• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.4
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• pp.631-636
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• 2002

It is necessary to improve mechanical and optical properties in the optical disk substrates as the information storage devices with high storage density using blue laser are being developed. Injection compression molding is regarded as the most suitable process to manufacture optical disk substrates for quality recording and read-out. In the present research, the effects of mold temperature and the insulation layer thickness on gapwise birefringence and the land-groove pattern were investigated. It was found that the values of the birefringence distribution were very sensitive to mold temperature history, and the level of birefringence reduced and, furthermore, the quality of replication was improved due to the insulation layer.

• Carbon letters
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• v.16 no.2
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• pp.86-92
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• 2015

Multi-walled carbon nanotube (MWCNT)/polycarbonate (PC) nanocomposite was prepared by direct melt mixing to investigate the effect of the shear rate on the surface resistivity of the nanocomposites. In this study, an experiment was carried out to observe the shear induced orientation of the MWCNT in the polymer matrix using a very simple melt flow indexer with various loads. The compression-molded, should be eliminated. MWCNT/PC nanocomposite sample exhibited lower percolation thresholds (at 0.8 vol%) and higher electrical conductivity values than those of samples extruded by capillary and injection molding. Shear induced orientation of MWCNT was observed via scanning electron microscopy, in the direction of flow in a PC matrix during the extrusion process. The surface resistivity rose with increasing shear rate, because of the breakdown of the network junctions between MWCNTs. For real applications such as injection molding and the extrusion process, the amount of the MWCNT in the composite should be carefully selected to adjust the electrical conductivity.

• Journal of Magnetics
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• v.4 no.2
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• pp.52-54
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• 1999

Injection molding is one of the methods to prepare dielectromagnets-permanent magnets made from hard magnetic powder (or from mixture of powders) bonded by dielectric materials. Magnetic properties of dielectromagnets are worse than those of sintered magnets made from the same hard magnetic powders, but this type of the permanent magnet has many advantages. One of them is simpler technology-easier in comparison to the technology of sintered magnets. The injection molded dielectromagnets do not need any final treatment. This technology permits to control magnetic, thermal and mechanical properties of dielectromagnets. The main chracteristics of dielectormagnets are magnetic properties, however mechanical properties have serious influence onto a range of their applications. The main factors shaping mechanical properties have serious influence onto a range of their applications. The main factors shaping mechanical properties of dielectromagnets are the kind and quantity of resin and the technology. The purpose of this investigateion was to find the correlation between infection conditions and the mechanical properties of dielectromagnets. Influence of two parameters of injection, temperature and pressure on mechanical and magnetic properties of dielectromagnets were not significantly changed. Increasing of pressure of injection also does not influence on mechanical properties of analysed samples, however increasing of temperature of injection significantly improved both compression and bending strength.

• Korea-Australia Rheology Journal
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• v.19 no.4
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• pp.183-190
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• 2007

Injection molding is one of the most common operations in polymer processing. Good quality products are usually obtained and major post-processing treatment is not required. However, residual stresses which exist in plastic parts affect the final shape and mechanical properties after ejection. Residual stresses are caused by polymer melt flow, pressure distribution, non-uniform temperature field, and density distribution. Residual stresses are predicted in this study by numerical methods using commercially available softwares, $Hypermesh^{TM},\;Moldflow^{TM}\;and\;ABAQUS^{TM}$. Cavity filling, packing, and cooling stages are simulated to predict residual stress field right after ejection by assuming an isotropic elastic solid. Thermo-viscoelastic stress analysis is carried out to predict deformation and residual stress distribution after annealing of the part. Residual stresses are measured by the hole drilling method because the automotive part selected in this study has a complex shape. Residual stress distribution predicted by the thermal stress analysis is compared with the measurement results obtained by the hole drilling method. The molded specimen has residual stress distribution in tension, compression, and tension from the surface to the center of the part. Viscoelastic deformation of the part is predicted during annealing and the deformed geometry is compared with that measured by a three dimensional scanner. The viscoelastic stress analysis with a thermal cycle will enable us to predict long term behavior of the injection molded polymeric parts.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.43-46
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• 2005

Micro molding technology is a promising mass production technology for polymer based microstructures. Mass production technologies such as the micro injection/compression molding, hot embossing, and micro reaction molding are already in use. In the present study, we have developed a numerical analysis system to simulate three-dimensional non-isothermal cavity filling for hot embossing, with a special emphasis on the free surface capturing. Precise free surface capturing has been successfully accomplished with the level set method, which is solved by means of the Runge-Kutta discontinuous Galerkin (RKDG) method. The RKDG method turns out to be excellent from the viewpoint of both numerical stability and accuracy of volume conservation. The Stokes equations are solved by the stabilized finite element method using the equal order tri-linear interpolation function. To prevent possible numerical oscillation in temperature Held we employ the streamline upwind Petrov-Galerkin (SUPG) method. With the developed code we investigated the detailed change of free surface shape in time during the mold filling. In the filling simulation of a simple rectangular cavity with repeating protruded parts, we find out that filling patterns are significantly influenced by the geometric characteristics such as the thickness of base plate and the aspect ratio and pitch of repeating microstructures. The numerical analysis system enables us to understand the basic flow and material deformation taking place during the cavity filling stage in microstructure fabrications.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.438-444
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• 2001

The objective of this study is to provide a simple methodology to find optimum processing conditions to fabricate sub-micron structured DVD-RAM substrates with superb optical and geometrical properties. It was found that the birefringence, which is regarded as one of the most important optical properties for an optical disk, was very sensitive to the mold wall temperature history. Also, the integrity of the replication, represented by the land-groove structure and the radial tilt were influenced by the mold temperature and the compression pressure. A set of optimum conditions were obtained by applying Design of Experiment and the objective functions composed of three different objectives.

• The Korean Journal of Rheology
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• v.10 no.4
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• pp.217-226
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• 1998

The anisotropy caused by the fiber orientation, which is inevitably generated by the flow during injection molding of short fiber reinforced polymers, greatly influences dimensional accuracy, mechanical properties, and other quality of the final product. Since the filling stage of the injection molding process plays a vital role in determining fiber orientation, an accurate analysis of flow field for the filling stage is needed. Unbalanced filling occurs when a complex or a multi-cavity mold is used leading to development of regions where the fiber suspension is under compression. It is impossible to make an accurate calculation of the flow field during filling with the analysis assuming incompressible fluid. A mold with four cavities with different filling times was produced to compare the numerical analysis results with the experimental data. There was a good agreement between the experimental and theoretical results when the compressibility of the polymer melt was considered for the numerical simulation. The fiber orientation states for compressible and incompressible fluids were also compared qualitatively as well as quantitatively in this study.

• Journal of the Korean Society of Industry Convergence
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• v.23 no.4_1
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• pp.531-539
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• 2020

When injection mold is repeatedly used for mass production, fatigue phenomenon due to cyclic stress may occur. The surface and interior of structure might be damaged due to cyclic stress or strain. The objective of this study was to analyze failure of SCM435 high-tension bolts connecting upper and lower parts of a three-stage injection molding machine. These bolts have to undergo an accurate heat treatment to prevent the formation of chromium carbide and the action of dynamic stresses. Bolts were fractured by cyclic bending stress in the observation of ratchet marks and beach marks. Damaged specimen showed an acicular microstructure. Impurity was observed. Chromium carbide was observed near the crack origin. Both shape parameters of the Vickers hardness were similar. However, the scale parameter of the damaged specimen was about 20% smaller than that of the as-received specimen. Much degradation occurred in the damaged specimen. Bolts should undergo an accurate heat treatment to prevent the formation of chromium carbide. They must prevent the action of dynamic stresses. Bolts need accurate tightening and accuracy of heat treatment and screws need compression residual stress due to peening.

• The Journal of Korean Academy of Prosthodontics
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• v.41 no.5
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• pp.626-639
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• 2003

Statement of problem : Recently, in attempts to reinforce the acrylic resin and to reduce the polymerization shrinkage, it has been reported that adding vinyloligo-silsesquioxane (vinyl-POSS) to PMMA significantly compensates for polymerization shrinkage and somewhat increases the fracture resistance. Purpose : There haven't been any studies on abrasion that can affect the adaptation of the denture in long-term use. In this study abrasion resistance was compared between acrylic resin with vinyl-POSS and commercialized acrylic resin for denture base. In addition, the difference in abrasion resistance according to molding methods was compared. Material and method : Using PaladentR 20 including vinyl-POSS. PaladentR 20, Lucitone 199R, SR IvocapR, denture bases were fabricated using compression molding technique and continuous-pressure injection technique. Surface hardness and abrasion were measured for each group, and the worn surfaces were observed under a scanning electron microscope. Results : 1. When surface hardness was measured for each material and molding technique, there was no statistically significant difference among the materials. (p<0.05) 2. When same denture base material and molding technique were used, the abrasion due to toothpaste solution was 5 times as severe as the abrasion due to soap solution. 3, When toothpaste solution was used, the abrasion decreased in the order of PaladentR20, PaladentR 20 including vinyl-POSS, SR IvocapR, and Lucitone 199R. However statistically significant difference was seen only among PaladentR 20, SR IvocapR, and Lucitone 199R. (p<0.05). 4. When soap solution was used, the abrasion was more severe in PaladentR 20 and including vinyl-POSS PaladentR 20 groups than in SR IvocapR and Lucitone 199R groups. (p<0.05). Conclusion : Addition of vinyl-POSS doesn't improve the abrasion resistance, and the abrasion resistance was similar to those of existing materials. Additional studies under different conditions are needed. For clinical application of vinyl-POSS, further investigations with different requirements and conditions are necessary.

• Proceedings of the Korean Magnestics Society Conference
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• 2013.12a
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• pp.95-95
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• 2013

The NdFeB magnet can be classified into the sintered magnet and bonded magnet. The former has superior magnet characteristics but the degree of freedom in shape is highly restricted, whereas the latter has a high degree of freedom, but its magnet characteristics are inferior to the former. When a NdFeB magnet is used at the elevated temperature, part of Nd must be replaced with a high priced Dy to increase its coercive force. For these reasons, a Dy free and high performance NdFeB bonded magnet is desired strongly. The author successfully developed a Dy free NdFeB anisotropic bonded magnet based on discovery of new phenomena called as d-HDDR reaction and its mass production process such as a thermally balanced hydrogen reaction furnace, micro capsuled powder, compression molding / injection molding under magnetic field, magnetic die and so on. Applied to DC brush seat motor for automotive use, the motor has become 50% small in size and weight. The commercialization of a half sized motor for automotive use has been realized up to the market share of 30%. At present, its commercialization is extending to various types of motors such as power tool, ABS motor, wiper motor, window motor, electric bike power motor, and compressor motor. It is expected that the applications will be increasingly enlarged to EV motor, wind generator, EPS motor, washing machine, and glass cutting machine. This innovative technology has realized Dy free high performance magnet and mudt make big contribution to not only rare element strategies but also energy conservation.