• Journal of the Society of Naval Architects of Korea
• /
• v.40 no.3
• /
• pp.9-15
• /
• 2003

An experimental study has been carried out as a basic research for development of the friction drag reduction technology for ships by polymer injection. Experimental apparatus and procedures have been devised and prepared to measure the changes of the wall friction with injection of a polymer solution and basic experimental data on the friction drag reduction are obtained for a turbulent fiat-plate boundary layer and fully-developed channel flows. Variations of the friction drag reduction with some important parameters of polymer injection, such as the concentration of polymer solution, its injection flow rate and the measuring position downstream from the injection slot, are also investigated. Important experimental data and results obtained in the present study are presented. The amount of friction drag reduction up to 50% is observed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.05a
• /
• pp.363-370
• /
• 2003

Shrinkage of injection molded parts is different form operational conditions of injection molding such as injection temperature, injection pressure and mold temperature, and mold design such as gate size. It is also various for different resins which have crystalline structure or not. In this study part shrinkage was investigated for various operational condition and resins; PBT for crystalline polymer, and PC and PMMA for amorphous polymer was used in experiment. Crystalline polymer shows higher part shrinkage by about three times than amorphous polymer. Part shrinkage increased as injection temperature and mold temperature increased and injection pressure decreased. Part shrinkage decreased as gate size increased since the pressure delivery is mush easier for large gate size. Part shrinkage according to the gate location was that the position in the part with close to the gate showed large shrinkage and this phenomenon might be occurred by residual stress.

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

• Polymer Science and Technology
• /
• v.6 no.6
• /
• pp.610-617
• /
• 1995

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2002.02a
• /
• pp.125-131
• /
• 2002

Surface defects in injection molded parts are due to the unsteady flow of polymer melt which are related to the geometries of cavity and gate, the operational conditions of injection and the rheological properties of polymer. In this study we have examined jetting phenomena in injection molding process for three kinds of PCs which have different molecular weight and structure, PBT and PC/ABS alloy with several injection speeds. We have used various cavity shapes that are tensile, flexural and impact test specimens with various gate and cavity thicknesses. Through this study we have observed that the formation of surface defect associated with jetting during filling stage in injection molding is strongly related to die swell. This means that the jetting is strongly affected by the elastic property rather than the viscous property in viscoelastic characteristics of molten polymer. Large die swell would eliminate jetting however, the retardation of die swell would stimulate jetting. In the point of mold design, reducing the thickness ratio of cavity to gate can reduce or eliminate jetting and associated surface defects regardless of magnitude of elastic property. It also enlarges process window that can produce steady flow of polymer melt in injection molding.

• Journal of computational fluids engineering
• /
• v.18 no.3
• /
• pp.20-25
• /
• 2013

In various manufacturing industries, an in-mold decoration (IMD) process for plastic objects is widely utilized because a film forming and an injection molding processes run simultaneously. In the present study, the deformation of polymer film and filling of resin in the IMD process were numerically investigated to evaluate the quality of the plastic object formed by the IMD process, which consists of thermoforming and injection molding processes. To obtain the initial shape of the polymer film during the injection molding process, the deformation of the polymer film in the thermoforming process was pre-formed using the vacuum conditions to attach the film to a cavity. Since the properties and deformation of polymer film are greatly affected by the behavior of polymer resin being injected into a mold cavity, numerical simulations for the injection molding and film forming were performed with one-way coupling method. The results showed that the injected resin could lead to the tearing of the polymer film in local regions near the corners. In order to verify the proposed numerical methodology, the numerical results of the deformation patterns printed on the initial polymer film were compared with the experimental data. The proposed methodology to couple film forming analysis with injection molding analysis can be used to predict the deformation of film in IMD process.

• Journal of Mechanical Science and Technology
• /
• v.17 no.5
• /
• pp.647-653
• /
• 2003

An important class of short-fiber reinforced composites is the sheet molding compound, which is recently developed and currently used in many engineering applications. Fatigue failure of the composites is a subject of major concern in design and cyclic crack propagation is of particular significance in the fatigue life prediction of short fiber composites. However, research on the fatigue behavior of polymer injection weld, especially short glass fiber-filled polymer injection weld, has not been carried out. In this study the analyses of the fatigue crack growth behaviors at weld line and in the bulk are performed based on low cycle fatigue test.

• Proceedings of the KSME Conference
• /
• 2008.11a
• /
• pp.996-999
• /
• 2008

Aspheric polymer lens fabrication using isothermal compression molding is presented in this paper. Due to increasing definition of an image sensor, higher precision is required by a lens which can be used as a part of an imageforming optical module. Injection molding is a factory standard method for a polymer optical lens. But achievable precision using injection molding has a formidable limitation due to the machining of complex mold structure and melting and cooling down a polymer melt under high pressure condition during forming process. To overcome the precision requirement and limitation using injection molding method, isothermal compression molding is applied to fabrication of a polymer optical lens. The fabrication condition is determined by numerical simulations of temperature distribution and given material properties. Under the found condition, the lens having a high precision can successfully be reproduced and does not show birefringence which results often in optical degradation.

• Fire Science and Engineering
• /
• v.5 no.2
• /
• pp.11-20
• /
• 1991

Dilute polymer solutions were injected into turbulent pipe flow of a Newtonian fluid. The local drag reduction for injection of polymer solution at the pipe wall was larger than that at centerline. From the above result we may conclude that the polymer additives were found to influence the flow in the neighborhood of the wall. The effects of the injection apparatus on the local drag reduction are small compared to the drag-reducing effects. The extent of drag reduction increased with polymer concentration and injection flow rate, and the maximum drag reduction obtained were 47% for Polyox Coagulant and 35% for Separan AP-273. In respect to polymer degradation, the polyacrylamide showed better shear stability than the polyethyleneoxide and thus the former expected to have a sharper molecular weight distribution.

• Elastomers and Composites
• /
• v.39 no.3
• /
• pp.193-208
• /
• 2004

Morphology of injection molded polymer blend was investigated by experimental and theoretical approach. In experiments, the effects of injection speed and injection temperature on the morphology of injection molded MPPO/Nylon 6 blend were investigated. The morphology distribution across the part thickness was clearly observed in injection molded blend. We could observe several distinct regions across the thickness of molded part: skin layer, subskin layer and core region. The skin layer where the dispersed phase is fine and highly deformed to the flow direction is observed to be located near the part surface. The subskin layer located at inner region of the skin layer also observed. In the subskin layer, the dispersed phase is coarser than that of skin layer and deforms to the flow direction. Based on the experimental results, the calculation scheme to predict the morphology of injection molded polymer blend was suggested. The morphology of injection molded polymer blend could be predicted in corporation with the result of flow analysis obtained from commercial software for injection molding process and the theory of drop behavior under the flow. The suggested calculation scheme could predict the effect of injection conditions on the morphology of injection molded parts.