• Composites Research
• /
• v.16 no.6
• /
• pp.10-15
• /
• 2003

In RTM process, the content of microvoids can be critical due to the fact that the presence of microvoids degrades mechanical properties on the fabricated composite parts. The present paper proposes an experimental method of observation in void formation and transport. VARTM processes are performed under observation with a digital video camera and then the microvoid formation in the flow front and transport are videotaped and observed both in channels and tows. The obtained data are used in the mathematical model in order to determine the model constants. Experimental results and expected results from the mathematical model show a good agreement with each other.

• Design & Manufacturing
• /
• v.17 no.1
• /
• pp.48-55
• /
• 2023

In this study, on the structure simulation for manufacturing a high strength/light weight 48V battery housing for a mild hybrid vehicle was conducted. Compression analysis was performed in accordance with the international safety standards(ECE R100) for existing battery housings. The effect of plastic materials on compressive strength was analyzed. Three models of truss, honeycomb and grid rib for the battery housing were designed and the strength characteristics of the proposed models were analyzed through nonlinear buckling analysis. The effects of the previous existing rib, double-sided grid rib, double-sided honeycomb rib and double-sided grid rib with a subtractive draft for the upper cover on the compressive strength in each axial direction were examined. It was confirmed that the truss rib reinforcement of the battery housing was very effective compared to the existing model and it was also confirmed that the rib of the upper cover had no significant effect. In the results of individual 3-axis compression analysis, the compression load in the lateral long axis direction was the least and this result was found to be very important to achieve the overall goal in designing the battery housing. To reduce the weight of the presented battery housing model, the cell molding method was applied. It was confirmed that it was very effective in reducing injection pressure, clamping force and weight.

• Journal of Korean Society for Quality Management
• /
• v.52 no.1
• /
• pp.43-56
• /
• 2024

Purpose: The injection molding process, crucial for plastic shaping, encounters difficulties in sustaining product quality when replacing injection machines. Variations in machine types and outputs between different production lines or factories increase the risk of quality deterioration. In response, the study aims to develop a system that optimally adjusts conditions during the replacement of injection machines linked to molds. Methods: Utilizing a dataset of 12 injection process variables and 52 corresponding sensor variables, a predictive model is crafted using Decision Tree, Random Forest, and XGBoost. Model evaluation is conducted using an 80% training data and a 20% test data split. The dependent variable, classified into five characteristics based on temperature and pressure, guides the prediction model. Bayesian optimization, integrated into the selected model, determines optimal values for process variables during the replacement of injection machines. The iterative convergence of sensor prediction values to the optimum range is visually confirmed, aligning them with the target range. Experimental results validate the proposed approach. Results: Post-experiment analysis indicates the superiority of the XGBoost model across all five characteristics, achieving a combined high performance of 0.81 and a Mean Absolute Error (MAE) of 0.77. The study introduces a method for optimizing initial conditions in the injection process during machine replacement, utilizing Bayesian optimization. This streamlined approach reduces both time and costs, thereby enhancing process efficiency. Conclusion: This research contributes practical insights to the optimization literature, offering valuable guidance for industries seeking streamlined and cost-effective methods for machine replacement in injection molding.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.10a
• /
• pp.269-272
• /
• 2005

For the three decades, the mold-filling of injection molding process was modeled as Hele-Shaw model. However, this model can not consider the 3D effect. In this paper, numerical simulations of three dimensional mold-filling during the filling phase were performed. The governing equations were discretized by segregated finite element method, which used equal order interpolation for pressure and velocity fields. The iterative linear equation solver (JCG, SOR) was employed for the solution of the momentum and pressure equations. Volume of Fluid (VOF) was employed for the melt front advancement. To check the validity of the numerical results, the results were compared with the experimental ones. The agreements between the experiment and the numerical results were found to be satisfactory.

• Journal of Powder Materials
• /
• v.6 no.1
• /
• pp.88-95
• /
• 1999

The purpose of this study is to investigate the manufacturing feasibility of WC-Co milling inserts via Powder Injection Molding (PIM) process. WC-Co is used in a wide variety of cutting tools due to its high hardness, stiffness, compressive strength and wear resistance properties. WC-Co parts for a high stress application were conventionally produced by the press and sinter method, which were Iimited to 2 dimensional shapes. Manufacturing WC-Co parts for a high stress application by PIM implies that tool efficiency can be highly improved due to increased freedom is design. P30 grade WC powder (WC-Co-TiC-TaC system) was mixed with RIST-5B133 binder and injection molded into milling inserts (Taegu Tech. Model WCMX 06T 308). The mean grain size of the powder was about 0.8$\mu$m. Injection molded specimens were debound by solvent extraction and thermal degradation method at various conditions. The specimens were sintered at 140$0^{\circ}C$ for 1 hr in vacuum. Carbon content, weight loss, dimensional change, and macro defects of the specimen were carefully monitored at each stage of the PIM process. PIMed WC-Co milling inserts reached 100% full density after sinteing. Its mechanical properties and micro-structures were comparable with the press and sintered milling insert. Carbon content of the sintered WC-Co insert was mainly determained by the atmosphere of thermal debinding. By controlling powder loading and injection molding condition, dimensional accuracy could be obtained within 0.4%. We confirm that PIM can not only be an alternative manufacturing method for WC-Co parts economically but also provide a design freedom for more effieient cutting tools.

• Design & Manufacturing
• /
• v.15 no.1
• /
• pp.48-56
• /
• 2021

The quality of products produced by injection molding process is greatly influenced by the process variables set on the injection molding machine during manufacturing. It is very difficult to predict the quality of injection molded product considering the stochastic nature of manufacturing process, because the process variables complexly affect the quality of the injection molded product. In the present study we predicted the quality of injection molded product using Artificial Neural Network (ANN) method specifically from Multiple Input Single Output (MISO) and Multiple Input Multiple Output (MIMO) perspectives. In order to train the ANN model a systematic plan was prepared based on a combination of orthogonal sampling and random sampling methods to represent various and robust patterns with small number of experiments. According to the plan the injection molding experiments were conducted to generate data that was separated into training, validation and test data groups to optimize the parameters of the ANN model and evaluate predicting performance of 4 structures (MISO1-2, MIMO1-2). Based on the predicting performance test, it was confirmed that as the number of output variables were decreased, the predicting performance was improved. The results indicated that it is effective to use single output model when we need to predict the quality of injection molded product with high accuracy.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
• /
• 2002.10b
• /
• pp.333-334
• /
• 2002

Injection-compression molding parts are many cases with complicated boundary condition which is difficult to analysis of mold characteristics precisely. In this study, the effects of various process parameters such as multi-point gate location, initial charge volume, injection time and pressure have been investigated using finite element method to fomulate the melt front advancement during the mold filling process. A general governing equation for tracking the filling process during injection-compression molding is applied to volume of fluid method. To verify the results of present analysis, they are compared with those of the other paper. The results show a strong effect of processing conditions as a result of variations in the three-dimensional complex geometry model.

• Korea-Australia Rheology Journal
• /
• v.19 no.4
• /
• pp.191-199
• /
• 2007

Precision injection molding process is of great importance since precision optical products such as CD, DVD and various lens are manufactured by those process. In such products, birefringence affects the optical performance while residual stress that determines the geometric precision level. Therefore, it is needed to study residual stress and birefringence that affect deformation and optical quality, respectively in precision optical product. In the present study, we tried to predict residual stress, final shrinkage and birefringence in injection molded parts in a systematic way, and compared numerical results with the corresponding experimental data. Residual stress and birefringence can be divided into two parts, namely flow induced and thermally induced portions. Flow induced birefringence is dominant during the flow, whereas thermally induced stress is much higher than flow induced one when amorphous polymer undergoes rapid cooling across the glass transition region. A numerical system that is able to predict birefringence, residual stress and final shrinkage in injection molding process has been developed using hybrid finite element-difference method for a general three dimensional thin part geometry. The present modeling attempts to integrate the analysis of the entire process consistently by assuming polymeric materials as nonlinear viscoelastic fluids above a no-flow temperature and as linear viscoelastic solids below the no-flow temperature, while calculating residual stress, shrinkage and birefringence accordingly. Thus, for flow induced ones, the Leonov model and stress-optical law are adopted, while the linear viscoelastic model, photoviscoelastic model and free volume theory taking into account the density relaxation phenomena are employed to predict thermally induced ones. Special cares are taken of the modeling of the lateral boundary condition which can consider product geometry, histories of pressure and residual stress. Deformations at and after ejection have been considered using thin shell viscoelastic finite element method. There were good correspondences between numerical results and experimental data if final shrinkage, residual stress and birefringence were compared.

• Korean Journal of Radiology
• /
• v.22 no.7
• /
• pp.1054-1065
• /
• 2021

Objective: We implemented a novel resectable myocardial model for mock myectomy using a hybrid method of three-dimensional (3D) printing and silicone molding for patients with apical hypertrophic cardiomyopathy (ApHCM). Materials and Methods: From January 2019 through May 2020, 3D models from three patients with ApHCM were generated using the end-diastolic cardiac CT phase image. After computer-aided designing of measures to prevent structural deformation during silicone injection into molding, 3D printing was performed to reproduce anatomic details and molds for the left ventricular (LV) myocardial mass. We compared the myocardial thickness of each cardiac segment and the LV myocardial mass and cavity volumes between the myocardial model images and cardiac CT images. The surgeon performed mock surgery, and we compared the volume and weight of the resected silicone and myocardium. Results: During the mock surgery, the surgeon could determine an ideal site for the incision and the optimal extent of myocardial resection. The mean differences in the measured myocardial thickness of the model (0.3, 1.0, 6.9, and 7.3 mm in the basal, midventricular, apical segments, and apex, respectively) and volume of the LV myocardial mass and chamber (36.9 mL and 14.8 mL, 2.9 mL and -9.4 mL, and 6.0 mL and -3.0 mL in basal, mid-ventricular and apical segments, respectively) were consistent with cardiac CT. The volume and weight of the resected silicone were similar to those of the resected myocardium (6 mL [6.2 g] of silicone and 5 mL [5.3 g] of the myocardium in patient 2; 12 mL [12.5 g] of silicone and 11.2 mL [11.8 g] of the myocardium in patient 3). Conclusion: Our 3D model created using hybrid 3D printing and silicone molding may be useful for determining the extent of surgery and planning surgery guided by a rehearsal platform for ApHCM.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.34 no.5
• /
• pp.575-582
• /
• 2010

In recent years, several rapid-mold-heating techniques that can be used for the injection molding of thin-walled parts or micro/nano structures have been developed. High-frequency induction heating, which involves heating by electromagnetic induction, is an efficient method for the rapid heating of mold surfaces. The present study proposes an integrated numerical model of the high-frequency induction heating process and the resulting injection molding process. To take into account the effects of thermal boundary conditions in induction heating, we carry out a fully integrated numerical analysis that combines electromagnetic field calculation, heat transfer analysis, and injection molding simulation. The proposed integrated simulation is extended to the injection molding of a thin-wall part, and the simulation results are compared with the experimental findings. The validity of the proposed simulation is discussed according to the ways of the boundary condition imposition.