• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.36-43
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• 2021

In this study, the optimal feed system and process conditions that can simultaneously minimize each warpage occurring in the two shape features of the 2P Header HSG, a connector part for automobiles, were determined through injection molding simulation analysis. First, we defined each warping deformation of the two features geometrically and quantified them approximately using the injection molding simulation data. For design optimization, a full factorial experiment was conducted considering the feed system, resin temperature, and packing pressure as design variables, and a follow-up experiment was conducted based on the analysis of the average warpage. In this study, an optimal design was generated considering both the warpage result and resin-saving effect. In the optimal design, the warpages of the two shape features were predicted to be 0.18 and 0.29 mm, and these warpages were found to meet the allowable limit of warpage, which is 0.3 mm, for part assembly.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.8
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• pp.1097-1103
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• 2010

Injection pressure, an important factor in the filling procedure, should be minimized to enhance injection molding quality. In addition, warping deformation and weld lines, which are representative failures, should be avoided to enhance injection molding quality. To improve injection molding quality, the design procedure for an automotive fog blank cover is divided into two stages. In the first stage, we optimally obtain injection molding process variables that minimize injection pressure and warping deformation by using design of experiments, approximation and optimization techniques equipped in PIAnO (Process Integration, Automation and Optimization), a commercial PIDO (Process Integration and Design Optimization) tool. Then, we determine the thickness of the automotive fog blank cover that enables us to avoid generating weld lines. The design results we obtain in this study are found far better than those of the initial design, which demonstrates the effectiveness of our design method.

• The korean journal of orthodontics
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• v.28 no.6 s.71
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• pp.905-914
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• 1998

The goals of this study were to present presurgical naso-alveolar molding (PNAM) appliance in unilateral cleft lip and palate treatment and to evaluate the effects of PNAM appliance on alveolar molding. Samples were consisted of 4 unilateral cleft lip and palate infants (3 males and 1 female, mean age=23.2 days after birth) who were treated with PNAM appliances in Department of Orthodontics, Seoul National University Dental Hospital. Average alveolar cleft gap between the greater and lesser segment was 8.27mm and average duration of alveolar molding treatment was 9.7 weeks. These patients' models were obtained at initial visit (T1) and alter successful alveolar molding (T2). Seven linear and five angular variables were measured by using photometry and digital caliper. All statistical analyses were performed by SPSS win ver. 7.5 program. Paired t-test was used to compare the mean values. 1. The posterior part of alveolar segments are the stable structures during alveolar molding treatment period in infants. 2. Forward growth of the greater segment may be hindered by the action of alveolar molding. 3. The closure of cleft gap during alveolar molding were usually due to inward and backward bending of the anterior part of the greater segment and outward bending of the whole lesser segment.

• Journal of the Korean Society of Industry Convergence
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• v.23 no.5
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• pp.773-787
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• 2020

In the injection molding process, the controlling stability of products quality is a very important factor in terms of productivity. Even when the optimum process conditions for the desired product quality are applied, uncontrollable external factors such as ambient temperature and humidity cause inevitable changes in the state of the melt resin, mold temperature. etc. Therefore, it is very difficult to maintain prodcut quality. In this study, a system that learns the correlation between process variables and product weight through artificial neural networks and predicts process conditions for the target weight was established. Then, when a disturbance occurs in the injection molding process and fluctuations in the weight of the product occur, the stability control of the product quality was performed by ANN predicting a new process condition for the change of weight. In order to artificially generate disturbance in the injection molding process, controllable factors were selected and changed among factors not learned in the ANN model. Initially, injection molding was performed with a polypropylene having a melt flow index of 10 g/10min, and then the resin was replaced with a polypropylene having a melt floiw index of 33 g/10min to apply disturbance. As a result, when the disturbance occurred, the deviation of the weight was -0.57 g, resulting in an error of -1.37%. Using the control method proposed in the study, through a total of 11 control processes, 41.57 g with an error of 0.00% in the range of 0.5% deviation of the target weight was measured, and the weight was stably maintained with 0.15±0.07% error afterwards.

• The Korean Journal of Rheology
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• v.11 no.2
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• pp.153-158
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• 1999

An improved method to predict preferred direction of gas in gas assisted injection molding processes is introduced. Resistance of resin flow is defined and this resistance of resin flow is not directly related to the resistance of gas flow. Pressure drop requirement was believed to be proportional to the resistance to gas flow in our previous work. Instead of using the pressure drop requirement, velocity of resin should be compared to predict the gas flow direction. This method predicts the gas flow direction from the knowledge of process variables such as resin flow length, cross section area of cavity, melt temperature, and short shot. A simulation package was used to confirm the method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.10 s.181
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• pp.2543-2551
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• 2000

Precision injection molding is an important technology for improving productivity and lowering costs in the fields of medical components, lenses and electrical connectors. The quality of injection molded parts is affected by various processing conditions such as filling time and packing pressure profile. It is difficult to consider all the variables at the same time for prediction of the quality. In this study, the genetic algorithm was used to obtain the optimal processing conditions for minimizing the volumetric shrinkage of molded parts. For a higher convergence rate, the method of design of experiments was used to analyze the relationship between processing conditions and volumetric shrinkage of molded parts, which served as analysis tool for the capability of searching optimal processing conditions but also greatly reduces the calculation time by utilizing the information of searching area. As a practical example, compact disks that require micron-level precision were chosen for the study.

• Transactions of Materials Processing
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• v.31 no.4
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• pp.240-245
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• 2022

In this study, to achieve good electrical conductivity of a charging terminal component in electric vehicles, we investigated the microstructure evolution of pure-Cu subjected to metal injection molding by controlling the sintering variables, such as temperature and time. Thus, three samples were sintered at temperatures ranging from 1000 ℃ to 1050 ℃ near to the melting temperature of 1085 ℃ for 1 and 10 h after thermal evaporation of binder at 730 ℃. Both procedures were made using a unified furnace under Ar+H₂ gas with high purity. The structural observation displayed that the grain size as well as the compactness (a reciprocal of porosity) increased simultaneously as temperature and time increased. This gave rise to high thermal conductivity of 90% IACS together with high density, which was mainly attributed to decrease in fractions of grain boundaries and micro-pores working as effective scattering center for electron movement.

• The korean journal of orthodontics
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• v.29 no.6 s.77
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• pp.649-661
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• 1999

The goals of this study were 1) to present pre-surgical naso-alveolar molding (PNAM) appliance for bilateral cleft lip and palate treatment and 2) to evaluate the effects of the PNAM appliance on the alveolar molding of the premaxilla and the lateral segments. Subjects consisted of 8 bilateral cleft lip and palate infants (7 males and 1 female, mean age at first visit = 61.6 days after birth) who were treated with PNAM appliances in Department of Orthodontics, Seoul National University Dental Hospital. Average alveolar cleft gap between the premaxilla and the lateral segment was $8.09{\pm}5.03mm$ and average duration of alveolar molding treatment was $8.8{\pm}3.1$ weeks. These patients' models were obtained at initial visit (T0) and after alveolar molding (T1). 20 linear and 14 angular variables were measured by using photometry and digital caliper, All statistical analyses were performed by Microsoft Excel 97 program. Paired t-test was used to discriminate the effect of alveolar molding by PNAM appliance. 1. Closure of the alveolar cleft gap in bilateral cleft cases by molding therapy was completed successfully, 2. Alveolar molding inhibited outward growth of lateral segments and produced inward bending of lateral segments. 3. By bending the anterior part of the vomer, the premaxilla could be rotated and moved. posteriorly via alveolar molding. Conclusion This appliance can be applied to bilateral cleft lip and palate infants with satisfactory results before cheiloplasty.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.4
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• pp.593-600
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• 2012

Thixomolding of Mg-alloy is a semi-solid injection molding process utilizing thixotropic phenomenon. Using this process, higher strength, thinner wall section and tighter tolerance without porosity are obtained. It has been applied for production of near-net-shape magnesium component. To design optimal thixomolding process of Mg-alloy part, molding conditions such as slurry temperature, mold temperature and injection time should be determined properly. Selection of these parameters has been dependent upon engineers' experience and intuitiveness. In this paper, to improve mechanical properties of the thixomolded product, optimal selection of process variables such as injection velocity, barrel temperature and die temperature in the process has been studied through microstructural analysis and Taguchi method. Performance of the process is verified through experiments.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.2
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• pp.17-25
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• 2001

In this paper, a theoretical study has been made to reduce the residual stress and birefringence in the injection-molded parts. An optimization program has been used to minimize the residual stresses and birefringence calculated from a simulation program. The thermally induced stress has been calculated using a linear viscoelasticity model. The flow stress and birefringence has been calculated using the Leonov's viscoelasticity model. This has been applied to the injection molding of a circular disc and a plate. the optimization has been done either by changing process variables while maintaining the mold temperature constant or by varying the mold-wall temperature with time. This study shows the significant reduction in residual stress and birefringence is possible through the optimization of processing conditions.