• 동력기계공학회지
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• 제18권3호
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• pp.51-58
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• 2014

Injection molding simulation provided optimized design results by analyzing quality problems while the product is in assembly or in the process of manufacturing with make automobile plastics. Frequent change of design, change of injection molding, repetition of test injection which was held in the old way can now be stopped. And quality upgrade is expected instead. This report deals with the effect which the position of injection molding automobile console gate and number has on product quality including pressure at end of fill, bulk temperature at end of fill, shear stress of end of fill, residual stress at post filling end, product weld lines and warpage results. Simpoe-Mold simulates the complete manufacturing process of plastic injected parts, from filling to warpage. Simpoe-Mold users, whether they are product designers, mold makers or part manufacturers, can identify early into the design stage potential manufacturing problems, study alternative solutions and directly assess the impact of such part modification, whatever the complexity and geometry of such parts, shell part as plain solid parts.

• 산업경영시스템학회지
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• 제38권1호
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• pp.44-51
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• 2015

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relations of injection system, casting condition, gate system, and cooling system. According to the various relations of the conditions, the location of product defects was differentiated. High-qualified products can be manufactured as those defects are controlled by the proper modifications of die casting mold with keeping the same conditions. In this research, Computer Aided Engineering (CAE) simulation was performed with the several layout designs in order to optimize the casting layout design of an automotive part (Housing). In order to apply them into the production die-casting mold, the simulation results were analyzed and compared carefully. With the filling process, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflow. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system. The simulation results were also applied into the production die-casting mold in order to compare the results and verify them with the real casting samples.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2002년도 금형가공 심포지엄
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• pp.180-186
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• 2002

The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce Al, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared as the die-castings and the thin walls of the plaster mold cavity may not be completely fillet Because of lower mechanical properties induced by the large grain structure and incomplete Idling, the conventional plaster casting process is not suitable for the trial die-casting Process. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have runner system, are made using these patterns. Imparted pressurized vibration to molten metal has made grain structure of castings much finer and improved fluidity of the molten metal enough to obtain complete filling at thin walls which can not be filled in the conventional plaster casting process.

• 한국기계가공학회지
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• 제13권4호
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• pp.21-27
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• 2014

The injection molding process has several advantages enabling it to produce large quantities of molded plastic products using a repetitive process. In recent years, it has been necessary to develop an injection molding process with micro/nano-sized patterns for application to the semiconductor industry and to the bio/nano manufacturing industry. In this study, we apply gas pressure to the inside of a mold and consider the gas dissolution phenomenon for a resin filling into a micro pattern with a line structure. Using numerical analysis, we calculate the filling ratio with respect to time for various internal gas pressures and various aspect ratios of the micro-patterns.

• 한국분말재료학회지
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• 제14권3호
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• pp.202-207
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• 2007

Novel polymer mold process for fabrication of microcomponents using metal nanopowders was developed and experimentally optimized. Polymer mold for forming green components was produced by using a hard master mold and polydimethylsiloxane (PDMS). In the preparation of metallic powder premix for the green components without any defect, 90 wt.% 17-4PH statinless steel nanopowders and 10 wt.% organic binder were mixed by a ball milling process. The green components with very clear gear shape were formed by filling the powder premix into the PDMS soft mold in surrounding at about $100^{\circ}C$. Cold isostatic pressing (CIP) was very potent process to decrease a porosity in the sintered microcomponent. The microgear fabricated by the improved process showed a good dimension tolerance of about 1.2%.

• 한국지능시스템학회논문지
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• 제11권6호
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• pp.465-469
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• 2001

In injection molding short shot is one of the frequent and fatal defects. Experts of Injection molding usually adjust process conditions such as injection time, mold temperature, and melt temperature because it is most economic way in time and cost. However, it is difficult task to find appropriate process conditions for troubleshooting of short shot as injection molding process is a highly nonlinear system and process conditions are coupled. In this paper, a modular fuzzy neural network (MFNN) has been applied to injection molding process to shorten troubleshooting time of short shot. Based on melt temperature and fill time, a reasonable initial mo이 temperature is recommenced by the NFNN, and then the mold temperature is inputted to injection molding process. Depending on injection molding result, specifically the insufficient quantity of an injection molded part. and appropriate mold temperature is recommend repeatedly through the NFNN.

• 산업경영시스템학회지
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• 제42권1호
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• pp.1-7
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• 2019

In the modern industrial period, the introduction of mass production was most important progress in civilization. Die-casting process is one of main methods for mass production in the modern industry. The aluminum die-casting in the mold filling process is very complicated where flow momentum is the high velocity of the liquid metal. Actually, it is almost impossible in complex parts exactly to figure the mold filling performance out with the experimental knowledge. The aluminum die-castings are important processes in the automotive industry to produce the lightweight automobile bodies. Due to this condition, the simulation is going to be more critical role in the design procedure. Simulation can give the best solution of a casting system and also enhance the casting quality. The cost and time savings of the casting layout design are the most advantage of Computer Aided Engineering (CAE). Generally, the relations of casting conditions such as injection system, gate system, and cooling system should be considered when designing the casting layout. Due to the various relative matters of the above conditions, product defects such as defect extent and location are significantly difference. In this research by using the simulation software (AnyCasting), CAE simulation was conducted with three layout designs to find out the best alternative for the casting layout design of an automotive Oil Pan_BJ3E. In order to apply the simulation results into the production die-casting mold, they were analyzed and compared carefully. Internal porosities which are caused by air entrapments during the filling process were predicted and also the results of three models were compared with the modifications of the gate system and overflows. Internal porosities which are occurred during the solidification process are predicted with the solidification analysis. And also the results of the modified gate system are compared.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 금형가공,미세가공,플라스틱가공 공동 심포지엄
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• pp.9-12
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• 2005

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filing difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation fur both the conventional molding and the RTR molding processes

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 추계학술대회 논문집
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• pp.266-270
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• 2007

Small injection molded articles such as lens and mobile product's parts are usually molded in multi-cavity mold. The problems occurred in multi-cavity molding are flow imbalance among the cavities. The flow imbalance affects on the dimensions and physical properties of molded articles. First of all, the origin of flow imbalance is geometrical imbalance of delivery system. However, even the geometry of delivery system is balanced well the cavity imbalance is being developed. This comes from the unsuitable operational conditions of injection molding. Among the operational conditions, injection speed is the most significant process variable affecting the filling imbalances in multi-cavity injection molding. In this study, experimental study of flow imbalance has been conducted for various injection speeds and materials. Also, the filling Imbalances were compared with CAE results. The dimensions and physical state of multi-cavity molded parts were examined. The results showed that the filling imbalances vary according to the injection speed and flow property of resins. Subsequently, the imbalanced filling and pressure distribution in the multi-cavity affect on the dimensions and physical states of molded parts.

• Design & Manufacturing
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• 제8권1호
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• pp.31-34
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• 2014

The Injection molding is used more than 70% of total production in plastic products. The injection molding process has 4 processes such as filling, packing, cooling and ejecting. It spends most of times in the cooling process. Therefore, it is important to control the mold temperature in producing plastic products. The cooling system and time affect the product's quality and productivity. Especially, cooling time has about 60% of total injection cycle time. Therefore, we can improve a productivity by shortening cooling time. In this study, the rapid cooling system was developed and performed a efficiency test. This system could refrigerate coolant to $1^{\circ}C$ and had to need 10 minutes for normal operating. However, if response time of temperature controller and sensor will be increased, the performance of this system will increase.