• Polymer(Korea)
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• v.38 no.6
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• pp.708-713
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• 2014

Most plastics products are being produced by injection molding process. However, mold shrinkage is inevitable in injection molding process and it deteriorates dimensional quality through deflections and warpages. Mold shrinkage depends upon the material property of resin as well as injection molding condition. In this study, material property of resin has been predicted for glass fiber reinforced polycarbonate to control the warpage, and computer simulation of injection molding has been performed using predicted property. It was observed that the deflection of part decreased by the glass fiber reinforced resin. In order to verify the validity of this method and confidence of results, experiments of injection molding were performed. The results of experiments and computer simulations showed good agreement in their tendency of deflections. Consequently, it was concluded that the method of designing the material property of resin conducted in this study can be utilized to control the dimensional accuracy of injection molded products.

• Journal of Power System Engineering
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• v.6 no.2
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• pp.68-72
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• 2002

Design of experiment was applied to analyze the shrinkage characteristics of the bobbin molded by injection molding. Among lots of design and processing conditions, the thickness of a bobbin and cooling conditions of a mold were considered. The temperature difference between top and bottom parts of the bobbin was considered as the objective to minimize the shrinkage of a bobbin. Optimal thickness of a bobbin was 2.0mm at the part of body and 1.5mm at the part of wing, respectively. Optimal cooling conditions such as cooling time and coolant inlet temperature were 12 second and $12^{\circ}C$, respectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.357-360
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• 2009

The cooling stage greatly affects the product quality in the injection molding process. The cooling system that minimizes temperature variance in the product surface will improve the quality and the productivity of products. In this research, we tried the back-propagation algorithm of artificial neural network to find an optimum solution in the cooling system design of injection mold. The cooling system optimization problem that was once solved by a response surface method with 4 design variables was solved by applying the back-propagation algorithm, resulting in a solution with a sufficient accuracy. Furthermore the number of training points was much reduced by applying the fractional factorial design without losing solution accuracy.

• Elastomers and Composites
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• v.51 no.4
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• pp.275-279
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• 2016

Additive manufacturing or 3D printing is a new manufacturing process and its application is getting growth. However, the product qualities such as mechanical strength, dimensional accuracy, and surface quality are low compared with conventional manufacturing process such as molding and machining. In this study not only mechanical characteristics of polymer sandwich panel having three dimensional core layer but also mechanical characteristics of core layer itself were analyzed. The shape of three dimensional core layer was pyramidal kagome structure. This core layer was fabricated by two different methods, injection molding with PP resin and material jetting type 3D printing with acrylic photo curable resin. The material for face sheets in the polymer sandwich panel was PP. Maximum load, stiffness, and elongation at break were examined for core layers fabricated by two different methods and also assembled polymer sandwich panels. 3D printed core showed brittle behavior, but the brittleness decreased in polymer sandwich panel containing 3D printed core. The availability of 3D printed article for the three dimensional core layer of polymer sandwich panel was verified.

• Transactions of Materials Processing
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• v.13 no.3
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• pp.230-235
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• 2004

A new design based on the appropriate geometry of molded part and type of runner system under the optimal processing conditions was proposed to minimize the micro weld lines on the sub deco surface molded by two shot molding. Theoretical and experimental studies were conducted to examine the cause of the weld lines during the overmolding process in two shot molding. Various dimensions and geometries of substrate$(1^{st}shot)$ and the wall thickness of overmold$(2^{nd}shot)$ have been proposed to avoid the weld lines which are the most inevitable appearance defects occurred on the sub deco. The each design proposal was analyzed by mold flow analysis after part modeling. The analysis results were compared with molded part from mass production tool. It could be seen that from the analysis that the proper geometry of plastic part and type of runner system considering pressure drop under the optimal processing conditions were the most influential factors to avoid weld lines occured on the sub deco.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.1
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• pp.44-50
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• 2015

This paper presents a heuristic process-optimization procedure for minimizing warpage in injection-molded parts based on the dynamic robust design methodology. The injection molding process is known to have intrinsic variations of its process conditions due to various factors, including incomplete process control facilities. The aim of the robust design methodology advocated by Taguchi is to determine the optimum design variables in a system which is robust to variations in uncontrollable factors. The proposed procedure can determine the optimal robust conditions of injection molding processes at a minimum cost through a trade-off strategy between the degree of warpage and the packing time.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.7
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• pp.591-596
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• 2014

Augmented reality is a novel human-machine interaction that overlays virtual computer-generated information on a real world environment. It has found good potential applications in many fields, such as training, surgery, entertainment, maintenance, assembly, product design and other manufacturing operations. In this study, a smartphone-based augmented reality system was developed for the purpose of monitoring and managing injection molding production lines. Required management items were drawn from a management content analysis, and then the items were divided into two broad management categories: line management and equipment management. Effective work management was enabled by providing those working on the shop floor with management content information combined with the actual images of an injection molding production line through augmented reality.

• 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 $1.786{\mu}m$.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.5
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• pp.75-80
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• 2015

Nowadays, flat-shaped cover glass is widely used for mobile devices. However, for its good design and convenience of use, curved cover glass has been demanded. Thus, many companies have tried to produce curved cover glass through the shaving technique, but the production efficiency is very low. Therefore, the molding technique has been adopted to increase the efficiency for the curved-glass production system. For a glass-molding system, several heating blocks are installed, and the flat cover glass is sequentially heated and molded. The production time for the cover glass is very different depending on the heating conditions; thus, the prediction of the production time for different heating conditions should be needed. Therefore, in this study, the computations were performed with different heating conditions (uniform and non-uniform) in the present cover glass-molding machine. For uniform and non-uniform heating conditions, the simple correlation between the heating time and the heater capacity and the heating time to achieve higher durability can be suggested, respectively.

• Design & Manufacturing
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• v.1 no.1
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• pp.17-21
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• 2007

In the manufacture and processing of large plastic materials, product quality is tested and verified through several techniques such as injection processing, residual stress through injection molding and shrinkage. With regards to the injection molding process, common problems such as inconsistent density is seen when different points of the product are discovered to have varying thickness levels. Sink marks in product are then evident. This occurs when there is poor molding conditions caused about by poor runner and packaging systems incorporated into the process. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique.