• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.9
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• pp.1-8
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• 2020

In this study, the optimal design of the multi-cavity mold layout and packing pressure for the automobile TCU connector cover is determined based on the injection molding analysis and the desirability function method for multi-characteristic optimization. The design characteristics to be optimized are the warpage and sink marks of the product, the scrap of the feed system, and the clamping force. The optimal design is determined by performing injection molding analysis and desirability analysis for design alternatives defined by a complete combination of five mold layouts and six-level packing pressure. The optimal design shows that the desirability values for individual characteristics are quite high and balanced, and the resulting values of individual characteristics are satisfactorily low.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.60-65
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• 2012

This paper deals with an CAE analysis and optimization of injection molding for a mobile phone cover. Two design goals are established in the optimization; one is to switch over the feed system from cold runner to hot runner for the purpose of reducing material costs, and the other is to minimize the warpage in order to improve product quality. By the full-factorial experiments for design parameters, we showed that the cold runner design could be changed to the hot runner design by replacing the current resin with a new resin of higher fluidity. In addition, we could significantly reduce the warpage of the cover product under the hot runner system by optimizing packing pressure and packing time.

• Design & Manufacturing
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• v.16 no.3
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• pp.44-49
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• 2022

In this study, the simulation of the resin transfer molding process method using MoldFlow has been investigated. This work explains the thermoset material model, fabric permeability model, the flow model and the cure model. It has been shown that the simulation result can predict filling and cure performances.

• Elastomers and Composites
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• v.52 no.4
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• pp.309-316
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• 2017

In injection molding, the quality of an injection molded product varies greatly depending on the molding conditions. Many researche studies have been conducted on the quality analysis of molded parts according to the molding conditions such as injection pressure, injection temperature, and packing pressure. However, there have not been many studies on the V/P switchover timing. It is known that when a large pressure is applied to a cavity in the packing phase, the cavity pressure is most affected by the packing pressure. In addition, depending on the position (timing) of the packing pressure, it can have a direct influence on quality based on the shrinkage and dimensions of the molded parts. In this study, the change in pressure profile in the cavity according to the V/P switchover position is confirmed. A CAE analysis program (Moldflow) was used to simulate and analyze two models using the PC and PBT materials. In order to compare these results with the actual injection molding results, injection molding was performed for each V/P switchover position, and the correlation between simulation and experiment, especially for the shrinkage of molded parts, was evaluated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1416-1419
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• 2005

Design and manufacturing of plastic injection mold with cavity pressure/temperature sensors were performed in the present study for tensile test specimen. Standards of mold-base and tensile test specimen were used to design an injection molding system. Cavity pressure and temperature sensors were placed on the side of fixed platen of injection mold machine to prevent them from external impact damage. Injection molding experiments with variations of injection speed and melt temperature were performed and polycarbonate tensile specimens were prepared for the tensile test. It was shown that injection molding processing parameters can have effect on the mechanical properties of the plastic injection molded part.

• Korean Journal of Computational Design and Engineering
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• v.1 no.2
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• pp.133-149
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• 1996

In order to reduce the trial-and-errors in design and production of injection molded plastic parts, there has been much research effort not only on CAE systems which simulate the injection molding process, but also on CAD systems which support initial design and re-design of plastic parts and their molds. The CAD systems and CAE systems have been developed independently with being built on different basis. That is, CAD systems manipulate the part shapes and the design features in a complete solid model, while CAE systems work on shell meshes generated on the abstract sheet model or medial surface of the part. Therefore, it is required to support the two types of geometric models and feature information in one environment to integrate CAD and CAE systems for accelerating the design speed. A feature-based non-manifold geometric modeling system has been developed to provide an integrated environment for design and analysis of injection molding products. In this system, the geometric models for CAD and CAE systems are represented by a non-manifold boundary representation and they are merged into a single geometric model. The suitable form of geometric model for any application can be extracted from this model. In addition, the feature deletion and interaction problem of the feature-based design system has been solved clearly by introducing the non-manifold Boolean operation based on 'merge and selection' algorithm. The sheet modeling capabilities were also developed for easy modeling of thin plastic parts.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.10
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• pp.1021-1028
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• 2015

Subminiature lenses are currently widely used in mobile phone cameras and are usually produced by injection molding. The lens molding process has the unique feature of a runner volume that is much larger than the part volume, and this feature should be considered when determining the mold design and molding conditions. In this study, a shell-type runner was proposed as an alternative to the conventional cylindrical runner used for lens molding. An injection molding simulation was performed by applying the proposed shell runner, and the simulation results were compared with those from the cylindrical runner case. It was found that the shell runner could considerably reduce the runner cooling time with only a slight increase in the injection pressure. The effect of the runner thickness was then investigated numerically in terms of the mold filling and cooling characteristics, from which an optimal runner thickness could be determined.

• Journal of Power System Engineering
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• v.18 no.3
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• pp.51-58
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• 2014

Injection molding simulation provided optimized design results by analyzing quality problems while the product is in assembly or in the process of manufacturing with make automobile plastics. Frequent change of design, change of injection molding, repetition of test injection which was held in the old way can now be stopped. And quality upgrade is expected instead. This report deals with the effect which the position of injection molding automobile console gate and number has on product quality including pressure at end of fill, bulk temperature at end of fill, shear stress of end of fill, residual stress at post filling end, product weld lines and warpage results. Simpoe-Mold simulates the complete manufacturing process of plastic injected parts, from filling to warpage. Simpoe-Mold users, whether they are product designers, mold makers or part manufacturers, can identify early into the design stage potential manufacturing problems, study alternative solutions and directly assess the impact of such part modification, whatever the complexity and geometry of such parts, shell part as plain solid parts.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.10
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• pp.32-39
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• 1995

The design of injection molded polymeric parts has been done empirically, since it requires profound knowledge about the moldability and causal effects on the properties of the part, which are not available to designers through current CAD systems. An interactive computer-based design system is developed in order to realize the concept of rational design for the productivity and quality of mold making. The knowledge-based CAD system is constructed by adding the knowledge -base module for mold feature synthesis and appropriate CAE programs for mold design analysis in order to provide designers, at the initial design stage, with comprehensive process knowledge for feature synthesis, performance analysis and feature-based geometric modeling. A knowledge-based CAD system is a new tool which enables the concurrent design with integrated and balanced design decisions at the initial design stage of injection molding.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.580-584
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• 2004

In the present study, an evaluation technology for heating channel layout was investigated in SMC molding system design. Conventional design rules of cooling channel in injection molding process were applied to the present work. Finite element thermal analysis with ANSYSTM was performed to evaluate the temperature distribution of mold surface. SMC mold was manufactured to test the effect of a proposed heating channel layout system on the temperature distribution of mold surface and infrared camera was applied to a measurement of temperature. It was shown that infrared camera application was possible in a measurement of temperature distribution on mold surface.