• Design & Manufacturing
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• v.11 no.2
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• pp.9-14
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• 2017

The design and manufacturing tehcnology of IC sockets beyond 0.3mm pitch were presented. We compared the developed IC socket with the conventional one especially on the core metal-insulation part. Advanced machining techniques were employed to provide high precision. Our wire electrodischarge machining and high speed machining centers were able to maintain the micro-scale precision. We performed an injection molding analysis using a commercial analysis tool to predict the performance of the developed IC socket. We found that the solidification of the plastic resin and the high level of the clamping force are responsible for the defects such as incomplete filling and short shot. From these results, we modified the IC socket and successfully remove the defects. We were also able to find out that the new design socket needs less maintenance cost.

• Design & Manufacturing
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• v.15 no.3
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• pp.13-18
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• 2021

In plate forming technology, cylindrical drawing process is widely used in industry due to technological development. In this study, we used stainless steel 3042B and stainless steel 304J1, which are the most commonly used materials in the production of cold and hot water tanks for water purifiers, among cylindrical drawing products. Under the same conditions, the thickness of the sidewall of the product formed by drawn experiment was studied. As a result of the experiment, the bottom thickness of stainless steel 304J1 was considered to be thick. It is judged that the defect rate can be reduced by changing the breaking phenomenon of the floor surface of the cold and hot water bottles to the material of stainless steel 304j1. Stainless steel 304 2B material shows a sharp change in thickness from punch corner R to sidewall position, while stainless steel 304J1 material showed a uniform change from punch corner R to sidewall position. Stainless steel 304J1 material is considered to improve the clamping of the product in the process of extracting the product after hand drawing. The appearance of stainless steel 3042B products is considered to produce more wrinkles in the flange, which exerts greater tensile force on the sidewall during molding, resulting in uneven sidewall thickness.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.11
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• pp.610-615
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• 2016

Diverse accessories are used in automobiles, such as navigation systems, front and rear cameras, spoilers, and sun visors. Sun visors block sunlight so that drivers can drive safely with a better view, and they are used in many automobile designs. However, when large plastic products are manufactured using injection molding, there are many difficulties that develop, like weld lines, short shots, flow marks, imperfections, and distortion. In this study, a CAE simulation was conducted based on previous results to predict potential problems in the injection molding of large products. The flow characteristics up to complete charge for the melting resins were captured using a computer-aided engineering simulation. The temperature departure on the front part of a flow was about $10^{\circ}C$ and very stable. The practical ejecting time of the cold runner was about 70 seconds in the simulation. Finally, the capability of a suitable injection machine was calculated and recommended by prediction of the injection pressure and the die clamping force.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.5
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• pp.94-101
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• 2013

Injection molding process is one of the most important methods to produce plastic parts with high efficiency and low cost. The objective of this study is to implement the best plastic injection molding process for LED TV speaker frame. Moldflow analysis and simulation of plastic injection molding process were carried out in order to predict optimal modeling operation conditions and then injection molded part was produced various type of resin temperature, filling time and injection pressure variation. the result was that the best injection molding condition is set as 60bar pressure, 2sec filling time and $310^{\circ}C$ degree. The study result would be useful to variety of plastic injection molding process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.6
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• pp.73-81
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• 2014

In this paper, multiple gate locations and process conditions under concern are automatically optimized by considering robustness to minimize the injection pressure required to mold an automotive dashboard. Computer simulation-based experiments using orthogonal arrays(OA) and a design-range reduction algorithm are consolidated into an iterative search scheme, which is then used as a tool for the optimization process. The robustness of a design is evaluated using an OA-based simulation of process fluctuations due to noise as well as the signal-to-noise ratio. The optimal design solution for the automotive dashboard shows that the robustness of the injection pressure is significantly improved when compared to the initial design. As a result, both the die clamping force and the pressure distribution in the part cavity are also much improved in terms of their robustness.

• Design & Manufacturing
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• v.17 no.1
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• pp.48-55
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• 2023

In this study, on the structure simulation for manufacturing a high strength/light weight 48V battery housing for a mild hybrid vehicle was conducted. Compression analysis was performed in accordance with the international safety standards(ECE R100) for existing battery housings. The effect of plastic materials on compressive strength was analyzed. Three models of truss, honeycomb and grid rib for the battery housing were designed and the strength characteristics of the proposed models were analyzed through nonlinear buckling analysis. The effects of the previous existing rib, double-sided grid rib, double-sided honeycomb rib and double-sided grid rib with a subtractive draft for the upper cover on the compressive strength in each axial direction were examined. It was confirmed that the truss rib reinforcement of the battery housing was very effective compared to the existing model and it was also confirmed that the rib of the upper cover had no significant effect. In the results of individual 3-axis compression analysis, the compression load in the lateral long axis direction was the least and this result was found to be very important to achieve the overall goal in designing the battery housing. To reduce the weight of the presented battery housing model, the cell molding method was applied. It was confirmed that it was very effective in reducing injection pressure, clamping force and weight.