• Transactions of Materials Processing
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• v.13 no.2
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• pp.180-187
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• 2004

A computer code was developed to simulate the filling stage of the injection/compression molding process by a finite element method. The constitutive equation used here was the compressible Leonov model. The PVT relationship was assumed to follow the Tait equation. The flow-induced birefringence was related to the calculated flow stresses through the linear stress-optical law. Simulations of a disk part under different process conditions including the variation of compression stroke and compression speed were carried out to understand their effects on birefringence variation. The simulated results were also compared with those by conventional injection molding.

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

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.784-787
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• 2003

The present work covers three-dimensional flow simulation and deformation analysis of injection molded plastic lenses using solid elements. A numerical scheme to evaluate part deformation has been proposed from the results of injection molding analysis. Proposed scheme has been applied to the injection molding processes of optical plastic lenses: a spherical lens and an aspheric lens for a photo pick-up device. Through the simulation processes. residual stress is estimated and the final deformed patters are obtained for both products. The reliability of the proposed approach has also been verified in comparison with the results of real experiments.

• 한국가시화정보학회:학술대회논문집
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• 2005.12a
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• pp.69-73
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• 2005

Three-dimensional density distributions of an impinging and eccentric flame have been analyzed numerically and experimentally by a combined optical system with a digital speckle tomography. The flame has been ignited by premixed butane/air from air holes and impinged vertically against a plate located at the upper side of tile burner nozzle. In order to compare with experimental data, computer synthesized phantoms of impinging and eccentric flames have been made and reconstructed by a developed three-dimensional multiplicative algebraic reconstruction technique (MART). A new scanning technique has been developed for the analysis of speckle displacements to investigate wall jet regions of the impinging flame including sharp variation of the flow direction and pressure gradient. The reconstructed temperatures have been compared with a temperature photography by an infrared camera and results of numerical analysis using a finite-element method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.4
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• pp.507-514
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• 2003

Most of CAE analyses for injection molding have been based on the Mele Shaw's approximation: two-dimensional flow analysis. in some cases, that approximation causes significant errors due to loss of the geometrical information as well as simplification of the flow characteristics in the thickness direction. Although injection molding analysis software using three-dimensional solid elements has been developed recently, such as Moldflow Flow3D, it does not contain a deformation analysis function yet. The present work covers three-dimensional deformation analysis or injection molded plastic parts using solid elements. A numerical scheme for deformation analysis has bun proposed from the results of injection molding analysis using Moldflow Flow3D. The accuracy of the proposed approach has been verified through a numerical analysis of rectangular plates with various thicknesses in comparison with the classical shell-based approach. In addition, the reliability of the approach has also been proved through an industrial example. an optical plastic lens, in comparison of real experiments.

• Smart Structures and Systems
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• v.24 no.6
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• pp.709-721
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• 2019

This paper investigates the framework of vision-based dense displacement and strain measurement of miter gates with the approach for the quantitative evaluation of the expected performance. The proposed framework consists of the following steps: (i) Estimation of 3D displacement and strain from images before and after deformation (water-fill event), (ii) evaluation of the expected performance of the measurement, and (iii) selection of measurement setting with the highest expected accuracy. The framework first estimates the full-field optical flow between the images before and after water-fill event, and project the flow to the finite element (FE) model to estimate the 3D displacement and strain. Then, the expected displacement/strain estimation accuracy is evaluated at each node/element of the FE model. Finally, methods and measurement settings with the highest expected accuracy are selected to achieve the best results from the field measurement. A physics-based graphics model (PBGM) of miter gates of the Greenup Lock and Dam with the updated texturing step is used to simulate the vision-based measurements in a photo-realistic environment and evaluate the expected performance of different measurement plans (camera properties, camera placement, post-processing algorithms). The framework investigated in this paper can be used to analyze and optimize the performance of the measurement with different camera placement and post-processing steps prior to the field test.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.11
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• pp.211-220
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• 2002

Optical disk drives read information by replacing a laser beam on the disk track. As information has become larger, the more accurate position control of a laser beam is necessary. In this paper, we report the analysis and fabrication of the micro mirror for optical disk drivers. A coupled simulation of gas flow and structural displacement of the micro mirror using the Finite-Element-Method is applied to this. The mirror was fabricated by using MEMS technology. Especially, the process using the lapping and polishing step after the bonding of the mirror and electrode plates was employed for the Process reliability. The mirror size was 2.5mm${\times}$3mm and it needed about 35V for displacement of 3.2 ${\mu}$.

• The Transactions of The Korean Institute of Electrical Engineers
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• v.59 no.3
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• pp.609-613
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• 2010

In this paper, we optimized and simulated the heatsink of 75W LED module for street lighting and evaluated the optical properties with the manufactured heatsink. the structure of LED package make simple as chip and heatslug and thermal flow is analyzed by using the FEM(Finite Element Method) with CFdesign V10. Also, we measured the temperature of heatsink and evaluated the optical properties with infrared thermal image camera and integrated sphere system for luminous flux in $1\;[m^3]$ box. As results, Heatsink optimized in 3 mm pin thickness, 6 mm base thickness and 16 number of pin count by using Heatsink-designer and got the results which is the temperature of $47.37\;[^{\circ}C]$ and thermal resistance of $0.48407\;[W/^{\circ}C]$. In thermal flow simulation, the temperature of heatsink decreased from $51.54\;[^{\circ}C]$ to $51.51\;[^{\circ}C]$ and the temperature of heatsink by the time in real measurement decreased from $47.03\;[^{\circ}C]$ to $46.87\;[^{\circ}C]$. Moreover, we improve 0.68 % in the decreased ratio of the luminous flux.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.195-198
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• 2007

The present work focuses on the prediction of birefringence in injection-molded plastic part and its improvement by rapid mold heating. To calculate birefringence, flow-induced residual stress is computed through a fully three-dimensional injection molding analysis. Then the stress-optical law is applied from which the order of birefringence can be evaluated and visualized. The birefringence patterns are predicted for a rectangular plate with a variation of mold temperatures, which shows that the amount of molecular orientation and birefringence level decreases with an increase of mold temperature. The effect of mold temperature on the order of birefringence is also studied for a thin-walled rectangular strip, and compared with experimental measurements. Both predicted and experimental patterns of birefringence are in agreements on the observation that the birefringence level diminishes significantly when the mold temperature is raised to above the glass transition temperature.

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.229-233
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• 2007

The present work focuses on the prediction of birefringence in injection-molded part and its improvement by rapid mold heating. To calculate birefringence, flow-induced residual stress is computed through a fully three-dimensional injection molding analysis. Then the stress-optical law is applied from which the order of birefringence can be evaluated and visualized. The birefringence patterns are predicted for a rectangular plate with a variation of mold temperature, which shows that the amount of molecular orientation and birefringence level decreases with an increase of mold temperature. The effect of mold temperature on the order of birefringence is also studied for a thin-walled rectangular strip, and the relevant results are compared with experimental measurements. Both predicted and experimental patterns of birefringence are in agreements on the observation that the birefringence level diminishes significantly when the mold temperature is raised over the glass transition temperature.