• Design & Manufacturing
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• v.7 no.1
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• pp.1-6
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• 2013

The injection molding process is a predominant method for producing plastic parts. In order to maximize productivity and molding quality in a injection mold, it is important that each cavity in a multi-cavity injection mold is identical. This requires that cavity dimensions should be identical and delivery system of melt to each cavity have to be the same. Despite the geometrically balanced layout in multi-cavity injection mold more than 4 cavities, it has been observed that the filling in each cavity results in imbalances. Most of cases, this phenomenon of filling imbalances have a bad effect on dimension accuracy, warpage, molding appearance and strength of molding parts. In this study, experiment were conducted to investigate the effect of filling imbalances on the molding quality(surface gloss, shrinkage, tensile strength) in the multy-cavity injection mold.

• Design & Manufacturing
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• v.6 no.2
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• pp.74-78
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• 2012

A multi-cavity injection mold system of protein chip for point-of-care with cavity temperature and pressure sensors was proposed in this work. In advance of manufacturing for the multi-cavity injection mold system, a single cavity injection mold system to mold protein chip was considered. Injection molding analysis for the presented system was performed to optimize the process of the molding and suggest guides to design. On the basis of the results for the single cavity system, a multi-cavity injection mold system for protein chip was analyzed, designed and manufactured with cavity temperature and pressure sensors. Results of balanced filling for protein chip models were obtained from the presented mold system.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.2
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• pp.376-381
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• 1990

An interactive computer program to design a mold cavity with the proper rigging system has been developed. In addition to the pattern and the risers generated in part 1 of this work, the various components of the gating system are generated in complete three dimensional models by a rational approach. Then they are laid interactively by the user, and united together with the pattern and the risers to result in the three dimensional model of the mold assembly. Finally, the vents and the mold box are constructed following the user's interactive specification and then the mold cavity is completed in a three dimensional geometric model by subtraction the mold assembly and the vents from the mold box. The three dimensional model of a mold cavity is useful for many related applications such as the solidification simulation for mold evaluation and the NC tool path generation for mold production.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.163-166
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• 2008

Injection molding operation consists of filling, packing, and cooling phase. The highest pressure is involved during the packing phase among the operation phases. Cavity pressure depends upon velocity to pressure switchover time and magnitude of packing pressure. The cavity pressure is directly related to stress concentration in the cavity of mold. Thus the observation and control of cavity pressure is very important to prevent mold cracking. In this study, cavity pressures were observed for operational conditions using the commercial CAE software,Moldflow. Operational conditions were velocity to pressure switchover time and packing pressure. Cavity pressures were also measured directly during injection molding. Simulation and experimental results showed good agreement.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.159-162
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• 2008

High pressure is involved during injection molding operation specially packing phase. Cracks in the mold are often occurred by high cavity pressure. In this study, structural analysis of mold has been performed using commercial softwares, Abaqus and Ansys, to investigate cause of crack in the injection mold. Structural analysis contains four cases: stress distribution according to the cavity pressure, stress concentration according to the boundary conditions, stress concentration for inter-locking design of mold, and stress concentration for distributed cavity pressure. Through this study it was observed that the locations of stress concentrations were coincident with locations of crack. Robust mold design is being required to withstand high cavity pressure.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.70-74
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• 2004

Pressure and temperature in the cavity of injection molding have been investigated. Special injection mold was designed to install pressure and temperature sensors. The sensors were supplied by KISTLER and the pressure and temperature were measured for various operational conditions, such as injection pressure, holding pressure, cooling time, mold temperature, and injection temperature. As injection pressure increased cavity pressure and temperature increase. There were no big differences in temperatures according to the holding pressures. As mold temperature increased pressure and temperature in the cavity increase. The flowability of resin increases as mold temperature increases subsequently the pressure in the cavity increases since the pressure loss is less in the low viscous medium than high ciscous medium. The cavity temperature highly depends upon mold temperature.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.89-94
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• 2008

The injection molding process is a predominant method for producing plastic parts. In order to maximize productivity and molding quality in a injection mold, it is important that each cavity in a multi-cavity injection mold is identical. This requires that cavity dimensions should be identical and delivery system of melt to each cavity have to be the same. Despite the geometrically balanced layout in multi-cavity injection mold more than 4 cavities, it has been observed that the filling in each cavity results in imbalances. Most of cases, this phenomenon of filling imbalances have a bad effect on dimension accuracy, warpage, molding appearance and strength of molding parts. In this study, experiment were conducted to investigate the effect of filling imbalances on the molding quality(surface gloss, shrinkage, tensile strength) in the multy-cavity injection mold.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.132-140
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• 2005

It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially whorl the family-mold has a volumetric difference between two cavities. In this study, we confirmed the cavity-filling imbalance by the temperature and the pressure sensors, and developed a variable-runner system for the cavity-filling balance. We carried out experiments fur balancing the cavity filling in the family-mold with the variable-runner system, and confirmed a balanced cavity-filing through analyzing the temperature and pressure change in each cavity as the cross-sectional area of the runner changed. We also examined the influence of the injection-speed to the balancing-capability of the variable-runner system in the experiment.

• Transactions of Materials Processing
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• v.15 no.1 s.82
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• pp.47-56
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• 2006

It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially when the family-mold has a volumetric difference between two cavities. In this study, the cavity-filling imbalance was confirmed by the temperature and the pressure sensors, and a variable-runner system was developed for balancing the cavity-filling. Experiments of balancing the cavity filling was carried out in the family-mold with the variable-runner system, and balancing the cavity-filling was confirmed by changing the cross-sectional area of a runner in the variable-runner system with the temperature and pressure sensors. The influence of the injection speed to the balancing-capability of the variable-runner system was also examined in the experiment.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.6
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• pp.117-121
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• 2004

Injection molding is the one of the most important processes for mass production of plastic parts. Usually injection molds for mass production are constituted to multi-cavity runner system to manufacture the more parts at a time. Multi-cavity molds are designed to geometrically balanced runner system to uniformly fill to each cavity. But, when injection molding is performed using a mold with balanced runner system filling imbalances are occurred between the cavity to cavity. The previous studies by Beaumont at. all reported that filling imbalance occurred by thermal unbalance on the mold and viscosity variation of resins and so on. In this study, we conducted experiments in order to know the causes of filling imbalance for 3 plate type mold with 8 cavities. And we exhibited a new so called 4BF mold (4 plate type Balanced Filling Mold) to be possible filling balance. We conducted a experimental injection molding to verify the efficiency of the 4BF mold. In the results of the experiment, we could confirmed the balanced filling possibility of the 4BF mold.