• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.281-284
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• 2008

Film insert melding is one of the surface processes that enhances functional or aesthetic qualities of an existing product's surface. In general, film insert molding consists of three processes including thermoforming, trimming and injection molding. Thermoforming, which is the first process of film insert molding, is the most important process because the variation of film thickness has an effect on the mold design and process conditions for the subsequent processes, that are, trimming and injection molding. This study is focused on predicting the film thickness distribution through film insert thermoforming process using commercial FEM code. In order to describe rheological behavior of thermoplastic film (ABS), G'Sell's viscoelastic constitutive law was adopted. The numerical model of film insert thermoforming was established, and the simulation to predict film thickness distribution was performed. Comparison between the results of simulation and experiment was made to validate the proposed finite element analysis.

• Design & Manufacturing
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• v.15 no.2
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• pp.56-62
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• 2021

In this study, design technology of a non-mechanical flow meter using fluidic oscillation generated during the fluid flow in the chamber was investigated. To with respect to design a splitter, which is the most important factor in fluid oscillation, a transient flow simulation analysis was performed for three types of shapes and changes in inlet flow velocity. The oscillation characteristics with respect to the time in each case were compared, and it was confirmed that the SM03 model was the best among the presented models. In addition, the FFT analysis of the fluid oscillation results for the SM03 model was used to obtain a linear correlation between the flow velocity change and the maximum frequency, and a frequency of 20.957 (Hz/m/s) per unit flow velocity was obtained. Finally, injection molding simulation and molding experiment of the chamber with the designed splitter were performed.

• The Korean Journal of Rheology
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• v.11 no.2
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• pp.159-167
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• 1999

Sandwich injection molding is one of the remarkable polymer processes recently developed from conventional injection molding. But it is almost impossible to do theoretical investigation that we've researched it through numerical simulation. In this paper, numerical simulation on the study of sandwich injection molding is based on Finite Element Method and FAN/Control Volume method. In addition to conventional filling parameter that can confirm skin polymer melt front, new filling parameters have been introduced to confirm core polymer melt front advancement. These filling parameters are defined in each layer which is divided to solve temperature field along the thickness direction. One can notice different filling patterns resulted from the variation of material properties such as viscosities and power-law indexes, and processing conditions such as switch-over times and wall temperatures. It gives us a better understanding of the sandwich injection molding process. And we can recognize that it's the core polymer spatial distribution after the completion of filling that is the most important key point to use this process for industrial molding process.

• Journal of the Korean Society of Industry Convergence
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• v.23 no.5
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• pp.773-787
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• 2020

In the injection molding process, the controlling stability of products quality is a very important factor in terms of productivity. Even when the optimum process conditions for the desired product quality are applied, uncontrollable external factors such as ambient temperature and humidity cause inevitable changes in the state of the melt resin, mold temperature. etc. Therefore, it is very difficult to maintain prodcut quality. In this study, a system that learns the correlation between process variables and product weight through artificial neural networks and predicts process conditions for the target weight was established. Then, when a disturbance occurs in the injection molding process and fluctuations in the weight of the product occur, the stability control of the product quality was performed by ANN predicting a new process condition for the change of weight. In order to artificially generate disturbance in the injection molding process, controllable factors were selected and changed among factors not learned in the ANN model. Initially, injection molding was performed with a polypropylene having a melt flow index of 10 g/10min, and then the resin was replaced with a polypropylene having a melt floiw index of 33 g/10min to apply disturbance. As a result, when the disturbance occurred, the deviation of the weight was -0.57 g, resulting in an error of -1.37%. Using the control method proposed in the study, through a total of 11 control processes, 41.57 g with an error of 0.00% in the range of 0.5% deviation of the target weight was measured, and the weight was stably maintained with 0.15±0.07% error afterwards.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.10
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• pp.1549-1554
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• 2010

Recently, plastic screws have replaced metal screws because of the former's light weight, thermal and electrical insulating properties, and anticorrosion characteristics. Plastic screws are usually produced by injection molding, which involves material shrinkage during the solidification of the polymer. This shrinkage results in the degeneration of the dimensional accuracy. In the present study, the effect of injection-molding conditions on the dimensional accuracy of plastic screws was investigated through a numerical simulation of injection molding; on the basis of this simulation, we could determine the mold-design parameters. The design of experiment was applied in accordance with the numerical analysis in order to optimize the injection-molding conditions with a view to improving the dimensional accuracy of the precision plastic screw.

• Polymer(Korea)
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• v.35 no.1
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• pp.1-6
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• 2011

Pressurized high temperature plastic resin flows into the cavity of mold and is solidified in injection molding process. Residual stress is being developed in injection molded part because of high temperature variations and high pressure. Developed residual stress relaxes as time goes. Consequently this makes part deformed and deteriorates quality of product. A measurement method of residual stress for injection molded transparent articles has been investigated using photoelasticity. Light, a composite of electromagnetic waves, is purified into a single wave by a polarized film. When this wave passes through the specimen, birefringence is developed according to the level of residual stress in the specimen and color fringed pattern appears after the second polarized film. Residual stress in the injection molded transparent flat a part has been measured quantitatively using the color fringed pattern. Optical characteristics have been a part also predicted by computer simulation and compared with experimental results.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.9
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• pp.5737-5742
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• 2015

Insert injection molding is a process in which molten plastic is injected into a mold that contains a pre-placed insert. During the injection stage, the insert can be deformed by the pressure applied by the polymer melts. The deformation of the insert changes the width of the flow path around the insert, which can cause several defects such as short shots or warpages of the parts. In order to reduce the deformation of the insert, it is important to achieve successful design of gating system, insert geometry, and molding conditions. In the present study, the insert deformations that occured during the injection molding of the BLDC motor stator were investigated by numerical analyses. The gate location and the insert shape were modified to reduce the insert deformation. Finally, the injection molding with the modified designs was carried out, and it was confirmed that the insert deformation was reduced.

• Design & Manufacturing
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• v.16 no.4
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• pp.24-33
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• 2022

Fiber-reinforced plastics(FRPs) have excellent specific stiffness and strength, so they are usually used as automotive parts that require high rigidity and lightweight instead of metal. However, it is difficult to predict the mechanical properties of injection molded parts due to the fiber orientation and breakage of FRPs. In this paper, the fiber orientation characteristics and mechanical properties of injection molded specimens were evaluated in order to fabricate automotive transmission side covers with FRPs and design a rib structure for improvement of their rigidity. The test molds were designed and manufactured to confirm the fiber orientation characteristics of each position of the injection molded standard plate-shaped specimens, and the tensile properties of the specimens were evaluated according to the injection molding conditions and directions of specimens. A gusset-rib structure was designed to improve the additional structural rigidity of the target products, and a proper rib structure was selected through the flexural tests of the rib-structured specimens. Based on the evaluation of fiber orientation and mechanical characteristics, the optimization analyses of gate location were performed to minimize the warpage of target products. Also, the deformation analyses against the internal pressure of target product were performed to confirm the rigidity improvement by gusset-rib structure. As a result, it could be confirmed that the deformation was reduced by 27~37% compared to the previous model, when the gusset-rib structure was applied to the joining part of the target products.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.47-52
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• 2001

Micro-injection molding and microfluidic devices with the help of MEMS technologies including the LIGA process are expected to play important roles in. micro-system industries, in particular the bioapplication industry, in the near future. Understanding fluid flows in micro-channels is important since micro-channels are typical geometry in various microfluidic devices and mold inserts for micro-injection molding. In the present study, both experimental and numerical studies have been carried out to understand the detailed flow phenomena in micro-channel filling process. Three sets of micro-channels of different thickness were fabricated and a flow visualization system was also developed to observe the filling flow into the micro-channels. Experimental flow observations were extensively made to find the effects of channel width and thickness, and effects of surface tension and volume flow rate and so on. And a numerical analysis system has been developed to simulate the filling flow into micro-channels with the surface tension effect taken into account. Discussed are the flow visualization experimental observations along with the predictability of the numerical analysis system.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.3
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• pp.370-376
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• 2011

Recently, the application range of plastic gears is widely expanding by the development of engineering plastics with good mechanical properties. Plastic gears have excellent performances such as light weight, water resistance and vibration absorbing ability for metallic gears. In this study, the optimization of injection molding process was done for the large disk type plastic gears of auto phoropter. Design Of Experiment (Taguchi method) was adopted to find a tendency of molding conditions that influence the flatness of disk type gear. Four main factors for molding conditions were selected based on injection temperature, filling time, packing pressure and mold temperature. Also, Filling, packing and cooling analyses were carried out to evaluate Z directional deflection of large disk type gear by using the simulation software (Moldflow) based on the DOE. From the results, it was found that the injection temperature and packing pressure are the most sensitive parameters for the Z directional deflection of large disk type gears.