• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2008.11a
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• pp.354-354
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• 2008

Recently, due to the tremendous growth of media technology, demands of the aspheric glass lens which is a high-performance and miniaturized is gradually increasing. Generally, the aspheric glass lens is manufactured by GMP(Grass Molding Press) method using WC(tungsten carbide) mold core. In this study, the thermal deformation which occurs in the cooling step of GMP was considered, and it was compensated the form of mold core. The lens which was molded by compensated mold core was satisfied that can be applied to the actual specifications.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.350-353
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• 2001

Due to the widen demand of plastic part in automobiles, more accurate numerical simulation works are needed to find optimum molding process like filling fiber orientation pressure control. Therefore, C-mold software was applied for the simulation of injection molding process and cooling process in this research. The purpose of this study is developing a ball seat which made by injection process with PA66 resin and it is applied to the automobile suspension system. It must secure low friction, wear resistance and dimensional accuracy. Specially this study aims to get the quality stabilization of injection molded bass-seat parts.

• Design & Manufacturing
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• v.10 no.3
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• pp.14-19
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• 2016

Thermally or electrically conductive filler reinforced polymer composites are extensively being developed as the demand for light weight material increases rapidly in industiral applications need good conductivity such as heat sink of the electronics or light. Carbon or ceramic materials like graphite, carbon nanotube or boron nitride are typical conductive fillers with good thermal or electical conductivity. Using these conductive fillers, the polymer composites in the market show wide range of thermal conductivity from approximately 1 W/mK to 20 W/mK, which is quite enhanced considering the thermal conductivity lower than 0.5 W/mK for most polymeric materials. The practical use of these composites, however, is yet limited to specific applications because most composites are still not conductive enough or too difficult to process, too brittle, too expensive for higher conductivity. For practical use of conductive composite, the thermal conductivity required depending on the heat releasing mode are studied first for simplified unit cooling geometry to propose thermal conductivities of the composites for reasonable cooling performance comparing with the metal heat sink as a reference. Also, as a practical design for heat sink based on polymer composite, composite and metal sheet hybrid structures are investigated for LED lamp heat sink and audio amplication module housing to find that this hybrid structure can be a good solution considering all of the cooling performance, manufacturing, mechanical performance, cost and weight.

• Journal of Korea Foundry Society
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• v.18 no.6
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• pp.541-549
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• 1998

Microstructural characteristics of hypereutectic Al-Si alloys during reheating at semi-solid temperature have been investigated. The size and morphology of primary Si particles in wedge-type mold-cast ingot has been compared with hot-rolled sheet and Si particulate reinforced Al composite. Effects of P and Sr addition on the morphological changes of primary Si particles have been also investigated. Observation of the solidification microstructures of the wedge-type mold-cast ingot at different cooling rates showed that alloying elements such as P and Sr affect the morphology of Si particles, especially in the area solidified at a slow cooling rate. Negligible change in the size of primary crystals was observed after reheating experiment, but ${\alpha}-halo$ formed around the Si particles and fine particles of Si precipitated in the surrounding area of the Si particles. In addition, there seemed to be no coarsening with increasing of holding time and the region of ${\alpha}-halo$ being decreased. Nucleation and recrystallization was accelerated with addition of alloying elements during hot rolling resulting in a decrease of primary Si particle size. In the case of extruded specimens, morphological change of primary Si particles was not observed after reheating. No ${\alpha}-halo$ formation was observed in Si reinforced Al composite because of the oxide film formed on the Si particles which acted as a diffusion barrier between substrate and the primary Si particles.

• Journal of Korea Foundry Society
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• v.2 no.2
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• pp.18-30
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• 1982

For the purpose of improving the casting yields of ductile iron castings, the casting conditions for riserlese design were investigated with 150mm cube. As the important casting conditions, chemical composition, pouring temperature, mold rigidity and cooling rate were confirmed. 1. We could obtain the sound castings with the hypereutectic ductile iron. 2. In order to reduce liquid contraction, the pouring temperature should be low as much as possible 3. We could obtain the sound castings through using the rigid mold without mold cavity deformation 4. The modulus of the castings should be 2.5cm one or larger.

• Journal of Korea Foundry Society
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• v.13 no.3
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• pp.268-275
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• 1993

In gravity die casting, die cooling systems are frequently employed with water cooling to remove the heat of the solidifying metal. Thermal modeling is an important technique in mold design for improving the productivity of the process. Computer simulation system which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of cyclic gravity die casting. The pre-processor is used for mesh generation in a PC system. The modified finite difference method is adopted for the main solidification simulation algorithm during all the casting cycles. The post-processor graphically presents the simulation results. Several experiments in automotive cast piston were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. The effects of cycle number on solidification pattern are also studied. Several experimental results for the prediction of shrinkage defects are compared with calculated results.

• Korean Journal of Materials Research
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• v.32 no.12
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• pp.538-544
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• 2022

In existing ceramic mold manufacturing processes, inorganic binder systems (Si-Na, two-component system) are applied to ensure the effective firing strength of the ceramic mold and core. These inorganic binder systems makes it possible to manufacture a ceramic mold and core with high dimensional stability and effective strength. However, as in general sand casting processes, when molten metal is injected at room temperature, there is a limit to the production of thin or complex castings due to reduced fluidity caused by the rapid cooling of the molten metal. In addition, because sodium silicate generated through the vitrification reaction of the inorganic binder is converted into a liquid phase at a temperature of 1,000 ℃. or higher, it is somewhat difficult to manufacture parts through high-temperature casting. Therefore, in this study, a high-strength ceramic mold and core test piece with effective strength at high temperature was produced by applying a Si-Na-Ti three-component inorganic binder. The starting particles were coated with binary and ternary inorganic binders and mixed with an organic binder to prepare a molded body, and then heat-treated at 1,000/1,350/1,500 ℃ to prepare a fired body. In the sample where the two-component inorganic binder was applied, the glass was liquefied at a temperature of 1,000 ℃ or higher, and the strength decreased. However, the firing strength of the ceramic mold sample containing the three-component inorganic binder was improved, and it was confirmed that it was possible to manufacture a ceramic mold and core via high temperature casting.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.38 no.1
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• pp.44-51
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• 2015

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relations of injection system, casting condition, gate system, and cooling system. According to the various relations of the conditions, the location of product defects was differentiated. High-qualified products can be manufactured as those defects are controlled by the proper modifications of die casting mold with keeping the same conditions. In this research, Computer Aided Engineering (CAE) simulation was performed with the several layout designs in order to optimize the casting layout design of an automotive part (Housing). In order to apply them into the production die-casting mold, the simulation results were analyzed and compared carefully. With the filling process, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflow. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system. The simulation results were also applied into the production die-casting mold in order to compare the results and verify them with the real casting samples.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.253-259
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• 2002

Micro cell structures with high aspect ratio were fabricated by injection molding method. The mold inserts had dimension $1.9cm\times8.3cm$ composed of a lot of micro posts and were fabricated by LIGA process. The size of the micro posts was $157{\mu}m\times157{\mu}m\times500{\mu}m$ and the gaps between two adjacent posts were $50{\mu}m$. Using Polymethylmethacrylate (PMMA) injection molding was performed. The key experimental variables were temperature, pressure, and time. By controlling these, good shaped mim cell structures with $50{\mu}m$ in wall thickness and $500{\mu}m$ in depth were obtained. In order to understand micro molding mechanism, shape changes of molded PMMA were studied with experimental variables. And the durability of mold insert was investigated, too. The results show that the most important factor in molding processes was the mold temperature that is closely related to the filling of the melt into the micro cavity. And the holding time before cooling showed a great effect on the quality of molded PMMA.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.6
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• pp.114-120
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• 2021

This study is focused on the root mean square and peak-to-valley based on the injection conditions of the f-theta lens, one of the main components of laser printers and laser scanning systems. The f-theta lens of an aspherical plastic lens requires ultra-preaction. Injection molding is typically used for the mass production of aspherical plastic lenses. In the injection-molding method, the resin in the lens shape is filled with the resin after melting the plastic pellets at a constant temperature and then cooled. It is necessary to maintain a uniform injection molding system to produce high-quality lenses. These injection-molding systems are influenced by different factors, such as pressure, speed, temperature, mold, and cooling. It is possible to obtain a lens that exhibits the optical characteristics required to achieve harmony. We investigated the root mean square and peak-to-valley caused by variations in temperature, a critical parameter in the melting and cooling of plastic resins generated inside and outside the injection mold.