastic hybrid injection molding process developed in this study uses the proven method of multi-component technology as a basis to combine plastic injection molding with metal die casting into one integrated process. In this study, the electrical conductivity and ampacity were verified to qualify the new process for the production of parts used in electronic devices. The electrical conductivity was measured, contacting both sides of the test sample with constant pressure, and the resistivity was measured using a micro ohmmeter. Also, the specific conductivity was subsequently calculated from the resistivity and contact surface of the conductor path. The ampacity defines the maximum amount of current a conductive path can carry before sustaining immediate or progressive deterioration. The manufactured hybrid multi-components were loaded with increasing currents, while the temperature was recorded with an infrared camera. To compare the measured infrared images, an electro-thermal simulation was conducted using commercial CAE software to predict the maximum temperature of the power loaded parts. Overall, during the injection molding process, it was demonstrated that multifunctional parts can be produced for electric and electronic applications.

• Korean Journal of Computational Design and Engineering
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• v.3 no.3
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• pp.201-209
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• 1998

To develop timely an optimal fan, a design system and a new manufacturing process used step by step have to be integrated. A small sized optimal fan for refrigerators, that was the goal on this project, was developed by the following principal processes. All processes are technologically linked in many directions: The existing fan was measured through reverse engineering. The measured data was used for the basic source of 3D design. The performance tests were carried and used as the data for the evaluation of the existing fan. Flow analysis by FANS-3D/sup [1]/ was performed at the given information (pressure drop and flow rate) to find out the configuration of optimal fan design. The flow patterns were investigated to measure the performance of fan through numerical experiment. The grid point data obtained by the above analysis turned into 3D high efficiency fan model by using CATIA. The product was manufactured by RP process (SLS, SLA) and tested the characteristic curves of the developed fan to compare with the existing fan. The modification of fan design were all examined to see any change in performance and checked to find any deficiency in assembling the fan into a duct. After the plastics flow analysis of the injection molding cycle to ensure acceptable quality fan, an optimal mold was processed by using tool-path for the newly designed fan.

• Transactions of Materials Processing
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• v.18 no.2
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• pp.128-134
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• 2009

The present study covers an integrated simulation method to evaluate optical performance of an aspheric plastic lens by connecting an injection molding analysis with a ray tracing simulation. Traditional ray tracing methods have based on the assumption that the optical properties of a lens are homogeneous throughout the entire volume. This assumption is to a certain extent unrealistic for injection-molded plastic lenses because material properties vary at every point due to the injection molding effects. To take into account the effects of the inhomogeneous optical properties of the molded lens, a numerical scheme is developed to calculate the distribution of refractive index induced from the injection molding process. This index distribution is then reflected onto CODE $V^{(R)}$ simulation and used to calculate ray paths in inhomogeneous media. The proposed tracing scheme is implemented on the tracing of an aspheric lens for a mobile phone camera module.

• Journal of Sensor Science and Technology
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• v.18 no.2
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• pp.154-159
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• 2009

This paper describes two methods - stamp-to-stick bonding and microtransfer molding - to integrate microfluidic channel into an optoelectrofluidic device for in-channel microparticle manipulation. We have demonstrated the optoelectronic microparticle manipulation in the channel-integrated optoelectrofluidic device using a liquid crystal display. As injecting a liquid sample containing $15{\mu}m$-diameter polystyrene particles into the fabricated channel, trapping and transport of individual microparticles have been successfully demonstrated. This channel-integrated optoelectrofluidic device may be useful for several in-channel applications based on the optoelectrofluidics such as optoelectronic flow control, droplet-based protein assay and bead-based immunoassay.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.38 no.3
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• pp.100-107
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• 2015

Recently as the manufacturers want competitiveness in dynamically changing environment, they are trying a lot of efforts to be efficient with their production systems, which may be achieved by diminishing unplanned operation stops. The operation stops and maintenance cost are known to be significantly decreased by adopting proper maintenance strategy. Therefore, the manufacturers were more getting interested in scheduling of exact maintenance scheduling to keep smooth operation and prevent unexpected stops. In this paper, we proposedan integrated maintenance approach in injection molding manufacturing line. It consists of predictive and preventive maintenance approach. The predictive maintenance uses the statistical process control technique with the real-time data and the preventive maintenance is based on the checking period of machine components or equipment. For the predictive maintenance approach, firstly, we identified components or equipment that are required maintenance, and then machine parameters that are related with the identified components or equipment. Second, we performed regression analysis to select the machine parameters that affect the quality of the manufactured products and are significant to the quality of the products. By this analysis, we can exclude the insignificant parameters from monitoring parameters and focus on the significant parameters. Third, we developed the statistical prediction models for the selected machine parameters. Current models include regression, exponential smoothing and so on. We used these models to decide abnormal patternand to schedule maintenance. Finally, for other components or equipment which is not covered by predictive approach, we adoptedpreventive maintenance approach. To show feasibility we developed an integrated maintenance support system in LabView Watchdog Agent and SQL Server environment and validated our proposed methodology with experimental data.