• International Journal of Precision Engineering and Manufacturing
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• v.2 no.1
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• pp.62-75
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• 2001

The design and manufacture of injection molded polymeric parts with desired properties is a costly process dominated by empiricism including repeated modification of actual tooling. This paper presents and expert design evaluation system which can predict the mechanical performance of a molded product and diagnose the design before the actual mold is machined. The knowledge-based system synergistically combines a rule-based expert system with CAE programs. An iterative boundary pressure reflection method(IBPR) is developed to automate the cavity filling simulation program and to predict thermo-mechanical properties of a molded part precisely. Mathematical models of weldline and frozen-in molecular orientation are established to determine the spatial variation of microstructural anisotropies of a molded part from the result of cavity filling simulation. The strength ellipse is devised as and index which represents th spatial distribution of the microstructural anisotropies of a molded part, Heuristic knowledge of injection molding, flow simulation, and mechanical performance prediction is formalized as rules of an expert consultation system. The expert system interprets the analytical results of the process simulation, predicts the performance, evaluates the design and generates recommendations for optimal design alternative.

• Proceedings of the KIEE Conference
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• 2007.11c
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• pp.112-116
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• 2007

If any of the set parameters such as the environment temperature, mold temperature are not maintained at a consistent level, the fail rate of injection molding products is increased. The price of the injection molding machine is very high, so in order to maximize the utilization of the machine that is required the production of a number of different products with minimum fail rate using a single machine. To prevent the defect products by an inspection process with perfect quality is very important to minimizing production of defect products in the molding process. Vision inspection systems are widely utilized in various manufacturing industries for quality assurance purposes. The vision inspection system consists of CCD camera and lighting system to capture the image of the subject of inspection, an image comparison algorithm using to determine the pass/fail of the products, and mechanical devices for the operation of the whole system. This research focuses on the development of the vision inspection system to process the inspection of an automobile parts. We developed a mechanical devices for the inspection of the injection molding products and an image comparison algorithm to determine the pass/fail result of the inspection based on the molding image and the accepted product image.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.269-272
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• 2004

The present study used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding process of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design & molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors, as critical ones influencing on the quality and productivity, of which is summarized as design guidance. The main contribution factors for cycle time can be sequentially enumerated as follows; hot spot, part thickness, coolant inlet temperature, melt temperature cooling line layout, etc.. As a first step critical factors of the design process of current monitor housing were investigated. And the optimal and better critical factors found in the first step were applied to a new product proving our process was correct. Moldflow software was used for injection molding simulation, and Minitab software for the statistical analysis. Finally, the productivity was increased by about 33 percents for our specific case.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.11 s.170
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• pp.2050-2057
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• 1999

It is necessary to improve mechanical and optical properties in the optical disk substrates as the information storage devices with high storage density using short wavelength laser are being developed. Injection compression molding is regarded as the most suitable process to manufacture optical disk substrates with high dimensional accuracy, low residual stresses, and superb optical properties. In the present study, polycarbonate optical disk substrates were fabricated by injection compression molding and the birefringence, regarded as one of the most important optical properties for optical disk, is measured. The effects of various processing conditions upon the development of birefringence distribution were examined experimentally. It was found that the values of the birefringence distribution were very sensitive to the mold wall temperature history and the variance of the birefringence distribution in the radial direction was affected by the level of the packing and the compression pressure.

• Korea-Australia Rheology Journal
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• v.16 no.4
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• pp.163-168
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• 2004

In this study, an ultrasonic technique was employed to obtain pressure-volume-temperature (PVT) rela­tionship of polymer melt by measuring ultrasonic velocities under various temperatures and pressures. The proposed technique was applied to on-line monitoring of injection molding process as an attempt to predict quality of molded parts. From the comparison based on Tait equation, it was confirmed that the PVT behav­ior of a polymer is well described by the variation of ultrasonic velocities measured within the polymer medium. In addition, the changes in part weight and moduli were successfully predicted by combining the data collected from ultrasonic technique and artificial neural network algorithm. The results found from this study suggest that the proposed technique can be effectively utilized to monitor the evolution of solid­ification within the mold by measuring ultrasonic responses of various polymers during injection molding process. Such data are expected to provide a critical basis for the accurate prediction of final performance of molded parts.

• Transactions of Materials Processing
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• v.24 no.6
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• pp.437-442
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• 2015

The development of polishing technology has enabled the production of injection molds with high quality surfaces and shapes. For products such as mobile phones which require high quality performance the use of plastic materials has many constraints such as shrinkage and deflection. The purpose of the current research is to use reverse engineering in order to find and analyze the data of a selected aspherical lens and then creating a process to design an improved lens. Additionally, the improved lenses are subject to molding analysis. In order to solve this problem, the lens construction program, Zemax, was used to analyze and optimize performance. In the case of optimization, the object was to eliminate spherical aberration and to find good MTF data. The result of the optimization data was similar to the MTF data found from a random lens. Specific resin and analysis conditions were selected and CAD modeling was done to enhance the injection molding analysis.

• IE interfaces
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• v.21 no.2
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• pp.221-228
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• 2008

The injection molding process is able to produce high precision manufactures as a single process with fast speed. However, the prices of both the mold and the molding machine are expensive, and the single process is very complex and difficult to compose of the exact relationship between the process setting conditions and the product quality. Therefore, the quality of a molded product often depends on a skillful engineer's operations in the design of both parts and molds. In this paper, the relationship between the process conditions and the defectiveness is built for better manufactures under settings of the appropriate parameters, and so it can reduce the setup time in the injection molding process. Quality Function Deployment (QFD) provides severe defectiveness factors along with the related process parameters. Also, neural networks estimate the relationship between defective factors and process setting parameters, and lead to reduce the defectiveness of molded parts.

• Journal of the Semiconductor & Display Technology
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• v.2 no.1
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• pp.7-9
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• 2003

In order to predict the moldability of an injection molded part, a simulation of filling is needed. Short shot is one of the most frequent troubles encountered during injection molding process. The adjustment of process conditions is the most economic way to troubleshoot the problematic short shot in cost and time since the mold doesn't need to be modified at all. But it is difficult to adjust the process conditions appropriately in no times since it requires an empirical knowledge of injection molding. In this paper, the intelligent CAE system synergistically combines fuzzy-neural network(FNN) for heuristic knowledge with CAE programs for analytical knowledge. To evaluate the intelligent algorithms, a cellular phone flip has been chosen as a finite element model and filling analyses have been performed with a commercial CAE software. As the results, the intelligent CAE system drastically reduces the troubleshooting time of short shot in comparison with the expert's conventional way which is similar to the golden section search algorithm.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.361-364
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• 2009

The cooling system optimization for injection molds was studied with a response surface method in the previous research. It took so much time to find an optimum solution for a large product due to an extensive amount of calculation time for the CAE analysis. In order to use the optimization technique in the actual design process, the calculation time should be much reduced. In this study, we tried to reduce the number of design variables with the concept of the close relationship between the depth and the distance of cooling channels. The optimum ratio of the distance to the depth of cooling channels for a 2-dimensional problem was 2.0 so that the optimum ratio was again sought out for 4 industrial products. The major cooling effect of the injection molds for large products rely on baffle tubes. The optimum ratio of the distance to the depth for baffle tubes was 2.0 for the large products. The result enables us to reduce the number of the design variables by half in the cooling system optimization problem.

• Journal of the Korean institute of surface engineering
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• v.41 no.1
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• pp.33-37
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• 2008

Polycarbonate has a high transmittance to light, low specific gravity, flexibility and cost-effectiveness that extends the application field of the polymer to bio-engineering, optics, electronic parts, etc. Moreover, electro plating of metallic film on PC could endow the parts the electromagnetic interference shielding capability. However, poor adhesion of copper on PC limited the wide usage in the industry. In this work, a composite(PC/ABS) and MmSH(Momentary mold Surface Heating) injection process were used to improve the plating characteristics; plating thickness, gloss and adhesion. Also plasma treatment and chemical treatment were employed for improving adhesion. Plating characteristics on PC/ABS were better than those on PC due to the anchoring effect of butadiene. MmSH injection process could ameliorate the gloss and coating adhesion. Also plating thickness and adhesion of PC and PC/ABS were increased by plasma treatment.