• Polymer(Korea)
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• v.32 no.6
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• pp.501-508
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• 2008

Small injection molded articles such as lens and mobile product parts are usually molded in multi-cavity mold. The problem occurring in multi-cavity molding is flow unbalance among the cavities. The flow unbalance affects the dimensions and physical properties of molded articles. First of all, the origin of flow unbalance is geometrical unbalance of the delivery system. However, even the geometry of the delivery system is well balanced, cavity unbalance occurs. This comes from the temperature distributions in the cross-section of runner. Temperature distribution depends upon injection speed because heat generation near runner wall is high at high injection speed. Among the operational conditions, injection speed is the most significant process variable affecting the filling unbalances in multi-cavity injection molding. In this study, experimental study of flow unbalance has been conducted for various injection speeds and materials. Also, the filling unbalances were compared with CAE results. The dimensions and weights of multi-cavity molded parts were examined. The results showed that the filling unbalances vary according to the injection speeds and resins. Subsequently, the unbalanced filling and pressure distribution in the multi-cavity affect the dimensions and physical states of molded parts.

• Design & Manufacturing
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• v.12 no.3
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• pp.55-59
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• 2018

In a multi-cavity mold having a runner layout of a fish bone structure, problems of unbalanced filling between cavities occur constantly. Unbalanced charging lowers the dimensional accuracy of a molded article and causes deformation after molding. To solve this problem, the gate size connected to each cavity is adjusted using the BGV (Balanced Gate Value) equation. In this paper, in order to solve the filling imbalance problem of the runner layout mold of fish bone structure through injection molding analysis study, we compared the charging imbalance phenomenon before and after improvement after adjusting the gate size by applying BGV equation. From the results of the molding analysis, the shrinkage ratio before and after the improvement of the molded article was improved by only about 0.08%. Based on these results, it was confirmed that the charging imbalance problem was not significantly improved even when the BGV equation was applied.

• 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.

• Proceedings of the Korean Geotechical Society Conference
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• 2005.03a
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• pp.1343-1350
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• 2005

In this study, the whole deformation conditions of domestic old tunnels and reinforcement methods for deformation tunnels were investigated and analysed, and the present conditions, occurrence cause and reinforcement methods of cavity behind the tunnel lining were investigated and analysed comprehensively. The deformation causes of domestic old tunnels could be classified in three kinds : change of earth pressure operating tunnel ground, material problem of concrete lining, mistake of design and construction. As a result of analysis, the tunnel deformation was occurred by not specific cause but various cause As a result of investigation for 455 domestic tunnel data, more than 70% of the tunnel deformation was related to leakage and the other deformation cause also accompanied leakage mostly. An applied reinforcement method was related to leakage and flood prevention measures, but application of reinforcement method for boundary area between tunnel and ground and tunnel periphery which influence on the tunnel stability was still defective. The cavity of domestic old tunnel occupied about 16% of the total tunnel length and about 68% of cavity was located in the crown of tunnel, and besides, the occurrence cause of cavity was analysed to design, construction and management cause. The filling method for cavity using filling material was comprehensively appling to cavity behind tunnel lining.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.7
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• pp.1294-1306
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• 1992

In order to determine the design parameters and processing conditions in injection molding, it is very important to establish the theoretical model with scientific base. In this study, a two dimensional model has been developed for the purpose and flow simulations of filling process are carried out. The moving boundary transient flow problem along the flat plane is solved efficiently by the Iterative Boundary Pressure Reflection Method which rearranges the impinged melt front along the physical boundary in scientific manner. The two dimensional modeling of filling process is applied to two examples : a three dimensional cover with two screw holes and a two-gated flat cavity with unbalanced runners. The numerical results show good agreement with experimental short shots, especially for the weldline locations and the pressure traces at various locations. They also provide the temperature, clamp force, and velocity field in the mold at different times during filling of cavity.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.6
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• pp.21-28
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• 2010

This study shows an optimization procedure for an automatic determination on the gate position to ensure the fill-uniformity within a part cavity by using the injection molding simulation. For an optimization, the maximum pressure-difference within a part cavity induced at the stage of filling is used to evaluate degree of fill-uniformity. In addition, a direct search scheme based on the reduction of design space is developed and applied in the optimization problem. This corresponding proposed methodology was applied in the optimization on the gate location for a CD-tray molding, as a result, showed the improvement of the fill-uniformity within the cavity.

• Tunnel and Underground Space
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• v.24 no.6
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• pp.449-463
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• 2014

There are many case studies and application cases in abandoned mines for hydraulic filling method filled by slurry or paste form, but research on the pneumatic filling is not applied in Korea. The damage of steel pipe is occurred by wear due to the flow of filling material in the bent area of steel pipe in traditional pneumatic filling method. In this study, the new pneumatic filling method was developed using a newly devised improved nozzle to improve the above problem. The model test for mine filling was performed in the laboratory for the simulated accessible or inaccessible mine cavities, and the filling efficiency by the results obtained from the test was calculated. The filling efficiency was analyzed from the variation of outlet angle, feed rate and grain size of sand in model test of simulated accessible mine cavity. The superiority of improved pneumatic filling method was proved through the analysis of filling efficiency by the results obtained from each model tests of gravitational, traditional, and improved filling method in simulated inaccessible mine cavity.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.12
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• pp.511-517
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• 2016

Current oil-type potential transformers for trains are filled with insulating oil, which could have problems like explosions due to rising inner pressure during train operation. Therefore, mold and dry-type potential transformers are being developed to prevent explosions. One problem in manufacturing mold-type transformers is preventing void formation around the coiled core inside the mold during epoxy filling, which could cause an electrical spark. Micro voids can remain in the resin after filling, and macro voids can occur due to the structure shape. A transformer that is being developed has a cavity at the junction of the core and the coil for better performance, and when highly viscous epoxy flows inside the cavity channel, macro voids can form inside it. Therefore, in this study, the free-surface flow of the mold filling procedure was analyzed numerically by applying the VOF method. The results were used to understand the phenomena of void formation inside the cavity and to modify the process conditions to reduce voids.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.24 no.12
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• pp.1570-1579
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• 2000

Finite element analysis of fluid flow with moving free surface has been carried out in two and tree dimensions. The new VOF-based numerical algorithm that has been proposed by the present authors was applied to several 2-D and 3-D free surface flow problems. The proposed free surface tracking scheme is based on two numerical tools that have been newly introduced by the present authots; the orientation vector to represent the free surface orientation in each cell and the baby-cell to determine the fluid volume flux at each cell boundary. The proposed numerical algorithm has been applied to 2-D and 3-D cavity filling and sloshing problems, which demonstrated versatility and effectiveness of the new free surface tracking scheme as well as the overall solution procedure. The proposed numerical algorithm resolved successfully the interacting free surface with each other. The simulated results demonstrated the applicability of proposed numerical algorithm to the practical problems of large free surface motion. Also, it has been demonstrated that the proposed free surface tracking scheme can be easily implemented in any irregular non-uniform grid systems and can be extended to the 3-D free surface flow problem without additional efforts.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.461-464
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• 2003

A new control volume finite element method is proposed for three dimensional analysis of polymer flow. Tetrahedral finite element is employed and co-located interpolation procedure for pressure and velocity is implemented. Inclusion of pressure gradient term in the velocity shape functions prevents the checkerboard pressure field from being developed. Vectorial nature of pressure gradient is considered in the velocity shape function so that velocity profile in the limit of very small Reynolds number becomes physically meaningful. The proposed method was verified through three dimensional simulation of pipe flow problem for Newtonian and power-law fluid. Calculated pressure and velocity field showed an excellent agreement with analytic solutions for pressure and velocity. Driven-cavity problem, which is reported to yield checkerboard pressure filed when conventional finite element method is applied, could be solved without yielding checkerboard pressure field when the proposed control volume finite element method was applied. The proposed method could be successfully applied to the three dimensional mold filling problem.