• Journal of Korean Society of Industrial and Systems Engineering
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• v.42 no.1
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• pp.1-7
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• 2019

In the modern industrial period, the introduction of mass production was most important progress in civilization. Die-casting process is one of main methods for mass production in the modern industry. The aluminum die-casting in the mold filling process is very complicated where flow momentum is the high velocity of the liquid metal. Actually, it is almost impossible in complex parts exactly to figure the mold filling performance out with the experimental knowledge. The aluminum die-castings are important processes in the automotive industry to produce the lightweight automobile bodies. Due to this condition, the simulation is going to be more critical role in the design procedure. Simulation can give the best solution of a casting system and also enhance the casting quality. The cost and time savings of the casting layout design are the most advantage of Computer Aided Engineering (CAE). Generally, the relations of casting conditions such as injection system, gate system, and cooling system should be considered when designing the casting layout. Due to the various relative matters of the above conditions, product defects such as defect extent and location are significantly difference. In this research by using the simulation software (AnyCasting), CAE simulation was conducted with three layout designs to find out the best alternative for the casting layout design of an automotive Oil Pan_BJ3E. In order to apply the simulation results into the production die-casting mold, they were analyzed and compared carefully. Internal porosities which are caused by air entrapments during the filling process were predicted and also the results of three models were compared with the modifications of the gate system and overflows. Internal porosities which are occurred during the solidification process are predicted with the solidification analysis. And also the results of the modified gate system are compared.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.3
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• pp.291-298
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• 2014

This study uses two numerical approaches to analyze the filling behavior of micro patterns on micro-injection molding for V-grooves pattern which cannot be simulated with conventional CAE packages. The parametric studies have been performed to examine the fidelity of micro patterns with respect to temperature, pressure, inlet velocity and pattern location on the mold according to the boundary condition from the macro pressure and velocity data which can be obtained by conventional CAE packages. Through these numerical approaches, the filling behavior of polymer melt in micro patterns can be understood, the quality of replication can be predicted, and the V-groove pattern can be shaped uniformly during the process of injection molding.

• Design & Manufacturing
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• v.6 no.1
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• pp.1-4
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• 2012

Plastic products are producted more than 70% of total processes in the injection molding. The injection molding process has 4 processes such as filling, packing, cooling and ejecting. It spends most of times in the cooling process. Therefore, it is important to control the mold temperature in producing plastic products. The time and system of cooling affect the product's quality and productivity. Especially, cooling time has about 60% of total injection cycle time. Therefore, we can improve a productivity by shortening cooling time. In this study, it was made a comparative study about cooling of linear channels and baffles and observed the variation of mold temperature on the coolant's temperature. As the result, the linear channel's cooling rate had faster than baffles and as coolant's temperature was increased, difference of cooling time was increased. Result of this study will be used widely to design for cooling system of injection mold.

• Elastomers and Composites
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• v.55 no.2
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• pp.120-127
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• 2020

In this study, molding shrinkage of PPS resin was investigated. Two types of PPS resins with differing glass fiber and calcium carbonate content were used for this purpose. To observe mold shrinkage, molding conditions based on injection temperature, injection speed, and the position of the cushion were selected. Circular and rectangular specimens were used for the study model. Injection molding simulation was performed to predict the filling pattern and mold shrinkage, and the simulation results were compared with the experimental conclusions. It was observed that the mold shrinkage showed the highest shrinkage (distributed from 0.05% to 0.32%) dependence on the injection temperature, and the lowest shrinkage (distributed from 0.05% to 0.31%) dependence on the injection speed. The role of the position of the cushion in mold shrinkage was difficult to observe. The results of the simulation mostly agreed with the experimental results; however, for some molding conditions, the mold shrinkage in the simulation was overestimated as compared to that in the experiment.

• Journal of Power System Engineering
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• v.12 no.6
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• pp.78-82
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• 2008

Plastic gears are more and more widely used in many industrial machine elements. Plastic gear has higher properties such as light weight, wear resistance, and vibration absorbing ability than metallic gears. But, in case of using an inaccurate plastic gear, its tooth breakage happen and fatigue life is shortened due to increase of applying load and temperature rising on the tooth flank. Inaccuracy of plastic gears such as pitch circle roundness and tooth profile generates vibration and noise. In this study, an internal plastic gears which is molded by a new injection mold structure are developed. The new mold structure is called the HR3P(hot runner type 3plate mold) that has an improved runner system in order to have good filling balance. As a result from this study, an internal gear with very accurate roundness was developed by using design of experiment.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.111-114
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• 2008

The Injection molding is used more than 70% of total production in plastic products. The injection molding process has 4 processes such as filling, packing, cooling and ejecting. It spends most of times in the cooling process. Therefore, it is important to control the mold temperature in producing plastic products. The cooling system and time affect the product's quality and productivity. Especially, cooling time has about 60% of total injection cycle time. Therefore, we can improve a productivity by shortening cooling time. In this study, the rapid cooling system was developed and performed a efficiency test. This system could refrigerate coolant to $1^{\circ}C$ and had to need 10 minutes for normal operating. However, if response time of temperature controller and sensor will be increased, the performance of this system will increase.

• Journal of Korea Foundry Society
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• v.12 no.5
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• pp.378-389
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• 1992

A numerical model based on the SOLA-VOF method, which can calculate the transient free-surface configuration of the melt, has been developed in order to analyze melt flow in the investment mold. The computational results were compared with experimental results obtained from pure aluminum investment casting. Heat transfer analysis, with and without consideration of melt flow effect has been performed. It can be concluded that analysis of melt flow in the investment mold, provides the optimum conditions for gating design. It also enables more precise solidification simulation, since heat loss, while filling the thin and complex investment mold, plays an important role in determining the solidification sequence.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.9-12
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• 2005

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filing difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation fur both the conventional molding and the RTR molding processes

• Design & Manufacturing
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• v.16 no.3
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• pp.44-49
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• 2022

In this study, the simulation of the resin transfer molding process method using MoldFlow has been investigated. This work explains the thermoset material model, fabric permeability model, the flow model and the cure model. It has been shown that the simulation result can predict filling and cure performances.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.7
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• pp.561-567
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• 2014

Precision injection mold is an essential element in order to manufacture small and precision plastic lenses used for phone camera. There are many critical factors to meet the requested specifications of high quality plastic lenses. One of the main issues to realize high quality is minimizing decenter value, which becomes more critical as pixel numbers increases. This study suggests the method to minimize decenter value by modifying ejecting structure of the mold. Decenter value of injection-molded lens decreased to 1 ${\mu}m$ level from 5 ${\mu}m$ by applying suggested ejecting method. Also, we also developed BIS (Built-in Sensor) based smart mold system, which has pressure and temperature sensors inside of the mold. Pressure and temperature profiles from cavities are obtained and can be used for deduction of optimal injection molding condition, filling imbalance evaluation, status monitoring of injection molding and prediction of lens quality.