• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.46-51
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• 2012

Injection pressure, an important factor in filling process, should be minimized to enhance injection molding quality. Injection pressure can be controlled by valve gate open timing. In this work, we decided the valve gate open timing to minimize the injection pressure. To solve this design problem, we integrated MAPS-3D (Mold Analysis and Plastic Solution-3Dimension), a commercial injection molding CAE tool, to PIAnO (Process Integration, Automation and Optimization), a commercial PIDO (Process Integration, and Design Optimization) tool using the file parsing method. In order to reduce computational cost, we performed an approximate optimization using meta-models that replaced expensive computer simulations. At first, we carried out DOE (Design of Experiments) using OLHD (Optimal Latin Hypercube Design) available in PIAnO. Then, we built Kriging models using the simulation results at the sampling points. Finally, we used micro GA (Genetic Algorithm) available in PIAnO. Using the proposed design approach, the injection pressure has been reduced by 13.7% compared to the initial one. This design result clearly shows the validity of the proposed design approach.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.8
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• pp.3625-3630
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• 2013

The modularization accomplished a big contribution in cost down and assembly-time shortening and the quality increase. But few improvements were made to this design largely due to the inflexibility of steel. In recent years, door modules made of PP-LFT material is manufactured using injection molding method. As a result, the plastic door modules allow more flexibility of door shape and become lighter. Warpage is generally large in the molded plastic door carrier plate due to the limitation of gate location and the fiber orientation. So after a few test injection the mold compensation processing for the improvement of an assembly characteristic. This research was performed to determine the factors that contribute to warpage for a injection-molded door carrier plate and presented differences in three mesh types of meshing method and its results. as a result we can improve process of tooling modification can reduce process of trial and error.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.14 no.10
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• pp.4713-4718
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• 2013

Nowadays, three-dimensional computer added design(3D CAD) tool are widely and actively used for design of mechanical machine. Because using the tool is more effective to understand design concept and to collaborate with other operation than using two-dimensional design tool. In this study, the 3D CAD tool which is called I-DEAS was applied for three-dimensional modeling of main parts and assembling of modeled parts for identification the entire shape of a injection molding machine. In addition, a study was also performed regarding reduction for the weight of main plates for saving production cost and energy in the machine. A finite element method(FEM) program in I-DEAS tool was used for the improvement study. First, the current main plates were structural analysed and then the plate deformations, weak regions and stress distributions were graped. By the FEM results, the 2nd improved designing of the plates was conducted such as reinforcement or slimming of the plate wall thickness. The 2nd structural FEM was performed for verification of the redesigned plates and then the FEM results were compared with the 1st FEM's result. The weight of the main plates were averagely reduced approximately 3 - 7%. By these results, it was seemed that the improved plates have a useful availability.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.1
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• pp.92-99
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• 2014

An aspherical lens, which resolves several problems with a spherical lens,typically serves asa key part of an optical system. Generally, an aspherical lens is fabricated using a diamond turning machine or by mean of injection molding. However, residual stress and/or tool marks can arise when using a commercial fabricating method such as DTM or injection molding. A polishing process, thus, is commonly used to obtain a high-precision aspherical lens. In this study, a polishing method using MR fluid was applied to minimize several problems, in this case residual stress and the creation of tool marks, during the cutting process. The MR polishing system was developed to polish aspherical lenses. A series of experiments were performed to obtain a very fine surface roughness. PMMA (the lens material for molding) was used as a workpiece, and the gap size, magnetic field intensity, wheel speed and feed rate were selected as the parameters in this study. Finally, a very fine surface roughness of Ra=2.12nm was obtained after MR polishing.

• Journal of the Microelectronics and Packaging Society
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• v.21 no.2
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• pp.65-70
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• 2014

Warpage of top packages to form thin package-on-packages was measured with progress of their process steps such as PCB substrate itself, chip bonding, and epoxy molding. The $100{\mu}m$-thick PCB substrate exhibited a warpage of $136{\sim}214{\mu}m$. The specimen formed by mounting a $40{\mu}m$-thick Si chip to such a PCB using a die attach film exhibited the warpage of $89{\sim}194{\mu}m$, which was similar to that of the PCB itself. On the other hand, the specimen fabricated by flip chip bonding of a $40{\mu}m$-thick chip to such a PCB possessed the warpage of $-199{\sim}691{\mu}m$, which was significantly different from the warpage of the PCB. After epoxy molding, the specimens processed by die attach bonding and flip chip bonding exhibited warpages of $-79{\sim}202{\mu}m$ and $-117{\sim}159{\mu}m$, respectively.

• Korean Journal of Cleft Lip And Palate
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• v.7 no.2
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• pp.93-106
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• 2004

본 연구의 목적은 편측성 구순구개열 (UCLP) 환자에서 술전 비치조 정형장치 (presurgical nasoalveolar molding appliance, PNAM) 와 구순 봉합수술의 치조골 정형효과를 3차원 (3-D) 분석을 통하여 평가하는 것이다. 연구대상은 16명의 UCLP 환자 (평균 파열부거리: 10.46mm) 이며 PNAM 장치에 의한 치료와 rotation-advancement법에 의한 구순 봉합수술을 받았다 처음 내원시 (평균연령: $37.0{\pm}27.89$ 일), PNAM 치료를 받고 난 후이며 구순봉합수술 1달 전 (평균연령: $119.25{\pm}40.18$ 일), 구순봉합수술 2달 후 (평균연령: $190.81{\pm}42.78$ 일)에 상악의 인상을 채득하였다. 그 후 laser scanning machine (Orapix, Dimennex, Seoul, Korea) 과 3-D view software (3Dxer, Dimennex) 를 사용하여 3-D모형을 제작하였다. 선, 각도, 정중선변이, 거리, 면적 항목을 3-D 모형상에서 계측하고, 각 시기별의 차이를 비교하기 위하여 Wilcoxon signed rank test를 사용하여 분석하였다. PNAM치료 동안과 구순 봉합수술 후에도 치조골 후방부는 안정된 구조물이었다. PNAM치료에 의한 파열부 거리의 감소는 대분절 (greater segment) 의 내측 굴곡 (bending) 에 의하여 발생하였다. 대분절 (greater segment)의 전방 성장은 PNAM치료에 의하여 억제되었으나, 구순 봉합수술 후에 회복되었다. 구순 봉합수술 후에 대분절과 소분절 사이의 전방부 각도의 증가는 구순 반흔 (lip scar) 의 압력에 의한 치조골 정형 효과 때문으로 생각된다. 정중선변이는 PNAM치료에 의하여 개선되었다. PNAM치료 동안과 구순 봉합수술 후에 구개부 (palatal segment) 의 면적은 계속 증가하였다. 치조골 면적과 거리 항목의 증가는 후방부에서 크게 나타났다. 이러한 결과는 PNAM치료에 의한 치조골 정형효과는 주로 전방부에서 발생하며, 치조골의 성장은 구순 봉합수술 후에 후방부에서 주로 발생한다는 것을 의미한다.

• Korean Journal of Materials Research
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• v.22 no.5
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• pp.227-236
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• 2012

Ionomer is a thermoplastic that is composed of covalent bonds and ionic bonds. It is possible to use this material in processes such as injection molding or extrusion molding due to the material's high oil resistance, weatherproof characteristics, and shock resistance. In this study, a new ionomer having a multifunctional group was prepared by a stepwise neutralization system with the addition of acidic and salt additives. In step I, to increase the contents of the multifunctional group and the acid degree in ethylene acrylic acid (EAA), MGA was added to the ionomer resin (EAA). A new ionomer was prepared via the traditional preparation method of the ionic cross-linking process. In step II, metal salt was added to the mixture of EAA and MGA. The extrusion process was performed using a twin extruder (L/D = 40, size : ${\varphi}30$). Ionomer film was prepared for evaluation of gas permeability by using the compression molding process. The degree of neutralized and ionic cross-linked new ionomer was confirmed by FT-IR and XRD analysis. In order to estimate the neutralization of the new ionomer film, various properties such as gas permeation and mechanical properties were measured. The physical strength and anti-scratch property of the new ionomer were improved with increase of the neutralization degree. The gas barrier property of the new ionomer was improved through the introduction of an ionic site. Also, the ionic degree of cross-linking and gas barrier property of the ionomer membrane prepared by stepwise neutralization were increased.

• Journal of Powder Materials
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• v.21 no.3
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• pp.215-221
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• 2014

Translucent alumina is a potential candidate for high temperature application as a replacement of the glass or polymer. Recently, due to the increasing demand of high power light emitting diode (LED), there is a growing interest in the translucent alumina. Since the translucent property is very sensitive to the internal defect, such as voids inside or abnormal grain growth of sintered alumina, it is important to fabricate the defect-free product through the fabrication process. Powder injection molding (PIM) has been commonly applied for the fabrication of complex shaped products. Among the many parameters of PIM, the flowability of powder/binder mixture becomes more significant especially for the shape of the cavity with thin thickness. Two different positions of the gate were applied during PIM using the disc type of die. The binder was removed by solvent extraction method and the brown compact was sintered at $1750^{\circ}C$ for 3 hours in a vacuum. The flowability was also simulated using moldflow (MPI 6.0) with two different types of gate. The effect of the flowability of powder/binder mixture on the microstructure of the sintered specimen was studied with the analysis of the simulation result.

• Composites Research
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• v.29 no.1
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• pp.7-15
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• 2016

The quality of polymeric automotive parts depends highly on an injection molding process, which causes various defects, such as warpage, sink marks, weld lines, shrinkage, residual stress, etc. This study is to determine the optimum processing parameters, such as packing pressure, mold temperature, melting temperature, and packing time for the manufacture of polycarbonate buttons in cars on the basis of FEM, the Taguchi method, and analysis of variance (ANOVA). As a result, the optimum processing parameters of buttons made of polycarbonate material were obtained as follows: 140 MPa of packing pressure, $105^{\circ}C$ of mold temperature, $292.5^{\circ}C$ of melting temperature and 1 second of packing time. A gain of S/N (signal to noise) ratio, 10.2, was obtained with the optimum values. Moreover, the melting temperature was found to be the most significant factor followed by the mold temperature.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2007.06a
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• pp.57-57
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• 2007

Aspheric glass lenses have many optical advantages, for glass have superior optical performance and an aspheric form can reduce optical aberrations. Recently, the use of it is rapidly expanding as the mass production becomes possible by glass molding press and so this method is considered as the best method for fabricating an aspheric glass lens, but it is difficult to control many parameters for pressing and cooling process. Design of experiments (DOE) is a very useful tool to design and analyze complicated industrial design problems. This study investigated the pressing conditions to mold aspheric glass lenses for mega pixel phone camera module using DOE method. We have applied fractional factorial design and the response variable was set form accuracy (PV) of aspheric surface of molded lens. The results of analysis indicates that all factors expect for pressing force of each step are available for the form accuracy (PV). It was the optimum condition of the designed pressing conditions for lowering the form accuracy(PV) value of molded lens that all factors were at the low level. The form accuracy (PV) of mold and molded lens under the optimum condition are $0.85\;{\mu}m$ and $0.922\;{\mu}m$ respectively.