• Proceedings of the KSME Conference
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• 2008.11a
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• pp.1107-1112
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• 2008

The objective of this paper is to investigate into the influence of the injection conditions on the insert deformation and the wall thickness of the injection part using the three-dimensional injection molding analysis. Full three-dimensional insert model was added to the injection molding analysis model to consider the effects of insert deformation during the injection molding process. In order to obtain the optimum injection molding condition with a minimum insert deformation, degree of experiments were utilized. From the results of the analyses, it was shown that the optimum injection condition is injection time of 1.6 sec, injection pressure of 30 MPa and packing time of 15 sec. In addition it was shown that the wall thickness is approached to target thickness when the core deformation is considered in the injection molding analysis.

• Transactions of the Korean Society of Automotive Engineers
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• v.25 no.1
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• pp.35-41
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• 2017

The use of engineering plastics in automotive components is increasing with the trend towards improving the car strength and reducing weight. Among the different choices of materials, engineering plastic emerged as the necessary material for achieving lower costs, reduced weight and improved production efficiency. To produce the automotive parts, it is important to predict defect and validation of injection molding prior to design. Injection molding analysis and structural analysis are widely applied as a part of the design process when developing automotive parts. Injection molding analysis, in particular, involves a highly complicated mechanism that requires deep knowledge of polymer properties as well as an analytic approach different from that used for a general isotropic material when the molded material is used as a structural material. This is because the parts made of polymer have pre-stress factors such as intrinsic deformation and residual stress. The most important factors for injection molded plastic products are injection molding condition and cavity design, taking into account ease of molding, mass production and application. Despite optimal injection molding conditions and cavity design, however, glass fiber orientation is critically linked to strength reduction. The application of injection molding and structural coupled analysis provides a low-cost solution for product molding and structural validation, all prior to the actual molding. The purpose of this study involves the validation, pre-study, and solution of defect in injection-molded polymer automotive parts using the simulation software for injection molding and structural coupled analysis. Finally, this thesis provides validation of an injection molding and structural coupled analytic mechanism that can demonstrate the effect of glass fiber orientation on mechanical strength. Design improvement ideas for the injection molded product of PPS (Poly Phenylene Sulfide)+40% glass fiber are also suggested.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.8
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• pp.50-55
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• 2020

This study investigates the injection molding of a plastic rack gear and focuses on deflections in the part. The causes of deflections were found and resolved through a trade-off study by injection molding analysis. Based on a warpage analysis, the fiber orientation was found to be a dominant factor in the occurrence of deflections. Changes in the part design and various injection conditions were analyzed for their effects in reducing deflections. Based on the trade-off study, a new part bottom design, injection time, and melt temperature were recommended. A trial injection was done for the new plastic rack gear, and measurements showed that its flatness surpassed that of the original part and met the specified requirement. The short injection time, low melt temperature, and symmetric similar configuration of the part contributed to the reduction in deflections. Therefore, optimized gate design and injection conditions as well as a new part design were validated through injection molding analysis in this study.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.579-580
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• 2006

In this study, an injection mold of tensile test specimen was manufactured by international standard. Pressure and temperature in the cavity of the injection mold was measured by sensors. Simulation of injection molding process was performed with the same condition of experiment and linear structural tensile analysis was also performed with the initial condition of the residual stress induced by injection molding analysis. Normalized elastic coefficient of tensile test was compared with that of structural analysis. It was shown that the residual stress induced by injection molding has an effect on both the experiment of tensile test and linear structural analysis.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.271-274
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• 2007

Housing and insulation of electrical connectors are made of plastic resin by injection molding process. The metallic inner tube is easily deformed by high pressure during the injection process. In order to prevent deformation of the inner tube, it is desirable to simulate it by structural CAE analysis. However, it takes a long time to calculate the stress- of the part by commercially available injection molding CAE software with sufficient accuracy. In this study, structural analysis in conjunction with injection molding analysis is proposed to improve accuracy of the structural analysis. Pressure distribution on the inner tube is predicted by the injection molding CAE analysis, and then mapped onto the mesh of structural analysis by a mapping algorithm developed in this study. As a result reliable result is obtained in shorter time than the conventional method. The predicted deformation of the inner tube is compared with the actual part after experiment.

• Design & Manufacturing
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• v.15 no.1
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• pp.66-71
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• 2021

In this study, die turning injection(DTI) mold design for manufacturing reservoir fluid tanks used for cooling in-vehicle batteries, inverters, and motors was conducted based on multi-field CAE. Part design, performance evaluation, and mold design of the reservoir fluid tank was performed. The frequency response characteristics through modal and harmonic response analysis to satisfy the automotive performance test items for the designed part were examined. Analysis of re-melting characteristics and structural analysis of the driving part for designing the rotating die of the DTI mold were performed. Part design was possible when the natural frequency performance value of 32Hz or higher was satisfied through finite element analysis, and the temperature distribution and deformation characteristics of the part after injection molding were found through the first injection molding analysis. In addition, it can be seen that the temperature change of the primary part greatly influences the re-melting characteristics during the secondary injection. The minimum force for driving the turning die of the designed mold was calculated through structural analysis. Hydraulic system design was possible. Finally, a precise and efficient DTI mold design for the reservoir fluid tank was possible through presented multi-field CAE process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.2
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• pp.37-43
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• 2003

This study makes to flow analysis of computational fluid dynamics(CFD) according to the basic theory of turbulent flow regarding high-pressure injection nozzle. It also makes structural analysis to find out the structural validity of the optimum shape of high-pressure injection nozzle. It divides to two areas such as plunger areas and high-pressure injection nozzle area including plunger.

• Design & Manufacturing
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• v.8 no.1
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• pp.1-4
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• 2014

Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.99-102
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• 2008

Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.11
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• pp.163-170
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• 2004

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, however, numerical analysis based on solid elements has been reported as more reliable approach than shell -based one. The present work covers three-dimensional injection molding simulation using MP1/Flow3D and relevant deformation analysis of an injection molded plastic lens based on solid elements. Numerical analysis has been applied to the injection molding processes of an aspheric lens for a photo pick-up device. The reliability of the proposed approach has been verified in comparison with the experiments.