Design & Manufacturing

Korean Society of Die & Mold Engineering (한국금형공학회)
권호 표지
DOI QR코드

DOI QR Code

Development of a precision machining process for the outer cylinder of vacuum roll for film transfer

실험계획법을 통한 3.5인치 도광판의 두께 편차 최적화에 대한 연구

  • Hyo-Eun Lee (Department of Mechanical Engineering, Dankook University) ;
  • Jong-Sun Kim (Digital Manufacturing Division, Korea Institute of Industrial Technology)
  • 이효은 (단국대학교 기계공학과) ;
  • 김종선 (한국생산기술연구원 디지털생산부문)
  • Received : 2024.06.15
  • Accepted : 2024.06.30
  • Published : 2024.06.30
Download PDF
⟨ Previous Next ⟩

Abstract

In this study, experimental design methods were used to derive optimal process conditions for improving the thickness uniformity of a 0.40 mm, 3.5 inch light guide panel. Process mapping and expert group analysis were used to identify factors that influence the thickness of injection molded products. The key factors identified were mold temperature, mold temperature, injection speed, packing pressure, packing time, clamp force, and flash time. Considering the resin manufacturer's recommended process conditions and the process conditions for similar light guide plates, a three-level range was selected for the identified influencing factors. L27 orthogonal array process conditions were generated using the Taguchi method. Injection molding was performed using these L27 orthogonal array to mold the 3.5 inch light guide plates. Thickness measurements were then taken, and the results were analyzed using the signal-to-noise ratio to maximize the CpK value, leading to the determination of the optimal process conditions. The thickness uniformity of the product was analyzed by applying the derived optimum process conditions. The results showed a 97.5% improvement in the Cpk value of 3.22 compared to the process conditions used for similar light guide plates.

Keywords

Acknowledgement

본 연구는 중소벤처기업부의 스마트제조혁신기술개발사업의 사출성형품의 품질 고도화를 위한 실시간 사출성형 품질예측 솔루션 개발(SE240060, 00140364)'과제의 지원을 받아 수행되었다.

References

  1. Rosato, D.V. and Rosato, M.G. "Injection Molding Handbook", Springer Science & Business Media, Berlin, Germany, 2012
  2. Fernandes, C., Pontes, A.J., Viana, J.C. and Gaspar-Cunha, "A. Modeling and optimization of the injection-molding process: A review", Adv. Polym. Technol. Vol. 37, pp. 429-449, 2018.
  3. Lee, H. S. "A Study on the Injection Molding for the Light Guide Plate of a Small Sized LCD (2): Influences of Processing Conditions on the Brightness", Trans. Mater. Process, Vol. 11, pp. 341-348, 2002.
  4. Hong, S. K., Min, I. K., Kang, J. J., and Yoon, K. H., "Numerical Prediction of Process Window for Injection Compression Molding of 7-inch LGP", Trans. Mater. Process, Vol. 20, pp. 5-10, 2011.
  5. Kim, M. Y., Lee, J. H., and Yoon, K. H., "An Experimental Study on Color Shift of Injection-Molded Mobile LGP Depending on Surface Micropattern", Polym., Vol. 12, pp. 1-14, 2020.
  6. Yu, Y. T., Mun, S. M., Jun, S. Y., and Kim, K. A., "A Study on Injection Condition Optimization and Deformation Improvement using Taguchi Design of Experiments", Des. Manuf., Vol. 17, pp. 62-69, 2023
  7. Lee, D. W, Kim, J. S., Lee, H. H., and Lee, S. H., "A study on CAE and injection molding of automotive thick-walled light guide with micro-optical patterns", Des. Manuf., Vol. 17, pp. 8-14, 2023
  8. Chung, Y. B. and Kim, Y. S., "Comparison and Application of Process Capability Indices", J. Soc. Korea Ind. Syst. Eng., Vol. 30, pp. 182-189, 2007.