• Journal of the Korean Society for Precision Engineering
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• v.22 no.9 s.174
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• pp.173-178
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• 2005

Recently plastic parts are molded for the purpose of mass production in multi-cavity system. Therefore, designer is usually designing mold that has geometrically balanced runner lay-out for filling balance at each cavity. Although, mold is manufactured with geometrically balanced runner lay-out, there are actually filling imbalances in the cavities. These filling imbalances phenomenon are caused by complicated interaction between melt and mold. In this study, based on previous studies for filling imbalances in cold-runner mold, filling imbalances in hot-runner mold were investigated by CAE and injection molding experiments. ABS and PMMA as amorphous polymer, PA as crystalline polymer were used to compare the filling imbalances. There were different results of CAE and experiment. The filling imbalances decreased as injection rate increased without regard to kind of resins and were lower than the one of cold-runner.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.598-601
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• 2005

Plastic parts are molded for the purpose of mass production in multi-cavity system. Therefore, designer is usually designing molds that has geometrically balanced runner lay-out for filling balance at each cavities. Although, mold is manufactured with geometrically balanced runner lay-out, there are actually filling imbalances in cavities. These filling imbalances phenomenon are caused by complicated interaction between melt and mold. In this study, based on previous studies for filling imbalances in cold-runner mold, filling imbalances in hot-runner mold were investigated by CAE and injection molding experiments. ABS, PMMA as amorphous polymer and PA, PP as crystalline polymer were used to compare the filling imbalances. The filling imbalances decreased as injection rate increased without regard to kind of resins and were lower than the one of cold-runner.

• Design & Manufacturing
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• v.6 no.1
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• pp.52-57
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• 2012

Aspect of filling imbalance that is originated from imbalanced share rate in runner is changed by material property, runner layout that are factors of changing viscosity and by injection pressure, injection speed, melt temperature and mold temperature that are injection conditions. In this paper, we made a study of runner system that is one of factor of filling imbalance and Sharp Conner Effect and Groove Corner Effect that are recently released. The study are showed that filling rate of between inside and outside cavity was influenced on shape of runner. Also, we suggested runner system for filling imbalance by adapting the two effects at multi cavity of unary branch type and theoretical investigated flow in the Shrap Conner runner type.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.329-332
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• 2008

Flow imbalance among the cavities was often observed in multi-cavity mold. The flow imbalance affects on the dimensions and physical properties of melded articles. First of all, the origin of flow imbalance is geometrical imbalance of delivery system. However, even the geometry of delivery system is balanced the cavity imbalance is being developed. This comes from the temperature distribution in the cross-section of runner, which is affected by the operational conditions. In this study, experimental study of flow imbalance has been conducted for various injection speeds. This study also suggests new runner design to eliminate flow imbalance in multi-cavity injection mold. Simulation and experimental results showed suggested new designed runner could eliminate or reduce flow imbalance in multi-cavity injection mold.

• Design & Manufacturing
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• v.9 no.1
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• pp.23-26
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• 2015

For mass production of plastics, injection molds have multi-cavities. However, filling imbalance between cavity to cavity always has occurred in multi-cavities mold, and this has caused low quality of plastics part. In this study, the closed-loop-control system which can control temperature of hot manifold and nozzle in hot runner mold for filling balance has been suggested, and a series of experiment about difference of filling time and weight in cavity-to-cavity was conducted. As a result of using closed-loop-control system, a remarkable improvement in reducing filling imbalance was confirmed.

• Design & Manufacturing
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• v.2 no.5
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• pp.16-20
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• 2008

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing; However, even though geometrically balanced runner is used, filling imbalances have been observed. In these day, the CAE has been used widely in injection molding. However, CAE with fusion mesh can't indicate such as jetting, flow mark and filling imbalance in multi cavity mold. In this study, we investigated the filling imbalance according to runner shapes by CAE analysis. As a result in CAE, in case of binary branch runner system, filling imbalance was indicated between cavity to cavity, but the flow pattern of each cavity uniformed in unary branch runner system.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.4
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• pp.95-100
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• 2004

Plastics is used to produce precise parts with an inclusion of a reinforcement material such as glass fiber or carbon fiber to improve the dimension accuracy. The plastic goods can be produced with inaccurate dimensions, low mechanical strength, or residual stress due to the over packing of cavity inside, if the filling balance of melt resin is not accomplished. To overcome this problem, it is necessary to design the runner system with the geometrical balance at the mold design stage. However, even if the balanced runner system is achieved, a severe filling imbalance is observed practically in a multi-cavity mold. In this study, experiments were performed with Taguchi method to achieve the filling balance in multi-cavity mold with a symmetric runner system, by the use of pure PA and PA with glass fiber 33%. The experimental results were investigated to understand the effect of related molding factors on the filling imbalance for two resins.

• Design & Manufacturing
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• v.2 no.3
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• pp.1-5
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• 2008

Plastic parts are molded for the purpose of mass production in injection molding. Therefore designer is usually designing molds that has geometrically balanced hot runner lay-out for filling balance at cavities. Although, mold is manufactured with geometrically balanced runner lay-out, there are actually filling imbalances in cavities. These filling imbalances phenomenon are caused by complicated interaction between melt and mold. In this paper, filling imbalances for internal gear based on injection molding in hot-runner mold were investigated by CAE and injection molding experiences.

• Journal of Practical Engineering Education
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• v.9 no.2
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• pp.119-124
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• 2017

In injection molding process, the runner system of the mold is a flow path for filling the cavity of the molded part during the advance of the screw by the force of the hydraulic cylinder, which involves the filling and packing process of the molten resin. Thus, the sprue, runner and gate greatly affect the appearance of the molded part, the physical properties of the resin, the dimensional accuracy and the molding cycle etc. Feed systems with incorrect runner and gate designs cause various molding defects, So it is important to maintain the optimum runner balance to prevent these defects. In order to improve the knowledge of practical mold technology, which is applied to the manufacturers of injection molds, a training model of the mold technology process is presented based on the technical guidance on the technical difficulties.

• International Journal of Fluid Machinery and Systems
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• v.8 no.3
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• pp.209-219
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• 2015

A robust multi-fidelity optimization methodology has been developed, focusing on efficiently handling industrial runner design of hydraulic Francis turbines. The computational task is split between low- and high-fidelity phases in order to properly balance the CFD cost and required accuracy in different design stages. In the low-fidelity phase, a physics-based surrogate optimization loop manages a large number of iterative optimization evaluations. Two derivative-free optimization methods use an inviscid flow solver as a physics-based surrogate to obtain the main characteristics of a good design in a relatively fast iterative process. The case study of a runner design for a low-head Francis turbine indicates advantages of integrating two derivative-free optimization algorithms with different local- and global search capabilities.