• Title/Summary/Keyword: Metal Injection Molding

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Numerical Analysis of the Filling Stage in Insert Injection Molding of Microfluidic Chip with Metal Electrodes (금속 전극을 포함한 미세유체 칩의 인서트 사출성형 충전 공정 해석)

  • Lee, Bong-Kee;Na, Seung-Sik
    • Journal of the Korean Society for Precision Engineering
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    • v.32 no.11
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    • pp.969-976
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    • 2015
  • In the present study, a numerical investigation of an insert injection molding process was carried out for the development of thermoplastic microfluidic chip plates with metal electrodes. Insert injection molding technology enables efficient realization of a plastic-metal hybrid structure and various efforts have been undertaken to produce novel components in several application fields. The microfluidic chip with metal inserts was proposed as a representative example and its molding process was analyzed. The important characteristics of the filling stage, such as the effects of filling time and thickness of the part cavity, were characterized. Furthermore, the detailed distributions of pressure and temperature at the end of the filling stage were investigated, revealing the significance of metal insert temperature.

A study on the manufacturing of metal/plastic multi-components using the DSI molding (DSI 성형을 이용한 금속/플라스틱 복합 부품 제조에 관한 연구)

  • Ha, Seok-Jae;Cha, Baeg-Soon;Ko, Young-Bae
    • 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.

A Study on Mechanical Properties Evaluation of Fiber-reinforced Plastic Cellular Injection-molded Specimens for the Development of High-strength Lightweight MHEV Battery Housing Molding Technology (고강성 경량 MHEV 배터리 하우징 성형기술개발을 위한 섬유강화 플라스틱 발포 사출 시험편의 기계적 물성평가에 관한 연구)

  • Eui-Chul Jeong;Yong-Dae Kim;Jeong-Won Lee;Sung-Hee Lee
    • Design & Manufacturing
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    • v.17 no.3
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    • pp.55-60
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    • 2023
  • The fiber-reinforced plastics and cellular injection molding process can be used to efficiently reduce the weight of battery housing components of mild hybrid electronic vehicles(MHEV) made of metal. However, the fiber orientation of fiber-reinforced plastics and the growth of foaming cells are intertwined during the injection molding process, so it is difficult to predict the mechanical properties of products in the design process. Therefore, it is necessary to evaluate the mechanical properties of the materials prior to the efficient stiffness design of the target product. In this study, a study was conducted to evaluated the mechanical properties of fiber reinforced cellular injection-molded specimens. Two types of fiber-reinforced plastics that can be used in the target product were evaluated for changes in tensile properties of cellular injection-molded specimens depending on the foaming ratio and position from the injection gate. The PP and PA66 specimens showed a decrease of tensile modulus and strength of approximately 30% and 17% depending on the foaming ratio, respectively. Also, the tensile strength decreased approximately 26% and 17% depending on the position from the injection gate, respectively. As a result, it was confirmed that the PP specimens have a significantly mechanical property degradation compared to the PA66 specimens depending on the foaming ratio and position.

The Effects of Discharge Condition on Mechanical properties of Injection Moldings (사출 조건이 사출품의 기계적 성질에 미치는 영향)

  • 최양호
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.6 no.1
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    • pp.84-91
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    • 1997
  • In producing moldings by using an injection mold, several variables such as the metal mold and the condition of injection molding should be selected properly in order to obtain good quality of moldings. In this study, focussed are the mechanical properties of injection moldings, since many researches on injection have been focussed mainly on the molding quality, injection pressure, and bulk temperature but the properties of injection moldings have not been studied extensively. The mechanical properties of present injection moldings can be improved simply by changing the molding material and the injection conditon without changind the metal mold. To have the final products meet the specified molding quality and mechanical properties at the same time, the bulk temperature of injection, pressure variation, volumetric shrinkage, stress, and cooling should be analized by CAE(computer aided engineering) after injection mold design. In this paper, the effects of dischare condition on mechanical properties of injection moldings are studied by testing the moldings which are injected by varying injection conditions.

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An Experimental Study on Rheological Characteristics of Metal Injection Molding by Feedstock Material (Feedstock 종류에 따른 금속분말사출성형 유동특성 분석을 위한 실험적 연구)

  • Jung, W.C.;Heo, Y.M.;Shin, K.H.;Yoon, G.S.;Chang, S.H.;Lee, J.W.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2009.10a
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    • pp.57-61
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    • 2009
  • In recently industry, with the miniaturization and high-precision of machine part, the development of mold manufacturing technology for mass production is accompanied by the development of new industrial field such as IT, NT and BT. The metal injection molding(MIM) process combines the well-known thermoplastic injection and powder metallurgy technologies to manufacture small parts for IT, NT, BT industrial. In this study, the bar type MIM mold with a 800um thickness is made for influence of feedstock material and injection parameter through an experiment.

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A study on the fiber orientation and mechanical characteristics of injection molded fiber-reinforced plastic for the rigidity improvement of automotive parts (자동차 부품의 강성 보강을 위한 섬유강화 플라스틱 사출성형품의 섬유 배향 및 기계적 특성에 관한 연구)

  • Eui-Chul Jeong;Yong-Dae Kim;Jeong-Won Lee;Seok-Kwan Hong;Sung-Hee Lee
    • Design & Manufacturing
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    • v.16 no.4
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    • pp.24-33
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    • 2022
  • Fiber-reinforced plastics(FRPs) have excellent specific stiffness and strength, so they are usually used as automotive parts that require high rigidity and lightweight instead of metal. However, it is difficult to predict the mechanical properties of injection molded parts due to the fiber orientation and breakage of FRPs. In this paper, the fiber orientation characteristics and mechanical properties of injection molded specimens were evaluated in order to fabricate automotive transmission side covers with FRPs and design a rib structure for improvement of their rigidity. The test molds were designed and manufactured to confirm the fiber orientation characteristics of each position of the injection molded standard plate-shaped specimens, and the tensile properties of the specimens were evaluated according to the injection molding conditions and directions of specimens. A gusset-rib structure was designed to improve the additional structural rigidity of the target products, and a proper rib structure was selected through the flexural tests of the rib-structured specimens. Based on the evaluation of fiber orientation and mechanical characteristics, the optimization analyses of gate location were performed to minimize the warpage of target products. Also, the deformation analyses against the internal pressure of target product were performed to confirm the rigidity improvement by gusset-rib structure. As a result, it could be confirmed that the deformation was reduced by 27~37% compared to the previous model, when the gusset-rib structure was applied to the joining part of the target products.

Design Regression for Identification of Optimal Components for Metal Powder Injection Molding

  • German, Randall M.
    • Proceedings of the Korean Powder Metallurgy Institute Conference
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    • 2006.09a
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    • pp.211-212
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    • 2006
  • Production components fabricated by metal powder injection molding are analyzed for features to identify the design window for this powder technology. This reverse approach lets the designer see where PIM has a high probability to succeed. The findings show that the most suitable components tend to be less than 25 mm in size and less than 10 g in mass, are slender, and have high complexity.

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Metal Injection Molding Analysis for Developing Embroidering Machine Rotary Hooks (자수기용 로터리 훅 개발을 위한 금속분말 사출성형해석)

  • Kim, Sang-Yoon;Park, Bo-Gyu;Jung, Jae-Ok;Cho, Kyu-Sang;Chung, Ilsup
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.17 no.4
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    • pp.160-168
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    • 2018
  • Among the components of rotary hooks, a core component of an embroidery sewing system, a study was conducted to apply metal injection molding to the manufacture of a hook body and a housing that was very difficult to mechanical working. The correlation of feedstock, a mixture of binder and SCM 415 metal powder, and properties of the pressure-volume-temperature interrelationship, viscosity, specific heat, and thermal conductivity were measured. Injection molds for the hook body and the housing were developed through injection molding analysis using these properties and conducted injection tests. Optimal injection gate position and number, injection pressure, and injection time were obtained through a comparison of analysis results with the experiment results.

Metal Injection Molding Analysis of WGV Head in a Turbo Charger of Gasoline Automobile (가솔린 자동차 터보차져용 WGV Head의 금속 분말 사출성형 해석)

  • Park, Bo-Gyu;Park, Si-Woo;Park, Dae-Kyu;Kim, Sang-Yoon;Jeong, Jae-Ok;Jang, Jong-Kwan
    • Transactions of the Korean Society of Automotive Engineers
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    • v.23 no.4
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    • pp.388-395
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    • 2015
  • The waste gate valve (WGV) for gasoline vehicles operate in a harsh high-temperature environment. Hence, WGVs are typically made of Inconel 713C, which is a type of Ni-based superalloy. Recently, the metal injection molding (MIM) process has attracted considerable attention for parts used under high-temperature conditions. In this study, an MIM analysis for the head and other parts of the WGV is conducted using a commercial CAE program Moldflow. Further, optimal manufacturing conditions are determined by analyzing flow characteristics at various injection times and locations. Moreover, to improve the accuracy of the analysis results, we compare the actual temperature of the mold during injection processing with that observed through the analysis. As the results, metal injection patterns of analysis are well in accord with these of short shot test. And the temperature variations of analysis is also very similar with those of feedstock when metal injection molding.

A Study of Outsell Molding Technology for Thin-walled Plastic Part (박판 플라스틱 부품의 Outsert Molding 기술에 대한 연구)

  • Lee, S.H;Ko, Y.B.;Lee, J.W.
    • Transactions of Materials Processing
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    • v.18 no.2
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    • pp.177-182
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    • 2009
  • A work of thin-walled outsell injection molding technology for a plastic part of moldframe applicable in a display product was performed in the present study. The thin-walled plastic part is one of the core parts in the display product, which supports and protects a light guide plate and back light unit from external environmental conditions. It globally has the shape of rectangular and surrounds the light guide plate and back light unit for each class of inch, however, the cross section of the part is not clear to define the thickness. This causes the difficult problem of injection molding itself for the part. Moreover, a metal outsell part makes a difficult problem in injection molding over it. Because the mold temperature control of the parts are not uniform in thickness direction due to the metal part. A careful injection melding analysis and injection mold design from the analysis results have to be proceeded to obtain a production of precision moldframe. Therefore, optimization for injection molding process and analysis of warpage characteristics were studied. Consequently, it was possible from the presented virtual manufacturing process that the manufacturing of precision thin-walled outsell moldframe.