• Transactions of Materials Processing
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• v.23 no.1
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• pp.41-48
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• 2014

The light guide plate has become the major component for the backlight module in general information technology products (e.g. mobile phones, monitors, etc.). High speed injection molding has been adopted for thin walled LGP giving advantages such as weight, shape, size, and reduction in production costs. In the current study, the rheological characteristics of high liquidity plastic resin PC(HL8000) were measured using a capillary rheometer to improve the reliability of the numerical analysis for high speed injection molding. With the measured viscosity and PVT of PC(HL8000), numerical analysis of injection molding was conducted using the simulation software(Moldflow). Filling time and deflection were predicted and compared with those of traditional PC resins(H3000, H4000). The results show that PC(HL8000) has significantly different rheological characteristics during high speed injection molding. Hence proper properties of the resin should be used to improve the accuracy of numerical predictions.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.2
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• pp.322-329
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• 1995

Series of experimental work was performed to mold tensile specimens by using the injection molding machine Mold temperature, melt temperature and packing time were chosen as processing parameters for studying the effects of those conditions on the linear shrinkage of final product. Here, each processing variable was decided from the numerical simulation and resin manufacturer's suggested value. The effects of molding conditions on the linear shrinkage in flow direction of the resin were analyzed by measuring the parts 2, 10, 30 and 60 days after molding. As a result, the linear shrinkage increased with the higher mold and melt temperature, and the change of mold temperature has shown more influence. The linear shrinkage of polypropylene has been found to progress up to 30 day with the lapse of the time, and the amount of the linear shrinkage has shown to be between 2.14% and 2.75%. In addition, the effects of packing pressure on the weight has shown to be extremely significant up to freezing time, and proper packing time of the tensile specimen has been found to be 2.0 seconds.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.186-191
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• 2008

Injection molding is used to manufacture various kinds of products including very thin plate like frames. One such product is Door video phone system Panel which is our present object of investigation. During the molding process, large deflection problems in the final product always provokes for the several trials for the accuracy. To solve the issue we use Moldflow6.2 which is injection molding simulation software. It simulates the product exactly the way it happens in actual manufacturing environment. Differences in the geometrical parameters such as thickness changes will lead to the large deformation problems in the frame. However in our present study we simulate it in a well defined condition under several trials. Interesting observations are made in minimizing the deformation of the frame during the injection molding process. This way of approach is very useful in further works if any changes have to be made in the product.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.4
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• pp.50-55
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• 2014

Currently, flat cover glasses are widely applied to mobile devices. However, for a good design and for convenience of use, curved cover glasses are in demand. Thus, many companies are attempting to produce curved cover glasses using a shaving technique, but the production efficiency is very low. Therefore, a molding technique has been adopted to increase the efficiency of curved glass production systems. For a glass molding system, a uniform temperature distribution of the mold is crucial to produce high-quality curved cover glasses. Before setting the heating conditions of the molding system for a uniform temperature distribution by a thermal analysis, verification is required. Therefore, in this study, temperature measurements were conducted for a prototype molding system and the experimental results were compared with simulation computations. The temperatures of the heating block surface were in good agreement with the computational results for transient and steady conditions.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.1
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• pp.39-46
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• 2013

This study aims to develop a plastic aspheric lens for a 13-megapixel mobile phone camera by injection-compression molding. A mold for injection-compression molding experiments was fabricated with a movable upper plate and four springs. During cavity filling for an aspheric lens with a thickness ratio of 2, a weldline was formed under conventional injection molding, whereas no weldline was formed under injection-compression molding with a compression stroke of 0.3 mm. The flow patterns were in good agreement with the simulation results. The birefringence decreased as the compression stroke increased, and the birefringence produced by injection-compression molding was very low and more uniform compared with that produced by injection molding. In addition, the bulk birefringence of an assembly composed of four plastic lenses was significantly affected by the orientation of the lenses to be mounted.

• International Journal of Precision Engineering and Manufacturing
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• v.7 no.1
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• pp.51-56
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• 2006

A computer code was developed to simulate both the thermal stresses introduced during the post-filling stage and the in-plane deformation after ejection process by finite element method based on the plane stress theory. The computer simulation was applied to the mold design of a 2 inch light guide plate (LGP) for thin film transistor (TFT)-liquid crystal displays (LCD). With injection molding experiments based on the design of experiments (DOE) technique, the influences of the processing conditions in injection molding on brightness and uniformity of the LGP were investigated, and the optimal processing parameters were selected to increase the brightness and uniformity. The verification experiment showed that the brightness and uniformity of the LGP were increased dramatically under the selected optimal processing conditions.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.246-250
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• 2001

In resin transfer molding (RTM), resin is forced to flow through the fiber perform of inhomogeneous permeability. This inhomogeneity is responsible for the mismatch of resin velocity within and between the fiber tows. The capillary pressure of the fiber tows exacerbates the spatial variation of the resin velocity. The resulting microscopic perturbations of resin velocity at the flow front allow numerous air voids to form. In this study, a mathematical model was developed to predict the formation and migration of micro-voids during resin transfer molding. A transport equation was employed to account for the migration of voids between fiber tows. Incorporating the proposed model into a resin flow simulator, the volumetric content of micro-voids in the preform could be obtained during the simulation of resin impregnation.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.11
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• pp.83-88
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• 2002

In order to predict the moldability of a 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 experts' conventional methodology which is similar to the golden section search algorithm.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.92-97
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• 2012

Injection mold is a manufacturing process used to produce parts of complicated shape at a low cost. Many factors affect the quality of injection molded part during injection molding process. A study on the optimization of injection mold is progressed by using a simulation software like Moldflow. Filling, packing and cooling phases of injection molding processes are analyzed according to the mold design considering the shrinkage of molded part, the degree of filling rate and the wearing of a mold. Taguchi method is applied to analyze the significance of processing parameter and the dynamic characteristics according to the variation of processing parameters. From the results, the mold temperature and packing pressure influenced the shrinkage of injection molded part.

• Advanced Composite Materials
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• v.18 no.2
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• pp.135-152
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• 2009

Liquid molding processes, such as resin transfer molding, involve resin flow through a porous medium inside a mold cavity. Numerical analysis of resin flow and mold filling is a very useful means for optimization of the manufacturing process. However, the numerical analysis is quite time consuming and requires a great deal of effort, since a separate numerical calculation is needed for every set of material properties, part size and injection conditions. The efforts can be appreciably reduced if similarity solutions are used instead of repeated numerical calculations. In this study, the similarity relations for pressure, resin velocity and flow front propagation are proposed to correlate another desired case from the already obtained numerical result. In other words, the model gives a correlation of flow induced variables between two different cases. The model was verified by comparing results obtained by the similarity relation and by independent numerical simulation.