• Journal of Computational Design and Engineering
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• 제2권2호
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• pp.96-104
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• 2015

Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD) data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

• 한국기계가공학회지
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• 제20권4호
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• pp.87-93
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• 2021

The mold industry is competitive, and mold should be processed under optimal conditions for efficient processing. However, the cutting conditions of the ball-end mill, which are a major factor in mold processing, are mostly set empirically, and considerable research is required for increasing the tool life and processing accuracy. In this study, a tool dynamometer and an eddy current sensor were used along with NI-DAQ, a data acquisition device, to obtain characteristic values of the cutting force and tool deformation during the ball end-mill machining of inclined surfaces at a machining center. The cutting force and tool deformation were measured in an experiment. It was found that the tool received the greatest cutting force at the end of the machining process, and the deformation of the tool increased rapidly. Furthermore, the cutting force tended to increase with the angle and number of rotations. The deformation increased rapidly during the machining of a 45° inclined surface.

• Design & Manufacturing
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• 제7권1호
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• pp.40-44
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• 2013

My company develops, manufactures injection mold and produces thin-walled cosmetics and food containers. Without high quality and low production cost, it is hard to compete in the market. To be competitive, a company has to utilize mold with as many cavities as possible to lower manufacturing cost. Eject plate abrasion and deformation cut down mold lifespan, troubles during injection lower productivity and foreign substances in molds cause abrasion. This study focuses on how to improve mold life and productivity, and to slow down mold abrasion.

• 대한기계학회논문집A
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• 제37권2호
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• pp.279-285
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• 2013

소형 복합재료 프로펠러를 제작하기 위한 기존의 알루미늄 몰드를 복합재료 몰드로 대체하기 위한 타당성 연구를 수행하였다. 소형 알루미늄 프로펠러의 세 날개는 복합재료 몰드를 만들기 위해 플러그로서 사용되었다. GRPG 복합재료 몰드와 프로펠러는 실내온도에서 압축과 진공법을 이용하여 불포화된 폴리에스테르 수지, Epovia 겔코트, 우븐과 매트 유리 섬유 등으로 만들어졌다. 표면의 경도와 거칠기, 압축과 흡입 몰드에 의한 강도와 변형은 실험에 의해 결정되었다. 결과는 ISO 484/2 규격과 몇몇의 알루미늄 합금과 비교되었다. 결과로부터 몰드의 변형은 날개 두께에 관한 공차를 만족하는 것을 알 수 있었다. GRPG 복합재료 몰드의 몇 가지 특징은 알루미늄 합금 몰드보다 좋았으며(표면의 매끈함, 중량, 작동 능력과 비용), 다른 몇 가지 특징들은 비슷하였다(분리 능력과 라이프 사이클). 결과적으로 복합재료 몰드는 소형 복합재료 선박 프로펠러를 만들기에 적합한 것을 알 수 있었다.

• Design & Manufacturing
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• 제11권1호
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• pp.34-38
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• 2017

Deformation frequently occurring in injection molded products is a phenomenon displayed due to uneven shrinkage distribution and orientation of the whole molded product. Shrinkage deformation is a very serious problem because it causes deformation of the molded article and shortens the performance of the product. In this paper, we are focusing on the warpage of keypad in mobile phone. In other words, we focused on minimizing keypad deformation. In the study, the Taguchi method was applied to find the injection molding conditions that minimize the deformation of the keypad. In the case of this keypad, the main factors influencing the shrinkage deformation were predicted as the melting temperature, coolant temperature and cooling time. In addition, the optimum molding conditions were obtained and the shrinkage strain was minimized. Experiments for the Taguchi method and verification of optimal molding conditions were performed using an injection molding analysis program.

• Design & Manufacturing
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• 제18권2호
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• pp.64-73
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• 2024

The purpose of this paper is to introduce a fusion method that combines the design of experiments (DOE) and machine learning to optimize the bias of plastic products. The study focuses on the plastic motor housing used in automobiles, which is manufactured through plastic injection molding. Achieving optimal molding for the motor housing involves the optimization of various molding conditions, including injection pressure, injection time, holding pressure, mold temperature, and cooling time. Failure to optimize these conditions can lead to increased product deformation. To minimize the deformation of the motor housing, the widely used Taguchi method, which is one of the design of experiment techniques, was employed to identify the injection molding conditions that affect deformation. Machine learning was then applied to various models based on the identified molding conditions. Among the models, the Random Forest model emerged as the most effective in predicting deformation amounts. The validity of the Random Forest model was also confirmed through verification. The verification results demonstrated the excellent prediction accuracy of the trained Random Forest model. By utilizing the validated model, molding conditions that minimize deformation were determined. Implementation of these optimal molding conditions led to a reduction of approximately 5.3% in deformation compared to the conditions before optimization. It is noteworthy that all injection molding outcomes presented in this paper were obtained through robust injection molding simulations, ensuring both research objectivity and speed.

• 소성∙가공
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• 제20권1호
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• pp.29-35
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• 2011

In the design of the injection molding process, various parameters including mold design parameters and molding conditions should be investigated to improve part quality. The mold temperature is one of important processing parameters that affect the flow characteristics, surface appearance, part deformation, mechanical properties, etc. Numerical analyses have been used to predict the temperature distribution of the mold under the given cooling or heating conditions. However, conventional analyses have been performed by assuming that the mold material is a single solid even though a number of plates are assembled to construct an injection mold. In the present study, a numerical approach considering the thermal contact resistance is proposed to provide more reliable prediction of the mold temperature distribution by reflecting the heat-resistance between assembled mold plates.

• 한국전산유체공학회지
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• 제18권3호
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• pp.20-25
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• 2013

In various manufacturing industries, an in-mold decoration (IMD) process for plastic objects is widely utilized because a film forming and an injection molding processes run simultaneously. In the present study, the deformation of polymer film and filling of resin in the IMD process were numerically investigated to evaluate the quality of the plastic object formed by the IMD process, which consists of thermoforming and injection molding processes. To obtain the initial shape of the polymer film during the injection molding process, the deformation of the polymer film in the thermoforming process was pre-formed using the vacuum conditions to attach the film to a cavity. Since the properties and deformation of polymer film are greatly affected by the behavior of polymer resin being injected into a mold cavity, numerical simulations for the injection molding and film forming were performed with one-way coupling method. The results showed that the injected resin could lead to the tearing of the polymer film in local regions near the corners. In order to verify the proposed numerical methodology, the numerical results of the deformation patterns printed on the initial polymer film were compared with the experimental data. The proposed methodology to couple film forming analysis with injection molding analysis can be used to predict the deformation of film in IMD process.

• Design & Manufacturing
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• 제2권3호
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• pp.16-21
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• 2008

In recent, the demands of household cases and disposable products is increased significantly because a living standard of newly-emerging nations was risen. Therefore, multi-cavity mold and stack mold for the realization of high-productivity have been researched in forefront nations. In this paper, CAE analysis for minimizing the mold core deformation was performed. Finally, 64 cavities injection mold for molding cap which has the insert-type core was fabricated according to the result of CAE analysis.

• 한국생산제조학회지
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• 제20권5호
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• pp.541-546
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• 2011

This study was numerically investigated on thermal deformation of AC4C and AC7A aluminum alloy casting material for manufacturing the automobile tire mold. The metal casting device was used in order to manufacture the mold product of automobile tire at the actual industrial field. The temperature distribution and the cooling time of these materials were numerically calculated by finite element analysis. Thermal deformation with stress distribution was also calculated form the temperature distribution results. The thermal deformation was closely related to the temperature difference between the surface and inside of the casting. As shown by numerical analysis result, the thermal deformation of AC7A casting material became higher than AC4C casting material. In addition, the results of displacement and stress distributions appeared to be larger at the center parts of casting than on its sides because of the shrinkage caused by the cooling speed difference.