• Transactions of the Korean Society of Automotive Engineers
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• v.25 no.1
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• pp.35-41
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• 2017

The use of engineering plastics in automotive components is increasing with the trend towards improving the car strength and reducing weight. Among the different choices of materials, engineering plastic emerged as the necessary material for achieving lower costs, reduced weight and improved production efficiency. To produce the automotive parts, it is important to predict defect and validation of injection molding prior to design. Injection molding analysis and structural analysis are widely applied as a part of the design process when developing automotive parts. Injection molding analysis, in particular, involves a highly complicated mechanism that requires deep knowledge of polymer properties as well as an analytic approach different from that used for a general isotropic material when the molded material is used as a structural material. This is because the parts made of polymer have pre-stress factors such as intrinsic deformation and residual stress. The most important factors for injection molded plastic products are injection molding condition and cavity design, taking into account ease of molding, mass production and application. Despite optimal injection molding conditions and cavity design, however, glass fiber orientation is critically linked to strength reduction. The application of injection molding and structural coupled analysis provides a low-cost solution for product molding and structural validation, all prior to the actual molding. The purpose of this study involves the validation, pre-study, and solution of defect in injection-molded polymer automotive parts using the simulation software for injection molding and structural coupled analysis. Finally, this thesis provides validation of an injection molding and structural coupled analytic mechanism that can demonstrate the effect of glass fiber orientation on mechanical strength. Design improvement ideas for the injection molded product of PPS (Poly Phenylene Sulfide)+40% glass fiber are also suggested.

• Journal of ILASS-Korea
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• v.17 no.4
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• pp.171-177
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• 2012

To understand oxygenated fuel characteristics including spray penetration length and spray angle at a real engine ambient pressure condition, DME was injected into a high pressure chamber by a piezo injector common rail system. The piezo injector common rail system was able to apply steady injection pressure, rapid response, and accurate injection quantity. Injection and ambient pressure were varied to confirm a relation with spray form. Using a direct photographing technique, development process of DME spray was captured. DME injection quantity was enlarged linearly as increasing of the injection pressure. In the high pressure chamber, when the injection pressure was enlarged the penetration length and velocity were increased due to a big momentum of fuel particle at the same ambient pressure. When ambient pressure was increased, the DME spray penetration length and velocity were decreased since the high ambient density of nitrogen was acted as a resistance. Although the ambient pressure and injection pressure were varied, each case of spray angle was almost same since the spray angle had a connection of the injector nozzle geometry.

• 한국연소학회:학술대회논문집
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• 2014.11a
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• pp.101-102
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• 2014

Rising oil price and environmental problems are causing automotive industry to increase fuel efficiency. Improved fuel efficiency in gasoline engine was made possible by development of DISI gasoline engine. Since fuel is injected inside cylinder directly, in-cylinder temperature can be reduced than multi-port injection engine and this leads to increased compression ratio. However, engine performance is largely dependent on mixture formation process due to in-cylinder fuel injection. Especially for spray guided and air guided DISI gasoline engine, injection direction is important factor to mixture preparation. It is because interaction between intake flow and spray affect fuel-air mixture. Hence, in this study, mixture formation characteristics were analyzed by varying injection direction using KIVA 3V release2 code. Residual gas was considered for assuming combustion. Therefore, initial condition for in-cylinder temperature was set equal to the end state of exhaust stroke of combustion cycle. Since angle between intake air flow direction and spray direction affects fluid flow and evaporation field, mixture distribution was affected by fuel injection direction dominantly.

• Journal of ILASS-Korea
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• v.10 no.1
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• pp.17-23
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• 2005

Even though a relatively complete knowledge base has been established for diesel sprays, much of the knowledge cannot be directly translated to correlate the characteristics of gasoline spray. The macroscopic characteristics of gasoline impingement spray was investigated with photographic and image processing technique by Particle Motion Analysis System. The injector with single hole nozzle diameter of 0.28 mm was used in this experiment and the injection duration was selected as 10 msec. The injection pressure with 0.3, 0.35, and 0.4 MPa, impingement distance or 70, 100 and 130m, impingement angle or 0.15, 30 and $45^{\circ}$ were employed for the variables to affect the spray characteristics of impinging spray. It is clear that there is the analogy on the spray tip penetration between the gasoline impinging jet and diesel free jet. The spray tip penetration of impinging gasoline spray is proportional to the quarter power of the time after start of injection. The maximum height of impinging gasoline spray is also proportional to the quarter power of the time regardless of impingement distance, impingement angle and injection pressure. In addition, the effect of impingement angle on the spray tip penetration is significant according to the time after start of injection, even though there is minor effect in the initial stage of time after start of injection. Moreover, there is no remarkable effect of injection pressure on the spray tip Penetration under the experimental condition used in this study.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.76-81
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• 2004

Injection molding is the most widely used process fir the industrial forming of plastic articles. During an injection molding process of composites, the fiber-matrix separation and fiber orientation are caused by the flow of molten polymer/fiber mixture. As a result. the product tends to be nonhomogeneous and anisotropic. Hence, it is very important to clarify the relations between separation orientation and injection molding conditions. So far, there is no research on the measurement of fiber orientation using image processing. In this study, the effects of fiber content ratio and molding condition on the fiber orientation-angle distributions are studied experientially. Using the image processing method, the fiber orientation distribution of welding pars in injection-molded products is assessed. And the effects of fiber content and injection mold shapes on the fiber orientation in case of fiber reinforced polymeric composites are studied experimentally.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.1
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• pp.9-13
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• 2014

The molding process can be divided into five separate steps: plastification, injection, holding, cooling, and finally ejection. In the plastic injection molding, the effect factor such as mold temperature, injection speed, packing pressure and inhomogeneous cooling under packing process affects both the article dimension and physical characteristics. Especially, the packing pressure is the most critical factor to affect molded articles quality among the packing parameters. In this paper, the CAE simulation considering the molding condition is performed to predict the faulty cause which appears in the packing process between cavities of injection molding machine. From the results of CAE simulation, the packing phenomena according to the product form and the gate position was investigated to improve the article quality and minimize the various molding defects. The effect of packing pressure and gate number on the injection molding was discussed.

• Korea-Australia Rheology Journal
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• v.16 no.1
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• pp.27-33
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• 2004

Application of gas assisted injection molding has been expanded during last two decades because of many advantages such as design flexibility, dimensional stability, reduction of machine tonnages, and so on. However, the surface defects including hesitation mark and gloss difference are observed for thick parts. Difficulties in lay-out of the gas channel and processing condition are another disadvantages. Liquid gas assisted injection molding(LGAIM), in which a liquid with a boiling point lower than the temperature of the polymer melt is injected into the melt stream, and travels with the melt into the mold where it vaporizes and pushes the melt downstream and against the cavity walls to create hollow channels within the part, is a good alternative of the conventional gas assisted injection molding especially in manufacturing simple and very thick parts. Though this is a new frontier of the innovation in the injection molding industry, there is no guideline for the design and processing conditions. In this paper, theoretical analysis has been made to describe the hollow formation dynamics in LGAIM. This model provides an insight into LGAIM process: explains why LGAIM has advantages over conventional gas assisted injection molding, and gives a guideline for the design and processing conditions.

• Journal of ILASS-Korea
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• v.12 no.2
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• pp.115-122
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• 2007

The spray characteristics and drop size measurements have been experimentally studied in liquid jets injected into subsonic crossflow. With water as fuel injection velocity, injection angle and atomize. internal flows were varied to provide of jet operation conditions. The injector internal flow was classified as three modes such as a non-cavitation flow, cavitation, and hydraulic flip flows. Pulsed Shadowgraph Photography measurement was used to determine the spatial distribution of the spray droplet diameter in a subsonic crossflow of air. And this study also obtains the SMD (Sauter Mean Diameters) distribution by using Planar Liquid Laser Induced Fluorescence technique. The objectives of this research are get a droplet distributions and drop size measurements of each condition and compare with the other flow effects. As the result, This research has been showned that droplet size were spatially dependent on air-stream velocity, fuel injection velocity, injection angle effects, and normalized distance from the injector exit length(x/d, y/d). There are also different droplet size characteristics between cavitation, hydraulic flip and the non-cavitation flows.

• Proceedings of the KSME Conference
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• 2001.11a
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• pp.778-784
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• 2001

Injection molding is a very important industrial process for the manufacturing of plastics objects. During an injection molding process of composites, the fiber-matrix separation and fiber orientation are caused by the flow of molten polymer/fiber mixture. As a result, the product tends to be nonhomogeneous and anisotropic. Hence, it is very important to clarify the relations between separation orientation and injection molding conditions. So far, there is no research on the measurement of fiber orientation using image processing. In this study, the effects of fiber content ratio and molding condition on the fiber orientation-angle distributions are studied experimentally. Using the image processing method, the fiber orientation distribution of weld-line parts in injection-molded products is assessed. And the effects of fiber content and injection molding conditions on the fiber orientation functions are also discussed.

• Journal of Mechanical Science and Technology
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• v.14 no.2
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• pp.236-250
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• 2000

Compression ignition direct injection diesel engines employed a high pressure injection system have been developed as a measure to improve a fuel efficiency and reduce harmful emissions. In order to understand the effects of the pressure variation, many experimental works have been done, however there are many difficulties to get data in engine condition. This work gives numerical results for the high pressure effects on spray characteristics in wide or limited space with near walls. The gas phase is modelled by Eulerian continuum conservation equations of mass, momentum, energy and fuel vapour fraction. The liquid phase is modelled using the discrete droplet model approach in Lagrangian form and the drop behavior on a wall is calculated with a new droplet-wall interaction model based on the experiments observing individual drops. The droplet distributions, vapour fractions and gas flows are shown in various injection pressure cases. In free spray case which the injection spray has no wall impaction, the spray dispersion and vapour fraction increase and drop sizes decrease with increasing injection pressure. The same phenomena appears more clearly in wall impaction cases.