• Transactions of Materials Processing
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• v.11 no.8
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• pp.641-650
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• 2002

For the production of complicated plastic parts in a cycle, a mold is needed.. The basic tasks of a mold are accommodation and distribution of the resin, shaping and cooling the melt and ejection of the molding. To achieve these goal a mold has several important parts and we classified types of molds. The 6 different major functions of a mold are explained and several types of molds are shown in her. I hope these explanation will help to understand injection molds for a design engineer.

• Journal of Korea Foundry Society
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• v.29 no.5
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• pp.204-212
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• 2009

The effects of addition of magnesium only and the simultaneous addition of magnesium and aluminum on the graphite morphology of the cast iron with the composition of 3.6wt.% and 2.5wt.%Si poured into shell stack mold were investigated. The nodularity and mechanical properties of the specimen with smaller cross-section were higher than those with langer one, when copper was not added. When the magnesium only was added, the nodularity was decreased with decreased residual magnesium content and the C. V, graphite was obtained with the magnesium content in the range of 0.010~0.015wt.%. When the magnesium and aluminum were added together, the nodularity was decreased with decreased residual magnesium and increased aluminum contents. When copper was added, the volume fraction of pearlite in the matrix, strength and hardness were higher and elongation was lower for specimen with smaller cross-section. The volume fraction of pearlite, strength and hardness were increased and the elongation was decreased with increased copper content for the specimen with C, V, graphite.

• Transactions of the Korean hydrogen and new energy society
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• v.23 no.2
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• pp.134-142
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• 2012

A bipolar plate is a major component of a fuel cell stack, which occupies 50~60% of the total weight and over 50% of the total cost of a typical fuel cell stack. In this study, a composite bipolar plate is designed and fabricated to develop a compact and light-weight direct methanol fuel cell (DMFC) stack for a small-scale Unmanned Aerial Vehicle (UAV) application. The composite bipolar plates for DMFCs are prepared by a compression molding method using resole type phenol resin as a binder and natural graphite and carbon black as a conductor filler and tested in terms of electrical conductivity, mechanical strength and hydrogen permeability. The flexural strength of 63 MPa and the in-plane electrical conductivities of 191 S $cm^{-1}$ are achieved under the optimum bipolar plate composition of phenol : 18%; natural graphite : 82%; carbon black : 3%, indicating that the composite bipolar plates exhibit sufficient mechanical strength, electrical conductivity and hydrogen permeability to be applied in a DMFC stack. A DMFC with the composite bipolar plate is tested and shows a similar cell performance with a conventional DMFC with graphite-based bipolar plate.

• Journal of Korea Foundry Society
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• v.29 no.3
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• pp.128-137
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• 2009

The effects of alloying elements on the mechanical properties of 3.6wt%C-2.6wt%C ductile cast iron poured into shell stack molds were investigated. The strength and hardness of the specimens obtained from the center layer in the 5-story stack mold were the lowest and those for other specimens were increased with increased distance from the center. The strength and hardness of the specimens obtained from the center layer were decreased with increased number of layers of the shell stack mold. The strength and hardness of the smaller specimens with the diameter of 9.5 mm were higher than those of 17.5 mm. On the other hand, the elongation of the former was lower than that of the latter. The strength and hardness were increased and the elongation was decreased roughly with the increased amounts of manganese and copper added, respectively. The strength and hardness were increased with the incrcased amount of molybdenum added to 0.40wt% and rather decreased with that to 0.80wt%. Those were greatly increased with the increased amount of tin added and the elongation was roughly decreased with it.

• 한국신재생에너지학회:학술대회논문집
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• 2005.11a
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• pp.554-557
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• 2005

The bipolar plate is a major component of the PEM fuel cell stack, which takes a large portion of stack cost. In this study, as alternative materials for bipolar plate of PEM fuel cells, graphite composites were fabricated by compression molding. Graphite particles mixed with epoxy resin were used as the main substance to provide electric conductivity. To achieve desired electric properties, specimens made with different mixing ratio, processing pressure and temperature were tested. To increase mechanical strength, one or two layer of woven carbon fabric were added to the original graphite and resin composite. Thus, the composite material is consisted of the three phases: graphite particles, epoxy resin, and carbon fabric. By increasing mixing ratio, fabricated pressure and process temperature, electric conductivity was improved. The results of tensile test showed that the tensile strength of two-phase graphite composite was about 5MPa, and that of three-phase composite was increased to 54MPa.

• Journal of Korea Foundry Society
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• v.30 no.2
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• pp.66-75
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• 2010

The effects of alloying elements on the mechanical properties of normalized and quenched 3.60wt%C-2.60wt%C ductile cast iron poured into shell stack mold were investigated. The strength and hardness of as-cast specimen were increased and the elongation of it was decreased with the additions of Mn, Cu and Sn. The strength and hardness were increased with the addition of 0.40wt%Mo and then rather decreased with the increased addition of 0.80wt%. The strength and hardness were increased with normalizing treatment and the strengths of normalized specimens were increased slightly with the addition of alloying elements except Mo. Meanwhile the yield strength of the normalized specimen was increased slightly with the addition of Mo, the tensile strength was not changed much. Meanwhile the hardness and strength of the quenched specimen were slightly increased with the addition of Mn, those were almost not changed with the amount added. The tensile strength of the quenched specimen with larger diameter, when the Cu had been added, and the tensile and yield strengths of them, when Mo had been added, were increased with the addition of alloying element. On the other hand, those were not changed with the amount added. For the case of specimen with smaller diameter, there were no effects of these two elements. When Sn had been added, the strength of hardened specimen with larger diameter was slightly increased with the amount added. However, that with smaller diameter was rather decreased with it. The effect of specimen diameter on the strength of quenched specimen with the addition of Cu, Mo and Sn was reduced.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.15 no.10 s.103
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• pp.1211-1216
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• 2005

Underwater acoustic transducers are widely used for SONAR application, whose important design parameters are shapes. materials, dimensions and supporting structures. Practical design method of transducers consists of manufacturing, experiments and modifications so that it requires much time and expenses. In this study, an analytical method was developed for the Tonpilz type transducers using the commercial finite element analysis code ATILA which can solve the electro-mechanical coupling problems. A finite element model was established including the transducer elements such as ceramic stack, head mass, tail mass, tensile bolt, and molding layers. The proposed model was verified and modified by comparing the in-air and in-water test results of prototypes. The developed analysis method will be effectively used for the sensitivity analysis of design parameters in transducer design process.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2005.11a
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• pp.247-250
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• 2005

Underwater acoustic transducers are widely used for SONAR application, whose important design parameters are shapes, materials, dimensions and supporting structures. Practical design method of transducers consists of manufacturing, experiments and modifications so that It requires much time and expenses. In this study, an analytical method was developed for the Tonpilz type transducers using the commercial finite element analysis code ATILA which can solve the electro-mechanical coupling Problems. A finite element model was established including the transducer elements such as ceramic stack, head mass, tall mass, tensile bolt, and molding layers. The proposed model was verified and modified by comparing the in-air and in-water test results of prototypes. The developed analysis method will be effectively used for the sensitivity analysis of design parameters in transducer design process.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.6
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• pp.1726-1732
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• 2008

Injection molding is one of plastic forming technology which can easily mass-produce plastic parts with various and even complex shape. The technology has lots of difficulties in making a good part due to phase change of material, high applied pressure, and fast melt flow speed in the cavity. To overcome the problems, they had to make trial and error method until the CAE(Computer Aided Engineering) could be a tool for concurrent engineering. In this paper, we investigate the optimal design for a plastic DVD tray part by systematic approach of the commercial CAE program. In design, we should consider two objectives which are both dimensional stability and cost-down. The dimension of the part is crucial because the tray should carry a DVD correctly, but the part is too thin to injection-mold easily. In order to improve the moldability, the mold is designed in the form of stack mold which is a kind of 4 hot runner system. In first, we changed the stack-mold system with one hot-runner to cost down, and decided the optimal position of the gate. After that, we investigate the effect of both the layout of cooling channels and the cooling temperature on the shrinkage of the DVD tray. A optimal simulation approach, the gate design is 2Gate#3 and the layout is Case2 cooling line as the optimal temperature of $70^{\circ}C$. The Moldflow and PC+ABS are used for the CAE program and material respectively.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.5
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• pp.39-46
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• 2006

The fuel cell is one of promising environment-friendly energy sources for the next generation. The bipolar plate is a major component of the PEM fuel cell stack, which takes a large portion of stack cost. In this study, as alternative materials for bipolar plate of PEM fuel cells, graphite composites were fabricated by compression molding. Graphite particles mixed with epoxy resin were used as the main substance to provide electric conductivity To achieve desired electrical properties, specimens made with different mixing ratio, processing pressure and temperature were tested. To increase mechanical strength, one or two layers of woven carbon fabric were added to the graphite and resin composite. Thus, the composite material was consisted of three phases: graphite particles, carbon fabric, and epoxy resin. By increasing mixing ratio of graphite, fabricated pressure and process temperature, the electric conductivity of the composite was improved. The results of tensile test showed that the tensile strength of the two-phase graphite composite was about 4MPa, and that of three-phase composite was increased to 57MPa. As surface properties, contact an91e and surface roughness were tested. Graphite composites showed contact angles higher than $90^{\circ}$, which mean low surface energy. The average surface roughness of the composite specimens was $0.96{\mu}m$.