• Design & Manufacturing
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• v.11 no.3
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• pp.29-34
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• 2017

Increased demand for parts with micro-pattern structure made of metals, ceramics, and composites in various fields such as medical ultrasonic sensors, CT collimators, and ultra-small actuator parts. Micro powder injection molding (PIM) is a technology for manufacturing micro size, high volume, complex, precision, net-shape components from either metal or ceramic powder. In the present study, a standard mold with a variable insert core capable of producing various micro patterns was investigated. An injection molding test was performed on a standard mold using a line type micro-pattern core having an aspect ratio of 2, a slenderness ratio of 70, a pattern size of $200{\mu}m$, and a pattern spacing of $150{\mu}m$. During the filling process, the deformation of the mold with large aspect ratio and slenderness ratio was analyzed by the experiment and the numerical simulation according to the position of the gate. We proposed a mold structure that minimizes mold deformation by gate modification and enables uniform pattern filling behavior.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.6
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• pp.3363-3369
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• 2014

Recently, considerable effort has been made to maintain a pleasant and safe indoor environment in buildings. For this, the use of a ventilation system attached to a range hood in kitchens has prevailed. Accordingly, diversiform designs for range hoods have been used. Press molding is normally used for range hood construction for several reasons. On the other hand, its economic efficiency is low in the case of a small production work. Considerable research has been carried out to solve this problem and it is believed that it is useful to use the change core method to develop molds. This study designed the core of a mold using the change core method and a total of four processes were used in its manufacture. As a result, the press molds, which are needed for shorter production runs and whose form is changeable, were developed. In addition, after the measurements in three-dimensions, the specimen passed a test within a tolerance of ${\pm}2.00mm$.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.5 no.3
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• pp.218-222
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• 2004

We developed the stamper structured mold with moving core type with nano pattern. Among the factors affecting the quality of injection molding plastic parts, We studied the effects of moving core surface heating method on the transcription of injection molding plastic parts with nano structures. Moving core surface heating has been tested by three different methods. The first was conventional injection molding process without heating moving core surface, the second was halogen lamp radiation heating process and the last was MmSH process using gas flame. As a result of making injection molded parts by using thermoplastic amorphous resins such as COC, PMMA, MmSH method which is the most high temperature of moving core surface showed the best nano pattern transcription of the three methods, but the outcome of conventional injection molding process was not better than others.

• Design & Manufacturing
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• v.13 no.2
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• pp.17-21
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• 2019

In this study, selective laser sintered 3D printing mold core and metal core were used to investigate the difference of the thickness shrinkage from the gate of the injection molded part at a constant interval. SLS 3D printing mold core was made of nylon-based PA2200 powder and the metal core was manufactured by conventional machining method. As the PA2200 powder material has low strength, thermal conductivity and high specific heat characteristics compared with metal, molding conditions were set with the consideration of molten temperature and injection pressure. Crystalline resin(PP) and amorphous resin(PS) with low melting temperature and viscosity were selected for the injection molding experiment. Cooling time for processing condition was selected by checking the temperature change of the cores with a cavity temperature sensor. The cooling time of the 3D printing core was required a longer time than that of the metal core. The thickness shrinkage of the molded part compared to the core depth was measured from the gate by a constant interval. It was shown that the thickness shrinkage of the 3D printing core was 2.02 ~ 4.34% larger than that of metal core. In additions, in the case of metal core, thickness shrinkage was increased with distance from the gate, on the contrary, in the case of polymer core showed reversed aspect.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.977-978
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• 2012

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.687-688
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• 2010

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.11
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• pp.103-108
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• 2019

The cooling rate and the uniformity of mold temperature, in the injection molding process, possess great influences on the productivity and quality of replications. The conformal cooling channel, which is of a uniform spacing from the mold cavity by the metal additive manufacturing process, receives much attention recently. The purpose of this study is to develop a mold core with a curved conformal cooling channel for a pottery-shaped thick-wall cosmetic container through the hybrid method of direct metal tooling (DMT) process. In this study, we design a mold core that contains the curved cooling channel for the container. A method that divides the cavity is proposed and the DMT process is carried out to form the curved cooling channel. The test mold core, with the curved conformal cooling channel, has been fabricated by the proposed method to confirm the feasibility of the design concept. We show that no leakage is observed for the additive manufactured test mold core, and its physical properties demonstrate that it can be sufficiently used as the injection mold core.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.10 no.1
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• pp.186-193
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• 2009

In this paper, we adopted E-MOLD patent technology in order to fabricate Prismless LGP(Light Guide Panel) fur cellular phone and estimate the transcription of injection-molded parts. Then, we manufactured the Ni stamper fur Prismless LGP using MEMS process. And the stamper was installed in the movable heated core which is the key part of a patented mold. Using this mold, we manufactured injection-molded plastic LGP parts with different mold temperatures so that we investigate effect of the temperature on the transcription of the parts. The CAE analysis was also conducted in order to compare with the experimental results. The transcription of LGP parts with various mold temperature displayed $100^{\circ}C$(25.0nm), $140^{\circ}C$(48.4nm), $180^{\circ}C$(52.1nm) and when compared with stamper(521Inm), transcription was superior at $180^{\circ}C$. According to the CAE results, moldability was improved as mold temperature ($50^{\circ}C{\sim}180^{\circ}C$) increased, but when filling time($1{\sim}2sec$) increases, it decreased at $160^{\circ}C$. And transcription and moldability were improved markedly at glass transition temperature($140^{\circ}C$).

• Journal of the Korea Convergence Society
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• v.6 no.1
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• pp.43-48
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• 2015

We studied on the injection molding conditions of defect-free PMMA lens for surgical light. When the heat temperature of mold is low, more imperfect molding or weldlines and flow marks have showed. A defective lens depends on low fluidity of the PMMA resin and its temperature is high, a flexural strain has occurred. The longer cooling time of specimens, the more cracks have occurred due to resin crystallization. In this study, optimal molding conditions for defect-free PMMA lens is as follows. The heat temperature of core mold was 110 [$^{\circ}C$] and also the cooling time was 25 [sec]. PMMA materials can realized low expense to produce plastic optical lens and applications.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.12
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• pp.1647-1653
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• 2011

The cycle time in injection moulding greatly depends on the cooling time of the plastic part that is controlled by cooling channels. Cooling channels are required to facilitate the heat transfer rate from the die to the coolant without reducing the strength of the die. Employing layered manufacturing techniques (LMT), a die embedding conformal cooling channels can be fabricated directly while conventional cooling channels are usually made of straight drilled hole. Meanwhile, H13 tool steel is widely used as the die material because of its high thermal resistance and dimensional stability. However, H13 with a low thermal conductivity is not efficient for certain part geometries. In this context, the use of functionally graded materials (FGMs) between H13 and copper may circumvent a tradeoff between the strength and the heat transfer rate. This paper presents a method for modeling of conformal cooling channels made of FGMs.