• Proceedings of the KSME Conference
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• 2001.06c
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• pp.621-626
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• 2001

Microcellular foaming process was developed at MIT in 1980's to save a quantity of raw materials and improve mechanical properties. There are many process variables in appling microcellular foaming process to the conventional injection molding process. Of all process variables, part dimension control and shrinkage are the most influential on the post molded dimension. The post molding dimensional change of thermoplastic resins is important to tool designers for predicting the specific difference of molded part vs. actual mold cavity. Generally, articles injection molded are smaller in size than the cavity; hence, the term shrinkage factor is used to define the allowance a designer specifies. It is important to consider the factors that influence molded part dimension. According to ASTM Designation: D 955, shrinkage from mold dimensions of molded plastics was measured. In injection molding, the difference between the dimensions of the mold and of the molded article produced therein from a given material may vary according to the design and operation of the mold. In this paper, shrinkage data of molded plastic parts was obtained. It can be an important information for designing optimum mold system in a microcellular foaming injection molding process.

• Design & Manufacturing
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• v.2 no.3
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• pp.40-44
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• 2008

Shaving in sheet metal forming is defined as a finish process to make the sheared surface clean which was blanked or pierced in the previous shearing stage. In this study the new shaving technique is applied to the progressive operation. The specimen is automatically fed by continuous movement of the strip. Which improve the positioning accuracy higher. For this study a square part which consist of blanking and piercing is selected for investigation and the progressive die which includes pre-piercing, pierce-shaving, half-blanking and blank-shaving etc is prepared for specimens of steel sheet(SPCC) and aluminum alloy sheet(AL5052). Experiments are carried out for several working variables such as shaving allowance, pre-shearing clearance and relative half-blanking depth. Consequently it was confirmed that the shaving by progressive die can be successfully employed to produce the clean parts requiring shaving process and optimum working conditions for shaving SPCC and AL5052 sheet metal are shaving allowance of 0.2mm(1.3% of thickness) and pre-shearing clearance of 5%.

• Design & Manufacturing
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• v.16 no.1
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• pp.21-26
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• 2022

In the CNC machining process, problems such as lowering of machine operation rate, setting errors, and machining precision occur due to the increase in setting time and preparation time. These machining errors cause delays in delivery and increase in cost due to an increase in the number of mounting and dismounting of the workpiece, an increase in measurement and reprocessing time, and an increase in the finishing time in the assembly process. Therefore, in this study, by automating the setting of the work piece using OMV (On Machine Verification), which is a meteorological measurement system, the preparation time for machining the work piece and the setting accuracy were improved, the rework rate was reduced, and the mold manufacturing process was shortened. Through the advancement, standardzation, and automation of the mold part manufacturing process, we have improved productivity by minimizing low-value-added repetitive tasks. In addition, the measurement time was reduced by more than 50% and the machining measurement rate was improved by more than 20%, eliminating repetitive work for correcting machining defects, and reducing the work preparation time by more than 15% through automatic setting.

• Design & Manufacturing
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• v.2 no.5
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• pp.30-33
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• 2008

Injection Molding is the most effective process for mass production of plastic parts. The injection molding process is composed with several steps such as Filling, Packing, Holding, Cooling, Ejecting. Among them, filling and packing process should be considered carefully to improve accuracy of dimension, surface quality of plastic parts. Usually the quality above-mentioned is managed with weight of part after molding on the field. In this paper, a series of experiment for molding automotive front bumper was conducted with cavitity temperature sensor to optimize switch-over time(V-P switching), hot runner vale gate sequence time during filling and packing step for the purpose of uniform quality, weight at every molding. As a result, it was found that it is effective method to use temperature sensor in injection molding for quality control of plastic molding.

• Journal of Korean Society for Quality Management
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• v.29 no.3
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• pp.86-96
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• 2001

The objective of this research is to develop a robust design methodology for plastic injection molded parts wherein warpage will be minimized by a complex method which is a kind of a simple direct search method. The design space considered for optimization is divided Into two sub-design space : mold and process conditions. Warpage is quantified using the Moldflow injection molding simulation software. The design methodology was applied to an actual part of a fax machine, the Guide-ASF model, through two different design policies. The significance of this study is the synthesis of a computer simulation of injection molding process and optimization technique to determine the optimal robust design solution.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.616-619
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• 2002

Spin casting is one of useful methods to manufacture metal parts with low mold cost and short delivery time. But the silicon rubber based conventional method has several problems such as poor dimensional accuracy, limitation in casting materials and its dependency on speciality in meld making process. To solve those problems, this paper suggests a steel based mold making method using direct CNC machining and the experimental results shows that the parts from the developed method has better dimensional accuracy and surface roughness than those from the conventional method.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.60-63
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• 2011

BLU(back light unit) is one of kernel parts of LCD(liquid crystal display) unit. New 3-D micro-lens pattern for LGP(light guide plate), one of the most important parts of LCD-BLU, had been researched. Instead of dot pattern made by chemical etching or laser ablation, SCS(slanted curved surface) micro-lens pattern was designed with optical CAE simulation. This study introduce the method of design using optical CAE simulation for SCS micro-lens, the new fabrication method of micro-mold with SCS micro-lens pattern.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.2 no.2
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• pp.33-37
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• 2001

The synthesis of gates of injection-molded parts has been done empirically, since it requires profound knowledge about the gate design,. which is not available to designers through current CAD systems. GATEWAY is a knowledge module which contains knowledge to Permit non-experts as well as mold design experts to generate acceptable gate design of injection-molded parts. A knowledge-based CAD system is constructed by adding the knowledge module, GATEWAY, for gate synthesis and appropriate CAE programs for mold design analysis to an existing geometric modeler to provide designers, at the initial stage, with comprehensive process knowledge for gate synthesis. Performance analysis and feature-based geometric modeling.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.614-619
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• 2007

The importance of simulation of plastic flow in the injection mold is increasing as the parts are more complex, but the small-scale enterprises can't afford to invest for the infra individually. CAE (Computer Aided Engineering) service was naturally born based on these needs. This paper presents the engineering collaboration model between the large and the small/medium enterprises in the field of injection molds. Based on the engineering collaboration hub and CAE service, small-scale enterprises could research the necessary technology and develop the proper products. The analysis results of CAE are provided by the integrated visualization system on the web. This paper also deals with the delivery shorting process of CAE service for electric/electronic parts which should meet the needs of customers as soon as possible.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.933-937
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• 1995

The design of injection molded prlymeric parts has been done empirically, since it requires profound knowledge about the moldability and causal effects on the properties of the parts. This study shows CAE approach for the design of the seat frame of fiber-reinforced composite material in order to realize the concept os rationsl design for the productivity and quality of mold making. The knowledge-based CAE system is constructed by adding the knowledge-basw module for the design evaluation and appropriate CAE programs for mold design analysis in order to provied designers, at the initial design stage, with comprehensive process knowledge for the performance analysis and the design evaluation. A knowledge-based CAE system is a new tool which enables the concurrent design with integrated and balanced design decisions at the initial design stage of injection molding.