• Composites Research
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• v.26 no.6
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• pp.363-372
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• 2013

Numerical simulation for Resin Transfer Molding manufacturing process is attempted by using the eXtended Finite Element Method (XFEM) combined with the level set method. XFEM allows to obtaining a good numerical precision of the pressure near the resin flow front, where its gradient is discontinuous. The enriched shape functions of XFEM are derived by using the level set values so as to correctly describe the interpolation with the resin flow front. In addition, the level set method is used to transport the resin flow front at each time step during the mold filling. The level set values are calculated by an implicit characteristic Galerkin FEM. The multi-frontal solver of IPSAP is adopted to solve the system. This work is validated by comparing the obtained results with analytic solutions. Moreover, a localization method of XFEM and level set method is proposed to increase the computing efficiency. The computation domain is reduced to the small region near the resin flow front. Therefore, the total computing time is strongly reduced by it. The efficiency test is made with a simple channel flow model. Several application examples are analyzed to demonstrate ability of this method.

• The Transactions of the Korean Institute of Electrical Engineers P
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• v.52 no.1
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• pp.35-41
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• 2003

In this paper, a machine vision system for recognizing and classifying the patterns and marks engraved by die molding or laser marking on the glass panels of computer monitors is suggested and evaluated experimentally. The vision system is equipped with a neural network and an NGC pattern classifier including searching process based on normalized grayscale correlation and adaptive binarization. This system is found to be applicable even to the cases in which the segmentation of the pattern area from the background using ordinary blob coloring technique is quite difficult. The inspection process is accomplished by the use of the NGC hypothesis and ANN verification. The proposed pattern recognition system is composed of three parts: NGC matching process and the preprocessing unit for acquiring the best quality of binary image data, a neural network-based recognition algorithm, and the learning algorithm for the neural network. Another contribution of this paper is the method of generating the training patterns from only a few typical product samples in place of real images of all types of good products.

• Journal of the Korean Society of Mechanical Technology
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• v.20 no.6
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• pp.824-829
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• 2018

Molding is the root industry of the manufacturing as a means to mass-produce developed prototypes. Molds are typically divided into injection molds and press mold industries. Injection molds produce the products by injection of molten plastic into a mold, and press molds are molded and bended plate. The ejection system, such as eject pins, is used to separate the manufactured products from the mold, which involves a number of hole operations. Location, diameter and depth of holes are often tabulated and managed collectively when designing 2D drawings. The design efficiency was realized by applying CATIA Automation to the 3D model and bringing in the data of the holes in the Excel data.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.358-361
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• 2000

To reduce the leadtime for a new model according to the strict market requirements, automobile manufacturer begins to utilize 3-dimensional CAD based techniques such as DMU(Digital Mock-Up). RP(Rapid Prototyping), VE(Virtual Engineering). But, not so many satisfactory utilities have been introduced to deal with the emotional properties such as embossment on the surface of interior parts and touch from material characteristics in virtual environment. It is required to manufacture prototype parts to verify actual feeling of the passengers in real automobile. This paper suggests a methodology to enhance emotional property via embedding embossment on the surface of prototype car interior trim without deterioration of dimensional accuracy using RIM(Reaction Injection Molding) and vacuum forming method.

• Transactions of Materials Processing
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• v.24 no.2
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• pp.101-106
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• 2015

Recently, silicone is being used for LED chip lens due to its good thermal stability and optical transmittance. In order to predict residual stresses, which cause optical birefringence and mechanical warpage of silicone, a finite element analysis was conducted for the curing of silicone during molding. For the analysis of the curing process, a dynamic cure kinetics model was derived based on the results of a differential scanning calorimetry (DSC) testing and applied to the material properties for finite element analysis. Finite element simulation results showed that a step cure cycle reduced abrupt reaction heat and showed a decrease in the residual stresses.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.5
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• pp.124-131
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• 2003

As the new model development lead time becoming shorter and the market requirements becoming more strict, automobile manufacturer begins to utilize 3-dimensional CAD system based techniques such as DMU (Digital Mock-up), Rf (Rapid Prototyping), VE (Virtual Engineering) to meet the market trends. But, no satisfactory utilities have been developed yet, to represent emotional properties such as embossment on the surface of interior parts, touch originated from material characteristics in virtual environment, so it is inevitable to manufacture prototype parts to verify actual feeling which passengers feel in automobile. This paper suggests a methodology to enhance the human sensitivity via embodying embossment on the surface of prototype car interior trim without deterioration of dimensional accuracy using RIM (Reaction Injection Molding) and thermoforming method.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2001.05a
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• pp.201-204
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• 2001

A Confocal Laser Scanning Microscope (CLSM) is applied to determine three-dimensional fiber orientation states in injection-molded short fiber composites. Since the CLSM optically sections the composites, more than two planes either on or below the surface of composites can be obtained. Therefore, three dimensional fiber orientation states are determined without destruction. To predict the orientation states, velocity and temperature fields are calculated by using a hybrid FEM/FDM method. The change of orientation state during packing stage is also considered by employing a compressible Hele-Shaw model. The predicted orientation states show good agreement with measured ones. However, some differences are found at the end of cavity. They may result from other effects, which are not considered in the numerical analysis.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.6
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• pp.52-57
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• 1999

Funtional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported by song etc. But a system which can build directly 3D parts of high performance functional material as metal part would need long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we tranlsated the wax patterns to numerous metal prototypes by new investment casting process combined conventional investment casting with rapid pototyping & rapid tooling process. with this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P part to metal part.

• Fibers and Polymers
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• v.2 no.4
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• pp.203-211
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• 2001

Residual stresses were predicted by a flow analysis in the mold cavity and residual stress distribution in the injection molded product was measured. Flow field was analyzed by the hybrid FEM/FDM method, using the Hele Shaw approximation. The Modified Cross model was used to determine the dependence of the viscosity on the temperature and the shear rate. The specific volume of the polymer melt which varies with the pressure and temperature fields was calculated by the Tait\`s state equation. Flow analysis results such as pressure, temperature, and the location of the liquid-solid interface were used as the input of the stress analysis. In order to calculate more accurate gap-wise temperature field, a coordinate transformation technique was used. The residual stress distribution in the gap-wise temperature field, a coordinate transformation technique was used. The residual stress distribution in the gap-wise direction was predicted in two cases, the free quenching, under the assumption that the shrinkage of the injection molded product occurs within the mold cavity and that the solid polymer is elastic. Effects of the initial flow rate, packing pressure, and mold temperature on the residual stress distribution was discussed. Experimental results were also obtained by the layer removal method for molded polypropylene.

• Applied Chemistry for Engineering
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• v.10 no.6
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• pp.949-953
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• 1999

Because epoxy molding compound(EMC) for semi-conductor encapsulants contains high concentrations of fillers, its flow behaviors are affected much by the concentrations and properties of those fillers. This paper reports the effects of a filler concentration, shape, size, and size distributions on the viscosity behavior of EMC(epoxy/silica). In addition, the prediction of viscosity behavior was performed using the Mooney equation. The maximum packing volume in the Mooney equation was calculated by Ouchiyama's packing model and Taguchi's optimization method, while the shpae factor was determined by fitting the experimental data. The results showed that the Mooney equation predicted the viscosity behavior of EMC very well.