• Title/Summary/Keyword: Molding Injection

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A Study on Injection Molding Analysis and Validation of Large Injection-Molded Body Using Design of Experiment (실험계획법을 이용한 대형 사출물의 사출성형 해석과 검증에 관한 연구)

  • Lee Hyoung-soo;Lee Hi-Koan;Yang Gyun-eui
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2005.05a
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    • pp.109-114
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    • 2005
  • The large injection molded parts technology such as instrument panel, front and rear bumper are presented for a precision molding. Some lead time and cost are required to product these part from design to mass product. Recently, CAE is widely used in product design, mold design and analysis of molding conditions to reduce time and cost. The optimal molding conditions can be obtained by DOE(Design of Experiment). The optimal design applications with CAE and DOE have been used in small molded parts. However, application to the large molded body is not reported. In this paper, optimization of injection molding process is studied for quality control in mass production of automobile bumper. Mold temperature difference is chosen through robust design of injection molding process, the molding process being optimized in term of shrinkage and deflection. The optimal conditions through DOE are validated by using injection molding analysis.

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A Study on Fuzzy Temperature Control for the Barrels of Injection Molding Machine using PC based PLC (PC 기반 PLC를 이용한 사출성형기 배럴의 퍼지 온도 제어에 관한 연구)

  • 김훈모
    • Journal of Institute of Control, Robotics and Systems
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    • v.9 no.10
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    • pp.768-773
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    • 2003
  • Injection molding has been widely used for the mass production of a plastic product. With the development of the relative technique, various injection molding techniques have been developed and we could get more precise plastic product. The temperature of a melting resin is an important factor in the injection molding and this temperature has direct influence on the quality of a plastic product. In the present injection molding machine, the deriation of a temperature controlled by PID control method is within 2$^{\circ}C$ in the injection molding machine but PID control method takes too much time to stabilize after preheating and its overshoot is so big. We applied fuzzy control to alleriate the problem. In this research, we experimented the fuzzy temperature control with the usage of PC based PLC.

Simulation and Experiment of Injection Molding Process for Superalloy Feedstock

  • Jung, Im Doo;Kim, Youngmoo;Park, Seong Jin
    • Journal of Powder Materials
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    • v.22 no.1
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    • pp.1-5
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    • 2015
  • Powder injection molding is an important manufacturing technology to mass produce superalloy components with complex shape. Injection molding step is particularly important for realizing a desired shape, which requires much time and efforts finding the optimum process condition. Therefore computer aided engineering can be very useful to find proper injection molding conditions. In this study, we have conducted a finite element method based simulation for the spiral mold test of superalloy feedstock and compared the results with experimental ones. Sensitivity analysis with both of simulation and experiment reveals that the melt temperature of superalloy feedstock is the most important factor for the full filling of mold cavity. The FEM based simulation matches well the experimental results. This study contributes to the optimization of superalloy powder injection molding process.

A Study on the Effects of Filling and Packing Phases on the Injection Modeling (사출성형에 대한 충전과 보압과정의 영향에 관한 연구)

  • 김현필;김용조
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2002.04a
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    • pp.112-118
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    • 2002
  • Injection molding process factors such as molding temperature, injection pressure, flow rate and flow velocity, must be controlled properly in filling and packing phases in the injection molding process. In this study, effects of these factors on the injection molding were investigated through the flow analysis fur the filling and packing phases. Molding troubles like flow mark, weld line, sink mark, short shot and warpage can be caused by these injection molding process factors. Among them, the short shot was caused by that the packing pressure could not reach properly to the filling end part in the packing phase and hence the flow rate could not be supplied to the full. In addition, as the flow rate for the volumetric shrinkage during the frozen phase could not be supplied properly by the packing pressure, the short shot appeared. Here, the volumetric shrinkage reduced with increasing the packing pressure and also the warpage of molded part increased with increasing the packing pressure.

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Linear Structural Analysis and Simple Tensile Test of Plastic Injection Molding Tensile Specimen (플라스틱 사출인장시편의 단순인장시험 및 선형구조해석)

  • Lee, D.M.;Han, B.K.;Lee, Sung-Hee
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2006.05a
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    • pp.230-233
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    • 2006
  • In this study, the effects of residual stress induced by plastic injection molding process on the tensile behavior of plastic tensile test specimen were investigated. To manufacture plastic tensile test specimens, an injection mold based on the international standard system was designed and made. Cavity pressure and temperature sensors were installed inside of the presented mold to monitor pressure and temperature values during the cycle of injection molding. Injection molding simulation was performed with the same condition of experiment and linear structural tensile analysis was also performed with the initial condition of the residual stress. It was shown that the residual stress induced by injection molding has an effect on the experiment of tensile test and linear structural tensile simulation.

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The Automatic Packaging System for 6mm Ball Injection Molding Product (6mm Ball 사출 성형품 자동 패키징 시스템)

  • Heo Y.M.;Shin G.H.;Yoon G.S.;Jang S.H.;Jung W.C.;Kim G.H.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2006.05a
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    • pp.573-574
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    • 2006
  • In this study, the automatic packaging system for small injection molding product is developed. In most of injection molding company, many problems such as manpower problem, productivity decline and inferiority rate increase are occurred since processes after injection molding are executed by hands. The automatic system which is developed is for packaging small injection molding products as 6mm ball. Finally, many problems of injection molding process are resolved and the productivity will increase by applying developed system to field and this technique lays the groundwork for developing similar automatic system.

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Design Optimization for Minimizing Warpage in Injection Molding Parts with Numerical Noise (수치적 노이즈가 존재하는 사출 성형품 휨의 최적설계)

  • Park, Changhyun;Kim, Sungryong;Choi, Donghun;Pyo, Byunggi
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.29 no.11 s.242
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    • pp.1445-1454
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    • 2005
  • In order to minimize warping deformation which is an essential factor in the failure of injection molding parts, this study proposes an optimization design method fer determining design variables of injection molding parts. First, using a commercial package program for injection molding analysis, namely, Computer Aided Plastics Application(CAPA), we investigate the effects of parameters of injection molding process. Next, an optimum design process is established by interfacing CAPA to PQRSM embedded in EMD10S, a design framework developed by the conte. of innovative Design Optimization Technology(iDOT). PQRSM is a very efficient sequential approximate optimization algorithm. Optimum design results demonstrate the effectiveness of the design method suggested in this study by showing that the results of the optimum design is better than those of the initial design. It is believed that the proposed methodology can be applied to other injection molding design applications.

A Study on the Manufacturing Technology of the Aspheric Lens using Injection Molding (사출금형을 이용한 비구면 렌즈의 제조기술에 관한 연구)

  • Choi H. Z.;Lee S. W.;Kang E. G.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2002.02a
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    • pp.76-83
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    • 2002
  • The injection molding of the plastic optics is basically same as the conventional molding except it requires very intricate control of all the molding processing parameters. In the plastic optics, the problem of injection molding is the shrinkage. The shrinkage must be removed and predicted. This shrinkage is becoming more important than any other problems in precision molding because it can affect the focal length of a lens or the total performance of the optical system. This study focused on avoiding the shrinkage that the mold design allows for the optics. In making mold, the surface accuracy(P-V) of the lower and lower mold are $0.201{\mu}m\;and\;0.434{\mu}m$ respectively. A surface roughness(Ra) is below $0.02{\mu}m$ due to selecting the appropriate tools and using the injection molding machine in high degree. In injection molding of the plastic lens, mold temperature, resine temperature and injecting pressure are important process parameters. Injection molding process is carried out according to varying mold temperature and injecting pressure. As a result P-V(peak to valley) of spheric lens is $3.478{\mu}m$ and that of aspheric lens is $1.786{\mu}m$.

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Machine Learning Model for Reduction Deformation of Plastic Motor Housing for Automobiles

  • Seong-Yeol Han
    • Design & Manufacturing
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    • v.18 no.2
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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.

A Study on Injection Characteristic using Active Temperature Control of Injection mold (사출 금형의 능동형 온도제어에 따른 사출특성에 관한 연구)

  • Cho, C.Y.;Sin, H.G.;Hong, N.P.;Seo, Y.H.;Kim, B.H.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2007.10a
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    • pp.302-305
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    • 2007
  • In recent years, many researches on new storage media with high capacity and information are developing. For manufacture of optical storage with high capacity, the injection molding process is generally used. In order to increase the filling ratio of the injection molding structure, the injection molding process required for high injection pressure, packing pressure and temperature control of the mold. However, conventional injection molding process is difficult to increase the filling ratio using injection master with the range of several nanometers and high aspect ratio. In order to improve and increase filling ratio of nano-structure with high aspect ratio, the active temperature control of injection mold was used. Experimental conditions were used injection pressure, time and temperature. Consequently, by using the peltier device into injection mold, we carried out the efficient and active temperature control of mold at low cost.

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