• Title/Summary/Keyword: Mold Parts

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Development of Film Fixing System for Improving Overlap Defects in the Film Insert Injection Molding Process (필름 인서트 사출성형 공정의 오버랩 불량 개선을 위한 필름 고정 시스템 개발)

  • Kim, Jung-Ho;Mun, Ji-Hun;Park, Hong-Seok
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.22 no.3
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    • pp.472-479
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    • 2013
  • We carried out research into an environmentally friendly injection molding process that involves filling the mold with polymer after thin films are fixed into the cavity, without the coating, plating process. Film insert injection molding is a new technique in which molten plastic resin is injected into the cavity after films are precisely attached to the side of the mold wall. In the film insert injection molding process, the insert film is moved by the flow of the molten plastic resin. Overlap defects cause a decline in the productivity and the quality of the manufactured goods. To reduce overlap defects, new injection mold parts are proposed to produce automotive exterior parts using thin films. It is suggested that the best possible method would be to fix the thin films to one side of the mold wall, and develop interior pins to fix the films in the mold. Based on this new pin fixing system, the problem of the film being moved by the flow of the molten resin was improved.

Stamping process design to develop a urea tank cover for excavators based on sheet metal forming analysis (굴삭기 요소수 탱크 커버의 신규 모델 개발을 위한 CAE 기반 프레스 성형 공정 설계)

  • Jeon, Yong-Jun;Heo, Young-Moo;Yun, Seok-Hyun;Kim, Dong-Earn
    • Design & Manufacturing
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    • v.14 no.2
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    • pp.49-55
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    • 2020
  • Recently, when a new component of construction equipment is designed, a stamping process capable of producing parts having high appearance quality and precision has been gaining attention. However, in general, as it is developed based on existing parts made by welding metal sheets and tubes, frequent to die modification occurs, which increases the time and cost of developing new parts. Thus, it is necessary to reduce the cost by shortening the die development period. In this study, a stamping process was designed for the urea tank cover, which is a part for excavators, to reduce the die development period through sheet metal forming analysis. The stamping process was designed by determining the blank holding force after selecting the initial blank shape and size. The round value at the corner was modified such that formability is ensured. After selecting process parameters, the thickness reduction rate and spring-back effect were reviewed.

Manufacturing and Molding Technology of $500{\mu}m$ 8Cavity Injection Molding System (500um급 8캐비티 사출금형설계 제작 및 성형기술)

  • Lee, S.H.;Cho, K.H.;Lee, J.W.;Ko, Y.B.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2008.10a
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    • pp.444-447
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    • 2008
  • Recently, the need of thin-walled injection molding and enhancement of its productivity is greatly increased. In this study, we designed and manufactured a injection molding system, which can mold a part with the thickness of $500{\mu}m$ and 8 cavity. And processing technique for the multi-cavity injection molding system, which is capable of mass productivity on the plastic parts, was considered. The problems of unbalance/imbalance on the molding process for the multi-cavity mold were predicted by numerical analysis using plastic injection molding commercial code. In addition, controllable system of melt front filling was introduced for a balanced filling using the mold temperature sensor on injection mold. It was shown that balanced filling with the suggested injection molding system was possible for $500{\mu}m$ plastic parts with 8 cavity layout.

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A Study on Injection Molding process for Manufacturing about Blower-fan (블로우팬의 사출성형공정에 관한 연구)

  • 김병곤;민병현
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2002.10a
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    • pp.316-319
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    • 2002
  • Injection mold is a manufacturing process used to produce parts of complicated shape at a low cost. Many factors affect the quality of injection molded part during injection molding process. A study on the optimization of injection mold is progressed by using a simulation software like Moldflow. Filling, packing and cooling phases of injection molding processes are analyzed according to the mold design considering the shrinkage of molded part, the degree of filling rate and the wearing of a mold. Taguchi method is applied to analyze the significance of processing parameters and the dynamic characteristics according to the variation of processing parameters. From the results, the mold temperature and packing pressure influenced strongly the shrinkage of injection molded part.

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A study on gas vent control of injection mold for the production of precision medical device parts (정밀 의료기기 부품 생산을 위한 사출금형의 가스벤트 제어에 관한 연구)

  • Lee, Jeong-Won;Son, Min-Kyu
    • Design & Manufacturing
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    • v.14 no.2
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    • pp.34-41
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    • 2020
  • Typical characteristics of medical device parts are that they can not be reused and there are many disposable products. Therefore, there is a need for an injection molding machine having excellent repeatability of molding conditions and a precision injection mold for mass production. Recently, the performance of an injection machine has made a remarkable evolution compared to the past. However, defects such as short-shot, flash, weld line, gas burning, warpage, and deformation, which are typical defects, still do not disappear at all. This is due to the lack of gas ventilation from the product cavities, even if the gas is smoothly vented from the sprue and runner of the mold. For this reason, the internal pressure of the cavity rises and is directly connected to the quality defects. In this study, an active gas vent system was designed to prevent defects due to trapped gas in the cavity. Since it can be easily adjustable in response to the molding conditions and the mold temperature changes, it is expected to improve productivity due to the reduction of the defective ratio.

Application of Commercial FEM Code to Coupled Analysis of Casting Deformation (범용 구조해석 프로그램의 주물 열변형 해석에의 적용성)

  • Kim, Ki-Young;Kim, Jung-Tae;Choi, Jung-Gil
    • Journal of Korea Foundry Society
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    • v.22 no.4
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    • pp.192-199
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    • 2002
  • Dimensional defects of castings are mainly due to the stresses and strains caused by a nonuniform temperature distribution and phase transformation during solidification and cooling, and by mechanical constraint between the mold and casting. It is, however, nearly impossible to trace movements of the casting and mold during solidification and cooling by experimental measurements for castings with complex shape. Two and three dimensional deformation analyses of the casting and the mold were performed using commercial finite element code, MARC. It was possible to calculate deformation and temperature distribution in the casting and mold simultaneously. Cooling curves of the casting obtained by calculation were close to that measured in the field since it was possible to treat latent heat evolution of the casting which could be divided into two parts, primary and eutectic parts. Mold bent inward just after pouring due to the temperature gradient across the mold thickness, and mold returned to its previous position with time. Plastic deformation occurred at the part of the casting where solidification was slow.

A Study on the 3D Injection Mold Design Using CATIA API (CATIA API를 이용한 사출 금형의 3차원 설계에 관한 연구)

  • 박주삼;김재현;박정환
    • Journal of the Korean Society for Precision Engineering
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    • v.20 no.12
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    • pp.115-125
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    • 2003
  • The design methodology of plastic injection molding die has been gradually moved from two-dimensional line drawings to three-dimensional solid models. The 3D design gives many benefits, a few of which are: ease of design change, data associativity from concept design to final assembly. In the paper represented is the implementation of a program which automatically generates 3D mold-bases and cooling-lines, conforming to given geometric constraints. It utilized a commercial CAD software and the related API(application program interface) libraries. We constructed a DB(database) of typical mold-bases assembled from standard parts, from which the geometry (position & dimension) of a mold-base and composed parts can be automatical]y determined by a few key parameters. Also we classified cooling lines into several typical types and constructed a DB, from which the position of cooling lines is automatically determined. The research is expected not only to simplify construction of a 3D mold-base model including cooling lines but also to reduce design efforts, by way of databases and automatized determination of geometric dimensions.

Fabrication and transcription estimation of prismless LGP for cellular phone using E-Mold technology (전열가열방식을 이용한 휴대전화용 복합기능 도광판 제작 및 전사성 평가)

  • Kim, Young-Kyun;Chung, Jae-Youp;Kim, Dong-Hak
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.10 no.1
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    • pp.186-193
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    • 2009
  • In this paper, we adopted E-MOLD patent technology in order to fabricate Prismless LGP(Light Guide Panel) fur cellular phone and estimate the transcription of injection-molded parts. Then, we manufactured the Ni stamper fur Prismless LGP using MEMS process. And the stamper was installed in the movable heated core which is the key part of a patented mold. Using this mold, we manufactured injection-molded plastic LGP parts with different mold temperatures so that we investigate effect of the temperature on the transcription of the parts. The CAE analysis was also conducted in order to compare with the experimental results. The transcription of LGP parts with various mold temperature displayed $100^{\circ}C$(25.0nm), $140^{\circ}C$(48.4nm), $180^{\circ}C$(52.1nm) and when compared with stamper(521Inm), transcription was superior at $180^{\circ}C$. According to the CAE results, moldability was improved as mold temperature ($50^{\circ}C{\sim}180^{\circ}C$) increased, but when filling time($1{\sim}2sec$) increases, it decreased at $160^{\circ}C$. And transcription and moldability were improved markedly at glass transition temperature($140^{\circ}C$).

Study of transcription ability of optic polymer and Micro-grooving machining of ultra-precision injection molding moulds (초정밀 사출성형 금형의 마이크로 홈가공과 전사성)

  • Kwak T.S.;Ohmori H.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2005.06a
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    • pp.623-624
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    • 2005
  • Micro injection molding is a branch of micro system technology and has been under development for the mass manufacture of micro parts. Enhanced technological products like micro optical devices are entering the market. This paper presents fundamental research on the injection molding technique in micro fabrication. In order to successful manufacturing of micro plastic parts, it is necessary to research for development of micro-injection machine, machining of micro mold, decision of optimum injection conditions and the research for polymer material. Therefore in this study, in order to machining of micro mold, a mold core with microscopic V-shaped groove was tooled by ultra-precise tooling machine. The transcription experiments with a polymer, PMMA resin on the surface of core with Ni plating were carried out and surface profile of injected parts was measured with AFM.

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Effects of Mold Precision in Micromini Cellphone Optical Systems (초소형 휴대폰 광학계의 금형 정밀도가 광학성능에 미치는 영향)

  • Ye, In-Soo;Cheong, Seon-Hwan;Choi, Seong-Dae;Hyun, Dong-Hoon
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.19 no.5
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    • pp.660-666
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    • 2010
  • In cellphone optical systems, a tiny difference of manufacturing has a strong influence on camera lenses. This study aims to find out the worst result by tolerances come from all parts in optical performance. First, 3D Measure Instrument, Roundness Measure Instrument, and Wavelength Measure Instrument were used for greater precision by making and measuring the parts to see how different from the drawings. It was confirmed that even narrow tolerances could result in defects by assembling. Tolerances in assembly should be concerned as those in parts through the research.