• Design & Manufacturing
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• v.14 no.4
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• pp.11-16
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• 2020

In this study, forming of carbon composite parts was performed using an injection/compression molding process. An impregnation of matrix is determined by ability of wet and flow rate between the matrix and reinforcement. The flow rate of matrix passing through the reinforcements is a function of permeability of reinforcement, a viscosity of matrix and pressure gradient on molding, and the viscosity of the matrix depends on the mold temperature, molding pressure and shear strain of matrix. Therefore, compression molding experiment was conducted using a heating mold in order to confirm the possibility of matrix impregnation. The impregnation of the matrix through the porosities between the woven yarns was confirmed by the cross-sectional SEM image of compression molded parts. An injection molding process was also performed at a short cycle time, high molding pressure and low mold temperature than those of compression experiment conditions. Deterioration of impregnation on the surface of molded parts were caused by these injection conditions and it could be the reason of decreasing the maximum tensile strength. In order to improve impregnation of matrix on the surface, injection/compression molding and insert-over molding were applied. As a result of applying injection/compression molding and insert-over molding, it was shown that the improvement of impregnation on the surface and the maximum tensile strength was increased about 2.8 times than the virgin matrix.

• The Transactions of The Korean Institute of Electrical Engineers
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• v.56 no.3
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• pp.604-610
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• 2007

Injection molding is the most common method of shaping plastic resins for manufacturing a variety of parts. This injection molding is accomplished by injection molding machines (IMM) which consists of a hewer, a reciprocating screw, barrel assembly, and an injection nozzle. The plastic resin is fed to the machine through the hopper and it should be heated to the target melting temperature, which depends on material properties, as closely as possible with very small temperature overshoot in the barrel. Since the barrel, which has temperature dependent specific heat and thermal conductivity in the operating temperature range, is heated by the several electric heater bands, it is not an easy task to control the temperature of the barrel owing to the interference of neighboring heaters and its material properties. Though PID controller with auto-tuning capability is widely adopted in the nm, the auto-tuning process should be carried out whenever the operating temperature is changed significantly. Recently, though the predictive controller is developed and shows good performance, it has drawbacks: 1. Since the heat transfer modeling process is very complicated and should be carried out again when the barrel is changed, it is somewhat inappropriate in the field. 2. The controller performance is not validated in whole operating temperature range. In this paper, cascade type simple PI controller with input restriction is proposed to find the possibility of controlling the barrel temperature in the whole operating temperature range. It is shown by experiment that the proposed controller shows good performance. This result can be applied to design of PI controller with auto-tuning capability.

• Transactions of Materials Processing
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• v.21 no.2
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• pp.107-112
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• 2012

Gas-assisted injection molding(GAIM) produces parts with hollow internal sections. The technique offers benefits to powder injection molding(PIM), with lower material usage and reduced time for de-binding processes. In this study, the effects of processing parameters on gas penetration length of gas-assisted powder injection molding(GAPIM) were investigated for SUS316L stainless steel powder feedstock. Experiments were planned based on the Taguchi method, involving processing variables such as melt temperature, shot size, gas pressure, and gas delay time. The most significant parameters affecting gas penetration length were gas delay time and shot size, while the effects of melt temperature and gas pressure was relatively insignificant.

• Advanced Composite Materials
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• v.16 no.4
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• pp.385-394
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• 2007

In this study, the effect of molding condition on the tensile properties for plain woven hemp fiber reinforced green composite was examined. The tensile properties of the composite were compared with those of the plain woven jute fiber composite fabricated by the same process. Emulsion type biodegradable resin or polypropylene sheet was used as matrix. The composites were processed by the compression molding where the molding temperature and its heating time were changed from 160 to $190^{\circ}C$ and from 15 to 25 min, respectively. The following results were obtained from the experiment. The tensile property of hemp fiber reinforced polypropylene is improved in comparison with polypropylene bulk. The strength of composite is about 2.6 times that of the resin bulk specimen. Hemp fiber is more effective than jute fiber as reinforcement for green composite from the viewpoint of strength. The molding temperature and time are suitable below $180^{\circ}C$ and 20 min for hemp fiber reinforced green composite. Hemp fiber green composite has a tendency to decrease its tensile strength when fiber content is over 50 wt%.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.1834-1839
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• 2003

Temperature and velocity distributions of hot air flows in rotational molding machines with two different shapes and structures of oven and inlet were investigated by using FLUENT, a commercial computational fluid dynamics code. The shape and structure of oven and inlet in current rotational molding machine were improved. Two different sizes of mold inside each oven were considered in the analysis. Temperature and velocity distributions of hot air flows in two different rotational molding machines were compared to each other. In order to reduce cycle time and improve product quality in current rotational molding machine, the improved shape and structure of oven and inlet were proposed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2008.11a
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• pp.75-76
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• 2008

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.11
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• pp.2355-2363
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• 2002

The accompanying paper, Part 1, has presented the physical modeling and basic numerical analysis results of both the flow-induced and thermally-induced residual stress and birefringence in injection molded center gated disks. The present paper, Part II, has attempted to investigate the effects of various processing conditions of injection/compression molding process on the residual stress and birefringence. The birefringence is significantly affected by injection melt temperature, packing pressure and packing time. Birefringence in the shell layer increases as melt temperature gets lower. The inner peak of birefringence increases with packing time and packing pressure. On the other hand, packing pressure, packing time and mold wall temperature affect the thermally-induced residual stress rather significantly in the shell layer, but insignificantly in the core region. Injection/compression molding has been found to reduce the birefringence in comparison with the conventional injection molding process. In particular, mold closing velocity and initial opening thickness in the compression stage of injection/compression molding process have significant effect on the flow-induced birefringence, but not on tile thermal residual stress and the thermally induced birefringence.

• Design & Manufacturing
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• v.14 no.4
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• pp.25-39
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• 2020

In this study, an edge device that monitors the injection molding process by measuring the mold vibration(acceleration) signal and the mold surface temperature was developed and evaluated its performance. During injection molding, signals of the injection start, V/P switchover, and packing end sections were obtained through the measurement of the mold vibration and the injection time and packing time were calculated by using the difference between the times of the sections. Then, the mold closed and mold open signals were obtained using a magnetic hall sensor, and cycle time was calculated by using the time difference between the mold closed time each process. As a result of evaluating the performance by comparing the process data monitored by the edge device with the shot data recorded on the injection molding machine, the cycle time, injection time, and packing time showed very small error of 0.70±0.38%, 1.40±1.17%, and 0.69±0.82%, respectively, and the values close to the actual were monitored and the accuracy and reliability of the edge device were confirmed. In addition, it was confirmed that the mold surface temperature measured by the edge device was similar to the actual mold surface temperature.

• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.368-374
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• 2005

In the present study we used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design and molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors. The contributing factors for the final cycle time could be enumerated as follows; the thickness of hot spot, main nominal part thickness, coolant inlet temperature, melt temperature and cooling line layout, etc.. As a first step, all the critical factors of design process applied to the current monitor housing were investigated through 6 sigma process. Thereafter, the optimal and better critical factors found in the first step were applied to new product design to prove that our process was correct. The Moldflow was used for injection molding simulation, and Minitab software for the statistical analysis, respectively. Finally, the productivity of new design was increased about 33 percents for our specific case.

• 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.