• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.361-364
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• 2009

The cooling system optimization for injection molds was studied with a response surface method in the previous research. It took so much time to find an optimum solution for a large product due to an extensive amount of calculation time for the CAE analysis. In order to use the optimization technique in the actual design process, the calculation time should be much reduced. In this study, we tried to reduce the number of design variables with the concept of the close relationship between the depth and the distance of cooling channels. The optimum ratio of the distance to the depth of cooling channels for a 2-dimensional problem was 2.0 so that the optimum ratio was again sought out for 4 industrial products. The major cooling effect of the injection molds for large products rely on baffle tubes. The optimum ratio of the distance to the depth for baffle tubes was 2.0 for the large products. The result enables us to reduce the number of the design variables by half in the cooling system optimization problem.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.8 no.5
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• pp.979-983
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• 2007

In this thesis, a strip layout drawing of LCD S/C (shield case) was prepared. In the press die, strip layout drawing is a major factor that decides the mass production of a product. The 3D CAD/CAM system was applied for the easy correction of the interference factor with other parts to be mounted. The material use ratio was enhanced to 60.17% by optimizing the blank layout and strip layout in double width array. Furthermore, the flatness of the product was made to fit the requirements by adding the bidding process intensively on the notching part where the occurrence of the change in shape is expected owing to the thin material. For the 3D CAD/CAM software, Unigraphics NX3.0 was used. The strip layout drawing was prepared in 12 processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.249-252
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• 2005

Recently, as the industrial demand for small quantity batch production of sheet metal components, the application of dieless forming technology to production of these component rise with the advantages of the reduction in manufacturing cost and time. In dieless forming processes, the determination of moving path of tool plays an important role in producing successfully formed parts. In order to obtain the optimized moving path of tool avoiding forming failure, it is necessary to examine the forming limit of sheet material. Therefore, in this study, as the new criterion to evaluate the formability of sheet material in dieless forming processes FDD(feeding depth diagram) with respect to feeding depth and punch diameter is proposed. Thus, the FDD for the sheet materials of STS304 and Ti-grade2 were obtained from a series of FDT(feeding depth test). In addition the possibility of the application of FLD in judging forming severity in dieless forming processes was investigated by comparing the results of FE analyses based on FLD and experimental FDT.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.3
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• pp.569-573
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• 2008

In this thesis, the drawing was prepared for the strip layout of the pickup frame In the press die, the drawing for press layout is a major factor in determining the mass production of the product. The 3D CAD/CAM system was applied to easily correct interference factors with other parts to be mounted. This study improved the material utilization ratio to 28.49% by optimizing the blank layout and strip layout in wide-width arraying. The 3D CAD/CAM software used is Unigraphics NX 4.0, and the strip layout drawing was prepared in 12 processes.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.5
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• pp.123-130
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• 2018

In this study, the optimum design of mold feed systems is determined for plug cover housing (PCH), which is a cover-assembly product that protects the wiring of automobile connectors. The design goal is to achieve the filling balance of the resin in the left and right covers while avoiding the occurrence of weld lines in the hinge as much as possible. For the optimization, an orthogonal array experiment and a main effect analysis of the design factors are performed, and the factors that cause the interactions with the two design characteristics are selected as the design variables. We present some design alternatives, i.e., some combinations of the design variables, and analyze the filling-simulation results, expected molding risk, and cost economics to select an optimum design solution among the design alternatives. In the optimal solution, the weld line is generated at a position outside the hinge, and the filling balance is also acceptable, showing that both design goals can be satisfied simultaneously despite conflicting with each other.

• Design & Manufacturing
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• v.16 no.1
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• pp.1-8
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• 2022

The importance of fast and accurate body temperature measurement with a portable thermometer is increasing. In order to reduce the temperature measurement response time of the infrared ear thermometer, it is very important to develop a structure for a thermometer having an efficient heat transfer path. Most of the existing ear thermometers are single structures that do not consider thermal efficiency, which may delay measurement time and reduce measurement accuracy. Therefore, in this study, the upper part of the thermometer in contact with the ear is made of a thermally conductive material, and the lower part of the thermometer is made of a thermal barrier material so that heat can be concentrated on the infrared sensor of the thermometer by blocking the upper part of the heat. For the efficiency of production, it was intended to be manufactured through the double injection process, and for this purpose, in this paper, the optimal process parameters were derived through the double injection process analysis.

• Design & Manufacturing
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• v.16 no.3
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• pp.22-27
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• 2022

The demand for new processing technology that can improve productivity is increasing in industries that require large-scale and various products. In response to this demand, a robot machining system with flexibility is required. Because of the low rigidity of the robot, the robot machining system has a large error during machining and is vulnerable to vibration generated during machining. Vibration generated during machining deteriorates machining quality and reduces the durability of the machine. To solve this problem, a stage for fixing the spindle during machining is required. In order to compensate for the robot's low rigidity, a system combining a piezoelectric actuator for generating a large force and a guide mechanism to actuate with a desired direction is required. Since the rigidity of flexible hinges varies depending on the structure, it is important to optimal design the flexible hinge and high-rigidity system. The purpose of this research is to make analytic model and optimize a flexible hinge and to design a high rigidity stage. In this research, to design a flexible hinge stage, a concept design of system for high rigidity and flexure hinge modeling is carried out. Based on analytic modeling, the optimal design for the purpose of high rigidity is finished and the optimal design results is used to check the error between the modeling and actual simulation results.

• Design & Manufacturing
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• v.18 no.2
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• pp.41-50
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• 2024

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.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.6
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• pp.482-489
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• 2020

This study conducted a prototype development and evaluation by performing die-casting mold design, mold manufacturing, and injection condition optimization based on flow and solidification analysis to meet the needs of the coupling parts produced by die casting. Through flow analysis, the injection conditions suitable for 100% filling in the cavity were found to be a molten metal temperature of 670 ℃, injection speed of 1.164 m/s, and filling pressure of 6.324~18.77 MPa. In addition, solidification close to 100 % occurred in all four cavities when the solidification rate was 69.47 %. A defect inspection on the surface and inside the product revealed defects, such as poor molding and pores. In addition, the dimensions of the injected product were within the target tolerance and showed good results. Through the feedback of the results of flow and solidification analysis, it was possible to optimize the mold design, and the injection optimization conditions were confirmed to be a total cycle time of approximately 6.5 seconds. Good quality carrier parts with an average surface hardness of approximately 45 mm from the gate measured at 97.48(Hv) could be produced.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.6
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• pp.1726-1732
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• 2008

Injection molding is one of plastic forming technology which can easily mass-produce plastic parts with various and even complex shape. The technology has lots of difficulties in making a good part due to phase change of material, high applied pressure, and fast melt flow speed in the cavity. To overcome the problems, they had to make trial and error method until the CAE(Computer Aided Engineering) could be a tool for concurrent engineering. In this paper, we investigate the optimal design for a plastic DVD tray part by systematic approach of the commercial CAE program. In design, we should consider two objectives which are both dimensional stability and cost-down. The dimension of the part is crucial because the tray should carry a DVD correctly, but the part is too thin to injection-mold easily. In order to improve the moldability, the mold is designed in the form of stack mold which is a kind of 4 hot runner system. In first, we changed the stack-mold system with one hot-runner to cost down, and decided the optimal position of the gate. After that, we investigate the effect of both the layout of cooling channels and the cooling temperature on the shrinkage of the DVD tray. A optimal simulation approach, the gate design is 2Gate#3 and the layout is Case2 cooling line as the optimal temperature of $70^{\circ}C$. The Moldflow and PC+ABS are used for the CAE program and material respectively.