• Design & Manufacturing
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• v.16 no.4
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• pp.67-74
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• 2022

Injection molding is a cyclic process comprising of cooling phase as the largest part of this cycle. Providing efficient cooling in lesser cycle times is of significant importance in the molding industry. Recently, lots of researches have been done for rapid cooling of a hot-spot area using CO2 in injection molding. The CO2 flows under high pressure through small, flexible capillary tubes to the point of use, where it expands to create a snow and gas mixture at a temperature of -79℃. The gaseous CO2 removes heat from the mold and releases it into the atmosphere. In this paper, a CO2 cooling module was applied to an injection mold in order to cool a large area cavity uniformly and quickly, and the cooling performance of the injection mold was investigated. The product was a high-curvature molded part with a molding area of 300x100mm. Heat cartridges were installed in a stationary mold, and CO2 cooling module was inserted inside a movable mold. Through structural analysis, it was confirmed that the maximum deformation of mold with CO2 cooling module was 0.09mm. A CO2 feed system with a heat exchanger was used for cooling experiments. The CO2 was injected into the holes on both sides of the supply pipe of the cooling module and discharged through hexagon blocks to cool the mold. It took 5.8 seconds to cool the mold from an average temperature of 140℃ to 70℃. Through the experiment using CO2 cooling module, it was found that a cooling rate of up to 12.98℃/s and an average of 10.18℃/s could be achieved.

• The Korean Journal of Rheology
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• v.11 no.2
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• pp.159-167
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• 1999

Sandwich injection molding is one of the remarkable polymer processes recently developed from conventional injection molding. But it is almost impossible to do theoretical investigation that we've researched it through numerical simulation. In this paper, numerical simulation on the study of sandwich injection molding is based on Finite Element Method and FAN/Control Volume method. In addition to conventional filling parameter that can confirm skin polymer melt front, new filling parameters have been introduced to confirm core polymer melt front advancement. These filling parameters are defined in each layer which is divided to solve temperature field along the thickness direction. One can notice different filling patterns resulted from the variation of material properties such as viscosities and power-law indexes, and processing conditions such as switch-over times and wall temperatures. It gives us a better understanding of the sandwich injection molding process. And we can recognize that it's the core polymer spatial distribution after the completion of filling that is the most important key point to use this process for industrial molding process.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.5
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• pp.575-582
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• 2010

In recent years, several rapid-mold-heating techniques that can be used for the injection molding of thin-walled parts or micro/nano structures have been developed. High-frequency induction heating, which involves heating by electromagnetic induction, is an efficient method for the rapid heating of mold surfaces. The present study proposes an integrated numerical model of the high-frequency induction heating process and the resulting injection molding process. To take into account the effects of thermal boundary conditions in induction heating, we carry out a fully integrated numerical analysis that combines electromagnetic field calculation, heat transfer analysis, and injection molding simulation. The proposed integrated simulation is extended to the injection molding of a thin-wall part, and the simulation results are compared with the experimental findings. The validity of the proposed simulation is discussed according to the ways of the boundary condition imposition.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.6
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• pp.1490-1500
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• 1995

Compression molding of SMC (Sheet Molding Compound) in a thin plaque with substructures like a rib is involved with the formation of surface defect along the centerline over the rib area called by sink mark depending on process parameters. The surface quality of the external panels in automotive manufacturing is so critical that this kind of defect should be eliminated during manufacturing stages. The effect of process parameters on sink mark formation and the distribution of chopped fiberglasses in the compression molded thin plaque with a rib was experimentally investigated in the present study. In order to estimate the effect of the molding parameters such as molding temperature, mold closing speed, depth of the rib, corner radius of the rib, and final molded part thickness of flat portion on the depth of sink mark and the distribution of fiberglasses in the molded SMC part with the rib under the present experimental conditions, the molding parameters used in experiments were non-dimensionalized equation for predicting the depth of sink mark was determined through dimensional analysis based on the experimental data. The orientation and distribution of fiberglasses and fillers which directly affect the formation and depth of sink mark were investigated by taking the photographs of the cross-sectional area of the molded specimen using scanning electron microscope. The experimental results proposed from this investigation are useful in understanding the formation of sink mark and predicting the depth of sink mark in compression molding of SMC with substructures.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.4
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• pp.1361-1366
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• 2010

This research aims to develop polymer composites which can be used for PEMFC separators by injection molding process. Considering the moldability and stiffness, we used PPS(Poly(phenylene sulfide)) and PP(Polypropylene) as base resin. In order to improve electrical conductivity and physical properties, we chose glass fiber, carbon fiber, carbon black, and both expanded graphite and synthetic graphite. The 3 type composites are prepared for injection molding of PEMFC separators. and CAE(Computer Aided Engineering) analysis was conducted to optimize injection processing parameters(injection pressure, heat time, mold temperature etc.). We did successfully fabricate the separators by injection molding, and measure the electrical conductivity of the samples by using four point probe device. Conclusively, PP/SG/CB composite showed better both electrical conductivity and moldability than the others.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.12
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• pp.1635-1640
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• 2011

The objective of this study is to design of a cooling system of the over-molding mold for a socket component of an automobile wiper by performing numerical analyses. Hot spots in which the temperature distributions are higher than those of other region, were estimated by an initial over-molding analysis for the initial design of the mold. On the basis of the initial over-molding analysis, two types of cooling system designs with a linear cooling channel and a volumetric heat sink, were considered to improve the cooling characteristics of hot spots. To obtain an appropriate cooling system design, the effects of the diameter and the position of the linear cooling channels on the cooling characteristics and the product qualities were quantitatively examined. In addition, the effects of the design of the volumetric heat sink on the cooling characteristics and deformation distributions in the molded product were investigated. The results of the over-molding analysis of the two types of cooling systems showed that the multi-sliced over-molding mold with a volumetric heat sink can improve both the product quality and the cooling characteristics of the mold.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.6
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• pp.63-68
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• 2017

The purpose of this study is to improve the whitening phenomenon around the PET preform gate for blow molding. CAE analysis of plastic injection molding has been applied to design of preform shape and select the injection molding conditions. A ceramic insulation gate with lower thermal conductivity than metal is applied to improve the whitening phenomenon created around the gate in the injection molding process. According to the results of CAE analysis, the warpage deformation at the square corner was estimated to be about 0.34 mm at the bottom. From the results of the temperature history analysis, it was confirmed that the resin near the gate cooled more rapidly than the cavity. Ceramic insulated gates were fabricated to reduce the cooling rate and experiments were conducted to confirm the effectiveness of the whitening phenomenon improvement. As a result of the ceramic insulation gate experiment, it was confirmed that the whitening phenomenon was significantly reduced around the gate.

• Elastomers and Composites
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• v.47 no.4
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• pp.347-354
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• 2012

There exist many merits in designing products and setting operational condition when computer aided engineering (CAE) is adopted in injection molding process. CAE also gives increasing efficient of molding, reducing developing time of product, and maintaining high quality products. Specially, it suggests design guidelines for new products and reducing wasting time to get steady state. Two and three dimensional computer simulations are available in injection molding and those results are somewhat different. However there are no guidelines for 2D and 3D computer simulations in using CAE in injection molding even though it is widely used in plastic industry. In this study, two and three dimensional computation results were compared for various part thickness, part shape, and number of finite element. Subsequently computational results were compared with experimental data such as pressure and temperature. The guidelines in two and three dimensional CAE analysis have been suggested through this study.

• Design & Manufacturing
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• v.13 no.3
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• pp.35-40
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• 2019

As the consumer market in the cosmetic, vehicle manufacturing and aerospace industries grows, the demand for manufacturing industries using on injection mold technology. Also, such manufacturing technology of metal machining is expensive, and the shape is limited. Cosmetic cushion fact products are divided into outer relevant to the exterior of the product and inner containers containing the actual contents. In the case of the inner container, it needs to be combined with the upper and lower cases. As environmental regulations are strengthened internationally, the use of a large number of component parts can result in significant losses in recycling and economics. Therefore, this study aims to perform injection molding analysis through injection molding simulation to develop a cushion fact container that can be recycled through the unification of products and materials using polypropylene to cope with environmental regulations. In the case of injection molding conditions, Injection Time(sec): 4.5, Cooling Time(sec): 13, Resin Temperature($^{\circ}C$): 240, and Pressure(MPa): 30 were determined. The results of injection molding simulation according to the two design methods were compared with the sync mark which shows the problem of filling and injection molding.

• Journal of Ceramic Processing Research
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• v.13 no.spc2
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• pp.328-331
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• 2012

With the recent development of super-precision optical instruments, camera modules for devices, such as portable terminals and digital camera lenses, are increasingly being used. Since an optical lens is usually produced by high-temperature compression molding methods using tungsten carbide (WC) alloy molding cores, it is necessary to develop and study technology for super-precision processing of molding cores and coatings for the core surface. In this study, Rhenium-Iridium (Re-Ir) thin films were deposited onto a WC molding core using a sputtering system. The Re-Ir thin films were prepared by a multi-target sputtering technique, using iridium, rhenium, and chromium as the sources. Argon and nitrogen were introduced through an inlet into the chamber to be the plasma and reactive gases. The Re-Ir thin films were prepared with targets having a composition ratio of 30 : 70, and the Re-Ir thin films were formed with a 240 nm thickness. Re-Ir thin films on WC molding core were analyzed by scanning electron microscope (SEM), atomic force microscope (AFM), and Ra (the arithmetical average surface roughness). Also, adhesion strength and coefficient friction of Re-Ir thin films were examined. The Re-Ir coating technique has received intensive attention in the coating processes field because of promising features, such as hardness, high elasticity, abrasion resistance and mechanical stability that result from the process. Re-Ir coating technique has also been applied widely in industrial and biomedical applications. In this study, WC molding core was manufactured, using high-performance precision machining and the effects of the Re-Ir coating on the surface roughness.