• Design & Manufacturing
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• v.7 no.1
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• pp.60-63
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• 2013

Recently, Silicone that one of the thermo-sets is used to making optical products such as LED lenses because of excellent thermal properties. LED lenses are required to keep the precise dimensions, so they must be molded to have the minimum deformation. Thermo-sets have the expansion characteristic on the part of thermal property, it is important to optimize the cure condition so that the deformation of the part become minimum. In this study, to investigate the relationship between the shrinkage by the curing and expansion by the thermal properties of the resin, reactive injection experiment was performed by setting the variables such as mold setting temperature, cure time. As a result, it was confirmed that there was a interval while the thermal properties were transferred to more active during the cure process. It is expected to help in determining the reactive injection molding conditions of the thermo-set parts as well as LED lens in order to reduce the amount of deformation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.5
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• pp.1-7
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• 2015

Cleaning by injecting dry ice and water is a generally adopted trend these days to clean molds (injection, diecasting foundry, press, rubber mold, etc). This cleaning method is performed manually, or by installing multiple high pressure spray nozzles. We have manufactured a turbine cleaning module device that is able to clean diecasting modules at any position and angle in the space by mounting an articulated robot instead of the existing pipe type injection nozzle, to minimize lead time and enhance working yield of the cleaning process. In this paper, we analyzed process factors that are required to design the turbine module by reviewing number of revolution, and results according to different blade angles and thicknesses of the mold release injection turbine module, using computational fiuid dynamics (CFD).

• Journal of the Korean Society for Precision Engineering
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• v.16 no.4 s.97
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• pp.110-115
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• 1999

The surface gloss of an injection molded part is one of the most significant point for evaluating the quality of products appearance. The effects of process condition on the gloss of ABS(Acrylonitrile-Butadiene-Styrene) molded part were investigated in this work. The measurements of gloss and morphology on the surface of molded part were carried out with different melt temperature, mold temperature, mold surface roughness, injection pressure and holding pressure. Gloss had a maximum value with melt temperature in the range of 210 to 220 ${^\circ}C$ and with mold temperature 40 to 50${^\circ}C$ and with injection pressure 80~90 MPa, respectively. Melt temperature was shown to have the largest effect on gloss in our work. Gloss was not improved in the region of melt temperature 240${^\circ}C$ above and of mold temperature 60${^\circ}C$ above. It was concluded that the variation of gloss was mainly caused by rubber particles migration under shear stress not by their aggregation or necklace.

• Design & Manufacturing
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• v.7 no.1
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• pp.55-59
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• 2013

A Light Emitting Diode(LED) is a semiconductor device which converts electricity into light. LEDs are widely used in a field of illumination, LCD(Liquid Crystal Display) backlight, mobile signals because they have several merits, such as low power consumption, long lifetime, high brightness, fast response, environment friendly. In general, LEDs production does die bonding and wire bonding on board, and do silicon and phosphor dispensing to protect LED chip and improve brightness. Then lens molding process is performed using mixed liquid silicon rubber(LSR) by resin and hardener. A mixture of resin and hardener affect the optical characteristics of the LED lens. In this paper, computational design of static mixer was performed for mixing of liquid silicon. To evaluate characteristic of mixing efficiency, finite element model of static mixer was generated, and fluidic analysis was performed according to length of mixing element. Finally, optimal condition of length of mixing element was applied to static mixer from result of fluidic analysis.

• Korean Chemical Engineering Research
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• v.49 no.1
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• pp.47-55
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• 2011

The optimum mold design and the optimum process condition were constructed upon executing process simulation of rubber injection molding with the commercial CAE program of MOLDFLOW (Ver. 5.2) in order to solve the process-problems of K company relating to cracks, which occurs at the inner cavity wall of C. V. joint boots. As a result it was confirmed that the real cracks occurs at the exactly same position of the cavity as exhibits the defects of weld and meld line and unsatisfactory curing according to the result of simulation. In order to prevent the occurrence of weld and meld line at the defect-position, the location of gate was altered to the optimum position of the cavity. Consequently the filling pattern was established to minimize the degree of the melt-fronts confronting or the melt-flows melding to prevent the occurrence of weld and meld line at the defect-position. It was observed that both gate-positions to maximize the degree of the formation of weld and meld line and air traps are located, respectively, in opposite direction each other with reference to the optimum gate position. In addition, the temperature of mold was raised by $10^{\circ}C$ and maintained at $170^{\circ}C$ for satisfactory curing.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.179-182
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• 2007

In recent, recycling of plastic material has became a major issue due to the landfills and environmental problem. This study investigated fluidity of thermoplastic vulcanizate(TPV), which is for automobile component parts such as weather strip in order to replace ethylene propylene rubber (EPDM). So, using the spiral flow test mold and panel cover mold, we conducted an experiment on fluidity of TPV with injection molding. As results of injection molding experiment, the recycled TPV's flow length was a little bit longer than virgin TPV and a case of panel cover, the filled weight was almost same quantity.

• International Journal of Precision Engineering and Manufacturing
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• v.7 no.1
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• pp.57-61
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• 2006

The research on surface modification technology has been advanced to improve the properties of engineering materials. Ion implantation is a novel surface modification technology that enhances the mechanical, chemical and electrical properties of substrate's surface using accelerated ions. In this research, nitrogen ions were implanted into AC7A aluminum substrates which would be used as molds for rubber molding. The composition of nitrogenion implanted aluminum and distribution of nitrogen ions were analyzed by Auger Electron Spectroscopy (AES). To analyze the modified surface, properties such as hardness, friction coefficient, wear resistance, contact angle, and surface roughness were measured. Hardness of ion implanted specimen was higher than that of untreated specimen. Friction coefficient was reduced, and wear resistance was improved. From the experimental results, it can be expected that implantation of nitrogen ions enhances the mechanical properties of aluminum mold.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.616-619
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• 2002

Spin casting is one of useful methods to manufacture metal parts with low mold cost and short delivery time. But the silicon rubber based conventional method has several problems such as poor dimensional accuracy, limitation in casting materials and its dependency on speciality in meld making process. To solve those problems, this paper suggests a steel based mold making method using direct CNC machining and the experimental results shows that the parts from the developed method has better dimensional accuracy and surface roughness than those from the conventional method.

• Proceedings of the Korean Society For Composite Materials Conference
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• 1999.11a
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• pp.139-142
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• 1999

Screw rotors are core parts of screw type air compressors, compressors in refrigerating machines and super chargers of automobiles etc. They are composed of a female and a male rotors which have complex section profiles and helically swept geometry. Screw type compressors have advantages of low noise, high efficiency, less needs in maintenance etc. Usually, machining process of screw rotors requires long machining time using CNC machine designed only for screw rotors, which increase the cost of production. In this work, the screw rotors for air-compressors were manufactured with fiber reinforced epoxy composite materials by resin transfer molding process. The mold for the RTM process was made of aluminum and silicon rubber and was designed for release of helical shape products. Composite screw rotors, manufactured by RTM process, have advantages of lightweight, less cost of production, good characteristics of vibration etc.

• Transactions of Materials Processing
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• v.24 no.6
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• pp.418-425
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• 2015

Based on eco-friendly advantages and the enhanced development in the chemical and physical characteristics, liquid silicone rubber (LSR) is widely used in producing precision parts in the automotive, medical, electronics, aeronautical and many other industries. In the current work, a thermoplastic-thermoset multi component injection molding (MCM) was developed for a waterproof automotive connector housing using PBT and LSR resins. Measurements of the rheological characteristics of PBT and LSR were made to improve the reliability of the numerical analysis for the multi component injection process. With the measured viscosity, pvT and curing data, numerical analysis of the multi cycle injection molding was conducted using simulation software (Sigma V5.0).