• Title/Summary/Keyword: Variable-Runner System

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An Experimental Study for the Filling Balance of the Family Mold (Family 금형의 충전 균형을 위한 실험적 연구)

  • Park H. P.;Cha B. S.;Rhee B. O.
    • Transactions of Materials Processing
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    • v.15 no.1 s.82
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    • pp.47-56
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    • 2006
  • It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially when the family-mold has a volumetric difference between two cavities. In this study, the cavity-filling imbalance was confirmed by the temperature and the pressure sensors, and a variable-runner system was developed for balancing the cavity-filling. Experiments of balancing the cavity filling was carried out in the family-mold with the variable-runner system, and balancing the cavity-filling was confirmed by changing the cross-sectional area of a runner in the variable-runner system with the temperature and pressure sensors. The influence of the injection speed to the balancing-capability of the variable-runner system was also examined in the experiment.

The Filling Balance of LDPE/ABS/PA6,6 Resin in Variable-Runner-System (가변러너시스템에서 LDPE/ABS/PA6,6 수지의 충전균형)

  • Park, H.P.;Cha, B.S.;Kang, J.K.;Rhee, B.O.
    • Transactions of Materials Processing
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    • v.15 no.9 s.90
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    • pp.641-647
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    • 2006
  • During the injection molding process an excessive packing can occur in the smaller volume cavity because of volumetric difference of the family-mold. It causes warpage by increased residual stress in the product and flesh by over packing. In this study, we used a variable-runner system for the filling balance of the cavities by changing the cross-sectional area of a runner, and confirmed the filling imbalance by temperature and pressure sensors. We carried out experiments to examine the influence of types of resins such as LDPE/ABS/PA6,6 on the filling balancing of the system, in order to help mold designers, who can easily adopt the variable-runner system to their design. We also examined filling imbalance in the system with CAE analysis.

Perfomance analysis of variable runner according to materials rheological characteristics in family mold (패밀리금형에서의 수지 유변학적 특성에 따른 가변러너의 성능 분석)

  • Choi, Kwon-Il;Park, Hyung-Pil;Cha, Baek-Soon;Lee, Byung-Ok;Gu, Bon-Heung
    • Design & Manufacturing
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    • v.2 no.6
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    • pp.23-27
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    • 2008
  • It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially when the family-mold has a volumetric difference between two cavities. In this study, the cavity-filling imbalance was confirmed by the temperature and the pressure sensors, and a variable-runner system was developed for balancing the cavity-filling. Experiments of balancing the cavity filling was carried out in the family-mold with the variable-runner system, and balancing the cavity-filling was confirmed by changing the cross-sectional area of a runner in the variable-runner system with the temperature and pressure sensors. The influence of the injection speed to the balancing-capability of the variable-runner system was also examined in the experiment.

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A Theoretical Study for the Filling Balance of the Family Mold Using Variable-Runner System (가변 러너 시스템을 이용한 패밀리 금형의 충전밸런스에 관한 이론적 연구)

  • Choi, Kwon-Il;Park, Hyung-Pil;Cha, Baeg-Soon;Rhee, Byung-Ohk;Koo, Bon-Heung
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2007.10a
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    • pp.275-278
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    • 2007
  • In family mold, defects are frequently occurred by an excessive packing the smaller volume cavity during molding. Although runner size could be optimized by CAE analysis or experimental data, the filling imbalance is hardly avoided in the actual injection molding process by various means. Before this study, we developed a variable-runner system for balancing the cavity-filling for three resins (ABS, LDPE, and PA66) in the family-mold, and examined the effect of cross-sectional area reduction of a runner in the system. In this study, we examined the conditions of the pressure and temperature in the system with a CAE analysis. We also analyzed the influence of the rheological characteristic of resins to the balancing-capability of the system in order to help mold designers easily adopt the variable-runner system to their design.

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An experimental study for the filling balance of the family mold (Family 금형의 충전 밸런스를 위한 실험적 연구)

  • Cha B. S.;Rhee B. O.;Park H. P.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2005.09a
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    • pp.132-140
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    • 2005
  • It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially whorl the family-mold has a volumetric difference between two cavities. In this study, we confirmed the cavity-filling imbalance by the temperature and the pressure sensors, and developed a variable-runner system for the cavity-filling balance. We carried out experiments fur balancing the cavity filling in the family-mold with the variable-runner system, and confirmed a balanced cavity-filing through analyzing the temperature and pressure change in each cavity as the cross-sectional area of the runner changed. We also examined the influence of the injection-speed to the balancing-capability of the variable-runner system in the experiment.

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Simulation-based Intake Manifold Runner Length Optimization for Improving Performance, Fuel Consumption and Emission of a Gasoline Engine (가솔린 엔진의 성능, 연비, 배출 가스를 동시에 고려한 시뮬레이션 기반 흡기 다기관 길이 최적화)

  • Kang, Yong-Hun;Choi, Dong-Hoon
    • Transactions of the Korean Society of Automotive Engineers
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    • v.18 no.5
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    • pp.62-67
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    • 2010
  • Exhausting fossil fuel and increasing concern of air pollution have brought on the change of the focus of developing new vehicles from performance to fuel economy and emission. The gasoline engines adopting the naturally aspirated way use the throttle-body for engine load control. Therefore, its pumping loss increases more than that of the diesel engine, and also mostly operating in a partial load condition has bad influence on fuel economy and emission. In these days, the continuous variable valve timing system and variable induction system are adopted in order to improve fuel consumption and emission. In this study, we optimize the runner length and operate region of variable induction system to simulataneously improve the performance, fuel economy, and emission of gasoline engine with employing GT-Power as a CAE tool for engine analysis and PIAnO as PIDO tool for process integration and design optimization.

Effects of processing Factors on Filling Imbalances in Multi-cavity Injection Mold. (다수 캐비티 사출금형에서 성형 인자가 충전 불균형에 미치는 영향)

  • Kang C. M.;Jeong Y. D.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2004.10a
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    • pp.54-57
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    • 2004
  • Almost all injection molds have multi-cavity runner for mass production, which are designed with geometrically balanced runner system in order to minimize filling imbalance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalances have sometimes been observed. These filling imbalances have historically been considered as result of uneven mold temperature and mold deflection, but it actually results from non-symmetrically shear, pressure, temperature distribution within melt material as it flows through the runner system. Filling imbalance could be decreased by modifying processing conditions that are related to shear, pressure, temperature such as injection rate, mold temperature, injection pressure, melt temperature. In this study, a series of experiment was conducted using Taguchi method to determine which processing condition influence as the primary cause of filling imbalance in geometrically balanced runner system. As a result of experiments, this paper could present an optimal processing condition to minimize variable that brings about filling imbalance geometrically balanced runner system

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Performance Analysis of 10kW Class Propeller Hydro Turbine by the Change of Flow Rates and the Number of Runner Vane Using CFD (CFD를 이용한 10kW급 모델 실험용 프로펠러 수차의 유량 및 러너 베인 깃 수 변화에 따른 성능해석)

  • Park, Ji-Hoon;Kim, You-Taek;Cho, Yong;Kim, Byeong-Kon;Lee, Young-Ho
    • The KSFM Journal of Fluid Machinery
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    • v.17 no.2
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    • pp.5-11
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    • 2014
  • Small hydro power, among other renewable energy resources, has been evaluated to have enough development value because it is a clean, renewable and abundant energy resource. In addition, small hydro power has the advantage of low cost development by using existing facilities like sewage treatment plants, water works and similar resources. But in the case of small hydro power systems, there are problems with degraded operation efficiency of turbine due to changes in flow rates. In order to overcome this, variable speed control can be achieved by using the power rectifier and permanent magnetic synchronous generator(PMSG) as a possible method to respond to the changes in flow rates. In this study, a commercial ANSYS CFD code was used to analyze the performance of 10kW class propeller hydro turbine and to also investigate flow characteristics at variable flow rates and runner vane.

Investigation of the Filling Unbalance and Dimensional Variations in Multi-Cavity Injection Molded Parts (다수 캐비티의 사출성형품에서 충전의 불균형과 성형품 치수 편차의 교찰)

  • Kang, Min-A;Lyu, Min-Young
    • Polymer(Korea)
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    • v.32 no.6
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    • pp.501-508
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    • 2008
  • Small injection molded articles such as lens and mobile product parts are usually molded in multi-cavity mold. The problem occurring in multi-cavity molding is flow unbalance among the cavities. The flow unbalance affects the dimensions and physical properties of molded articles. First of all, the origin of flow unbalance is geometrical unbalance of the delivery system. However, even the geometry of the delivery system is well balanced, cavity unbalance occurs. This comes from the temperature distributions in the cross-section of runner. Temperature distribution depends upon injection speed because heat generation near runner wall is high at high injection speed. Among the operational conditions, injection speed is the most significant process variable affecting the filling unbalances in multi-cavity injection molding. In this study, experimental study of flow unbalance has been conducted for various injection speeds and materials. Also, the filling unbalances were compared with CAE results. The dimensions and weights of multi-cavity molded parts were examined. The results showed that the filling unbalances vary according to the injection speeds and resins. Subsequently, the unbalanced filling and pressure distribution in the multi-cavity affect the dimensions and physical states of molded parts.

Development of High Precision Fastening torque performance Nut-runner System (고정밀 체결토크 성능 너트런너 시스템 개발)

  • Kim, Youn-Hyun;Kim, Sol
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.20 no.4
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    • pp.35-42
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    • 2019
  • Nut fasteners that require ultra-precise control are required in the overall manufacturing industry including electronic products that are currently developing with the automobile industry. Important performance factors when tightening nuts include loosening due to insufficient fastening force, breakage due to excessive fastening, Tightening torque and angle are required to maintain and improve the assembling quality and ensure the life of the product. Nut fasteners, which are now marketed under the name Nut Runner, require high torque and precision torque control, precision angle control, and high speed operation for increased production, and are required for sophisticated torque control dedicated to high output BLDC motors and nut fasteners. It is demanded to develop a high-precision torque control driver and a high-speed, low-speed, high-response precision speed control system, but it does not satisfy the high precision, high torque and high speed operation characteristics required by customers. Therefore, in this paper, we propose a control technique of BLDC motor variable speed control and nut runner based on vector control and torque control based on coordinate transformation of d axis and q axis that can realize low vibration and low noise even at accurate tightening torque and high speed rotation. The performance results were analyzed to confirm that the proposed control satisfies the nut runner performance. In addition, it is confirmed that the pattern is programmed by One-Stage operation clamping method and it is tightened to the target torque exactly after 10,000 [rpm] high speed operation. The problem of tightening torque detection by torque ripple is also solved by using disturbance observer Respectively.