• Proceedings of the KAIS Fall Conference
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• 2010.05b
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• pp.1245-1248
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• 2010

플라스틱은 가공이 용이하기 때문에 우리 생활에 널리 이용되고 있다. 과거에는 단순히 제품의 외장제로 이용되었지만 산업이 발달함에 따라 금속을 대체 할 정도로 사용 범위가 증가하고 있다. 또한 사용량이 증가함에 따라 제품의 생산량을 증가시키기 위해선 다수 캐비티의 금형 사용이 필수적으로 되었다. 다수 캐비티 사출성형에서 각 캐비티 간 제품의 품질 및 물성을 향상시키기 위해선 각 캐비티로 충전되는 수지가 균형을 이루어야 한다. 하지만 기하학적으로 균형을 갖추고 있는 러너를 설계하여도 실제 사출성형에서는 불균형 충전이 일어나게 된다. 이러한 불균형 충전은 미국의 Beaumont에 의해서 처음 규명된 뒤 충전불균형 현상을 해결하기 위해 많은 연구가 진행되었다. 본 논문에서는 다수 캐비티 사출성형에서 균형충전을 위한 러너시스템을 제안하였다. 이 러너시스템은 온도가 불균일한 수지의 흐름을 혼합함으로써 수지의 흐름을 균일하게 하여 균형충전을 이루도록 하였다. 또한 사출성형해석프로그램인 Moldflow를 이용한 유동해석을 통해 그 효과를 나타내 보았다.

• Design & Manufacturing
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• v.2 no.3
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• pp.6-9
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• 2008

This paper describes the process of structure analysis and injection molding analysis to manufacture the forming injection dies for huge glass insert. Factors such as filling time, filling pressure, material temperature, shrinkage, warpage were investigated by using the analysis software, Moldflow. Runner system and cavity structure were designed and manufactured through the results of deformation analysis data for glass insert. Filling time and filling pressure were analyzed in 3.756sec and 43.37MPa.

• Design & Manufacturing
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• v.2 no.2
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• pp.6-9
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• 2008

Injection molding is representative process of plastic production. Most of numerical analyses for injection molding have been based on the Hele Shaw's approximation: two-dimensional flow analysis. The present work covers numerical analyses of injection molding using three-dimensional solid elements. The accuracy of the analysis results has been verified through some numerical examples in comparison with the various conditions. In this study, moldflow software was used to analyze the cooling analysis. The results of cooling analysis and testing catapult were compared for plastic products.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.7
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• pp.111-115
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• 2008

This paper describes the optimization of injection molding conditions to minimize sink marks. Sink marks, which refer to a small depression on the surface opposite a thick wall thickness, are often encounted in injection molded plastic parts. Part geometry, material properties and processing conditions during injection molding can affect the sink mark depth. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique. By actual injection molding using optimized mold and molding conditions, it confirmed that sink mark depth decreased zero compared to 1mm level in the conventional mold and process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.262-265
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• 2007

Cooling circuit of injection mold affects part quality and cycle time of injection molding process. Examination on mold cooling circuit is usually omitted in part design stage because cooling circuit is designed in the mold design stage. It is desirable to examine mold cooling circuit with respect to part quality in the part design stage. In order to make the examination process convenient and fast, cooling circuit design should be automated without intervention of skilled designer. In this study, optimization of cooling circuit design is automated with commercial softwares; Visual DOC and Moldflow MPI. Effect of initial value for optimization is examined for the optimization result.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.6
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• pp.68-74
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• 2002

This research covers the development of axi-symmetric plastic elements for injection molding with insert steel such as high stiffness Sabot. The functional requirements of sabot are concentricity and fracture resistance about vertical and horizontal forces. For these, an analysis of characteristics of PEI(polyetherimide) polymer is performed by standard test specimen with accordance of ASTM test guidance. Moldflow analysis and simulation of injection molding process are carried out in order not only to estimate of the warpage but also to predict the characteristics of residual stresses which both product and structure of mold may have. A new vertical side injection machine and transverse mold have been constructed. Results of the measuring concentricity and fracture test after molding of sabot are satisfied to design specification over Cp $ratio{\geq}1.33$. Finally, this technique needs more research application to others axi-symmetric elements having different radius with insert steel md structure analysis from now on.

• Proceedings of the KAIS Fall Conference
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• 2006.11a
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• pp.261-264
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• 2006

본 논문에서는 다양한 곡률반경의 연속에 의하여 살 두께 차가 큰 사출성형품에 불균일한 수축으로 인한 변형이 생성되어 이를 방지하기 위한 적정 CAE 냉각설계를 수행하였다. SAN 및 PMMA 재질의 Jar용기에 대한 균일냉각구조와 최적성형조건을 금형설계에 적용하고자 사출성형의 중요인자인 사출압력, 수지온도, 금형온도, 냉각조건 등을 moldflow 프로그램을 활용하여 연구를 수행하였다. 연구결과로서, 적정 변수인 사출압력 상승, 수지온도 낮춤, 급속냉각으로 후로우 등의 불량현상을 분석하였고 변형 및 불량을 극소화시킬 수 있는 냉각구조와 사이클 시간을 단축시킬 수 있는 사출성형조건을 제시하였고 적정 냉각모듈로부터 냉각시간을 단축하였다.

• Proceedings of the KAIS Fall Conference
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• 2004.06a
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• pp.72-74
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• 2004

본 연구의 목적은 천안시 소재 (주)삼우금형의 생산 제품인 휴대폰 충전기에 대해 CAE 프로그램인 Moldflow와 CAPA를 이용하여 유동해석과 냉각해석을 수행함으로써 성형불량을 최소화하고 좋은 설계를 얻을 수 있는 최적의 성형조건을 얻으려는 것이다. 사출성형 관련 설계를 설계초기 단계에서 CAE기술을 활용하여 합리적인 설계로 나아가기 위한 구체적인 과정을 기술하였다. 제품 성형에 있어서의 문제점을 최소화하고 재료비 절감, 설계납기 단축, 제품 품질 향상을 달성하기 위해서 CAE 해석을 통하여 현재 제품의 문제점을 도출하고 그 해결책을 제시하였다.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.443-448
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• 2008

Fiber reinforced injection molded parts are widely used in recent years because of their improved properties of materials such as specific stiffness, specific strength, and specific toughness. The demand for products with high precision is increasing and it is important to minimize the warpage of the products. The warpage of short-fiber reinforced product is caused by anisotropy induced by fiber orientation as well as the residual stresses induced during the molding process. In order to reduce the warpage of the part, it is important to achieve successful mold design, processing control, and part design. In the present study, the design of gating system, molding condition, and part structure were carried out and verified with numerical analysis using a commercial CAE code Moldflow. The numbers and locations of gates were iteratively determined, and the molding conditions which can decrease the warpage of the part were investigated. Finally, slight structural modification of the part was conducted to reduce the locally concentrated warpage.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.293-296
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• 2008

Injection molding operation consists of filling, packing, and cooling phase. The highest pressure is involved during the packing phase among the operation phases. Cavity pressure depends upon velocity to pressure switchover time and magnitude of packing pressure. The cavity pressure is directly related to stress concentration in the cavity of mold. Thus the observation and control of cavity pressure is very important to prevent mold cracking. In this study, cavity pressures were observed for operational conditions using the commercial CAE software, Moldflow. Operational conditions were velocity to pressure switchover time and packing pressure. Cavity pressures were also measured directly during injection molding. Simulation and experimental results showed good agreement.