• Journal of Korea Foundry Society
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• v.27 no.1
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• pp.31-35
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• 2007

In order to develop the semi-solid forming technology for magnesium alloy the rheological and thixotropic behavior of Mg alloy slurry with varying shear rates and cooling rates was investigated and simulated with considering the viscosity based on microstructures and processing variables. The viscosity of slurry of Mg alloy (AZ91D) in semi-solid region was exponentially increased with a solid fraction, and was decreased with increasing a shear rate. In order to analyze precisely the rheological behavior, the ANYCAST program modified with the Carreau model and the different heat transfer coefficient between the cast and mold was used to simulate the flow behavior of Mg semi-solid slurry during the injection into a casting mold in a high pressure diecasting machine. The simulated rheological behavior of Mg alloy slurry was matched well with the experimental results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.111-114
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• 2005

Experimental and numerical studies were carried out in order to investigate the processability and the transcriptability of the injection molding of micro structures. For this purpose, we designed a mold insert having micro rib patterns on a relatively thick base part. Mold insert has a base of 2mm thickness, and has nine micro ribs on that base plate. Width and height of the rib are $300{\mu}m\;and\;1200{\mu}m$, respectively. We found a phenomenon similar to 'race tracking', due to 'hesitation' in the micro ribs. As the melt flows, it starts to cool down and melt front located in the ribs near the gate cannot penetrate further because the flow resistance is large in that almost frozen portion. When the base is totally filled, the melt front away from the gate is not frozen yet. Therefore, it flows back to the gate direction through the ribs. Consequently, transcriptability of the rib far from the gate is better. We also verified this phenomenon via numerical simulation. We further investigated the effects of processing conditions, such as flow rate, packing time, packing pressure, wall temperature and melt temperature, on the transcriptability. The most dominant factor that affects the flow pattern and the transcriptability of the micro rib is flow rate. High flow rate and high melt temperature enhance the transcriptability of micro rib structure. High packing time and high packing pressure result in insignificant dimensional variations of the rib. Numerical simulation also confirms that low flow rate causes a short shot of micro ribs and high wall temperature helps the filling of the micro ribs.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.129-135
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• 2021

Injection molding is a manufacturing method of melting the polymer resin and injecting it into a mold to molding it into the desired form. Due to the short molding time and outstanding formability, complex products can be shaped with high precision and it is the most widely used polymer molding method. However, there may be areas that are not filled depending on the location of the injection gate where polymer resin is injected. Formability is determined by deformation and surface precision due to the impact of residual stress after molding. Hence, choosing the location of the injection gate is very important and molding analysis of injection molding is essential to reduce the cost of the mold. This study evaluated the injection formability based on the location of the injection gate of the vertical machining center ATC tool port using injection molding analysis and the results were compared and analyzed. Injection molding analysis was conducted on filling, packing, and deformation according to the location of the gate of the ATC tool port. From each injection gate location, filling time, pressure, and maximum deformation were compared. At gate 2, conditions of molding time and the location of the gate were far superior in production and quality. Gate 2 produced the smallest deformation of 0.779mm with the best quality.

• Design & Manufacturing
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• v.13 no.3
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• pp.35-40
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• 2019

As the consumer market in the cosmetic, vehicle manufacturing and aerospace industries grows, the demand for manufacturing industries using on injection mold technology. Also, such manufacturing technology of metal machining is expensive, and the shape is limited. Cosmetic cushion fact products are divided into outer relevant to the exterior of the product and inner containers containing the actual contents. In the case of the inner container, it needs to be combined with the upper and lower cases. As environmental regulations are strengthened internationally, the use of a large number of component parts can result in significant losses in recycling and economics. Therefore, this study aims to perform injection molding analysis through injection molding simulation to develop a cushion fact container that can be recycled through the unification of products and materials using polypropylene to cope with environmental regulations. In the case of injection molding conditions, Injection Time(sec): 4.5, Cooling Time(sec): 13, Resin Temperature($^{\circ}C$): 240, and Pressure(MPa): 30 were determined. The results of injection molding simulation according to the two design methods were compared with the sync mark which shows the problem of filling and injection molding.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.1
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• pp.62-75
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• 2001

The design and manufacture of injection molded polymeric parts with desired properties is a costly process dominated by empiricism including repeated modification of actual tooling. This paper presents and expert design evaluation system which can predict the mechanical performance of a molded product and diagnose the design before the actual mold is machined. The knowledge-based system synergistically combines a rule-based expert system with CAE programs. An iterative boundary pressure reflection method(IBPR) is developed to automate the cavity filling simulation program and to predict thermo-mechanical properties of a molded part precisely. Mathematical models of weldline and frozen-in molecular orientation are established to determine the spatial variation of microstructural anisotropies of a molded part from the result of cavity filling simulation. The strength ellipse is devised as and index which represents th spatial distribution of the microstructural anisotropies of a molded part, Heuristic knowledge of injection molding, flow simulation, and mechanical performance prediction is formalized as rules of an expert consultation system. The expert system interprets the analytical results of the process simulation, predicts the performance, evaluates the design and generates recommendations for optimal design alternative.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.3
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• pp.370-376
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• 2011

Recently, the application range of plastic gears is widely expanding by the development of engineering plastics with good mechanical properties. Plastic gears have excellent performances such as light weight, water resistance and vibration absorbing ability for metallic gears. In this study, the optimization of injection molding process was done for the large disk type plastic gears of auto phoropter. Design Of Experiment (Taguchi method) was adopted to find a tendency of molding conditions that influence the flatness of disk type gear. Four main factors for molding conditions were selected based on injection temperature, filling time, packing pressure and mold temperature. Also, Filling, packing and cooling analyses were carried out to evaluate Z directional deflection of large disk type gear by using the simulation software (Moldflow) based on the DOE. From the results, it was found that the injection temperature and packing pressure are the most sensitive parameters for the Z directional deflection of large disk type gears.

• Journal of the Semiconductor & Display Technology
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• v.2 no.1
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• pp.7-9
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• 2003

In order to predict the moldability of an injection molded part, a simulation of filling is needed. Short shot is one of the most frequent troubles encountered during injection molding process. The adjustment of process conditions is the most economic way to troubleshoot the problematic short shot in cost and time since the mold doesn't need to be modified at all. But it is difficult to adjust the process conditions appropriately in no times since it requires an empirical knowledge of injection molding. In this paper, the intelligent CAE system synergistically combines fuzzy-neural network(FNN) for heuristic knowledge with CAE programs for analytical knowledge. To evaluate the intelligent algorithms, a cellular phone flip has been chosen as a finite element model and filling analyses have been performed with a commercial CAE software. As the results, the intelligent CAE system drastically reduces the troubleshooting time of short shot in comparison with the expert's conventional way which is similar to the golden section search algorithm.

• Proceedings of the Korean Society Of Semiconductor Equipment Technology
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• 2002.11a
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• pp.127-129
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• 2002

In order to predict the moldability of an injection molded part, a simulation of filling is needed. Short shot is one of the most frequent troubles encountered during injection molding process. The adjustment of process conditions is the most economic way to troubleshoot the problematic short shot in cost and time since the mold doesn't need to be modified at all. But it is difficult to adjust the process conditions appropriately in no times since it requires an empirical knowledge of injection molding. In this paper, the intelligent CAE system synergistically combines fuzzy-neural network(FNN) for heuristic knowledge with CAE programs for analytical knowledge. To evaluate the intelligent algorithms, a cellular phone flip has been chosen as a finite element model and filling analyses have been performed with a commercial CAE software. As the results, the intelligent CAE system drastically reduces the troubleshooting time of short shot in comparison with the expert's conventional way which is similar to the golden section search algorithm.

• Restorative Dentistry and Endodontics
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• v.18 no.1
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• pp.1-26
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• 1993

The purpose of this study was to investigate the effect of acid etching on the surface appearance and fracture toughness of five glass ionomer cements. Five kinds of commercially available glass ionomer cements including chemical curing filling type, chemical curing lining type, chemical curing metal reinforced type, light curing tilling type and light curing lining type were used for this study. The specimens for SEM study were fabricated by treating each glass ionomer cement with either visible light curing or self curing after being inserted into a rubber mold (diameter 4mm, depth 1mm). Some of the specimens were etched with 37% phosphoric acid for 0, 15, 30, 60, go seconds, at 5 minutes, 1 hour and 1 day after mixing of powder and liquid. Unetched ones comprised the control group and the others were the experimental groups. The surface texture was examined by using scanning electron microscope at 20 kV. (S-2300, Hitachi Co., Japan). The specimens for fracture toughness were fabricated by curing of each glass ionomer cement previously inserted into a metal mold for the single edge notch specimen according to the ASTME399. They were subjected to a three-point bend test after etching for 0, 30, 60, and 90 seconds at 5 minutes-, 1 hour-and 1 day-lapse after the fabrication of the specimens. The plane strain fracture toughness ($K_{IC}$) was determined by three-point bend test which was conducted with cross-head speed of 0.5 mm/min using Instron universal testing machine (Model No. 1122) following seven days storage of the etched specimens under $37^{\circ}C$, 100% humidity condition. Following conclusions were drawn. 1. In unetched control group, crack was present, but the surface was generally smooth. 2. Deterioration of the surface appearance such as serious dissolving of gel matrix and loss of glass particles occured as the etching time was increased beyond 15 s following Immediate etching of chemical curing type of glass ionomer cements. 3. Etching after 1 h, and 1 d reduced surface damage, 15 s, and 30s etch gave rough surface appearance without loss of glass particle of chemical curing type of glass ionomer cements. 4. Light curing type glass ionomer cement was etched by acid, but there was no difference in surface appearances according to various waiting periods. 5. It was found that the value of plane stram fracture toughness of glass ionomer cements was highest in the light curing filling type as $1.79\;MNm^{-1.5}$ followed by the light curing lining type, chemical curing metal reinforced type, chemical curing filling type and chemical curing lining type. 6. The value of plane stram fracture toughness of the chemical curing lining type glass ionomer cement etched after 5 minutes was lower than those of the cement etched after 1 hour or day or unetched (P < 0.05). 7. Light curing glass ionomer cement showed Irregular fractured surface and chemical curing cement showed smooth fractured surface.

• Journal of Korea Foundry Society
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• v.29 no.1
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• pp.33-37
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• 2009

Cartesian grid system has mainly been used in the casting simulation even though it does not nicely represent sloped and curved surfaces. These distorted boundaries cause several problems. A special treatment is necessary to clear these problems. In this paper, we propose a new method that can consider the cutting cells which are cut by casting and mold based on the partial cell treatment (PCT). This method provides a better representation of geometry surface and will be used in the computation of velocities that are defined on the cell boundaries in the Cartesian grid system. Various test examples for several casting process were computed and validated. The analysis results of more accurate fluid flow pattern and less momentum loss owing to the stepped boundaries in the Cartesian grid system were confirmed. By using the cut cell method, performance of computation gets better because of reducing the whole number of meshes.