• Design & Manufacturing
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• v.18 no.2
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• pp.64-73
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• 2024

The purpose of this paper is to introduce a fusion method that combines the design of experiments (DOE) and machine learning to optimize the bias of plastic products. The study focuses on the plastic motor housing used in automobiles, which is manufactured through plastic injection molding. Achieving optimal molding for the motor housing involves the optimization of various molding conditions, including injection pressure, injection time, holding pressure, mold temperature, and cooling time. Failure to optimize these conditions can lead to increased product deformation. To minimize the deformation of the motor housing, the widely used Taguchi method, which is one of the design of experiment techniques, was employed to identify the injection molding conditions that affect deformation. Machine learning was then applied to various models based on the identified molding conditions. Among the models, the Random Forest model emerged as the most effective in predicting deformation amounts. The validity of the Random Forest model was also confirmed through verification. The verification results demonstrated the excellent prediction accuracy of the trained Random Forest model. By utilizing the validated model, molding conditions that minimize deformation were determined. Implementation of these optimal molding conditions led to a reduction of approximately 5.3% in deformation compared to the conditions before optimization. It is noteworthy that all injection molding outcomes presented in this paper were obtained through robust injection molding simulations, ensuring both research objectivity and speed.

• Korean Chemical Engineering Research
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• v.60 no.2
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• pp.295-299
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• 2022

In this paper, paint-free metallic plastic material, polypropylene (PP) and acrylonitrile styrene acrylate (ASA) materials were investigated on the applications for bumper skid plate and outside mirror housing parts. In order to maximize metallic effect, type, size and content of aluminum pigment were optimized based on flop index. Hybrid aluminum pigments with different aspect ratios were used to conceal weld lines. By controlling the fluidity of the material, the flow mark problem, generated on the surface of the part, was resolved. We also investigated the surface defects of flow and weld lines by using the developed modeling and simulation.

• Transactions of the Korean hydrogen and new energy society
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• v.23 no.5
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• pp.484-492
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• 2012

The TMS(Thermal Management System) heater in a fuel cell vehicle has been developed to prevent a decline of fuel cell durability and cold start durability. Main functions of the COD(Cathode Oxygen Depletion) heater are depletion of oxygen in a cathode as heat energy and consumption of electric power for rapid warming up of a fuel cell stack. This paper covers subjects including the design specification of a heater, heater controller for detection of overheat and reliability assessment including coolant pressure cycle test of a heater. To verify the design concept, burst pressure and deformation analysis of plastic housing were carried out. Also, temperature distribution analysis of heater surface and coolant inside of housing were carried out to verify the design concept. By designing the plastic housing instead of a steel housing, the 30% weight lightening and 50% cost reduction were attained. A module-based design of a TMS system including a heater or reducing the watt density of a heater is a problem to be solved in the near future work.

• Journal of Welding and Joining
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• v.34 no.1
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• pp.21-25
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• 2016

The automotive vehicle is made through the following processes such as press shop, welding shop, paint shop, and general assembly. Among them, the most important process to determine the quality of the car body is the welding process. Generally, more than 400 pressed panels are welded to make BIW (Body In White) by using the RSW (Resistance Spot Welding) and GMAW (Gas Metal Arc Welding). Recently, as the needs of light-weight material due to the $CO_2$ emission issue and fuel efficiency, new joining technologies for aluminum, CFRP (Carbon Fiber Reinforced Plastic) and etc. are needed. Aluminum parts are assembled by the spot welding, clinching, and SPR (Self Piercing Rivet) and friction stir welding process. Structural adhesive boning is another main joining method for light-weight materials. For example, one piece aluminum shock absorber housing part is made by die casting process and is assembled with conventional steel part by SPR and adhesive bond. Another way to reduce the amount of the car body weight is to use AHSS (Advanced High Strength Steel) panel including hot stamping boron alloyed steel. As the new materials are introduced to car body joining, productivity and quality have become more critical. Productivity improvement technology and adaptive welding control are essential technology for the future manufacturing environment.

• Transactions of the Korean Society of Automotive Engineers
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• v.22 no.3
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• pp.143-147
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• 2014

The ECU which is operating inductive actuator like motor or solenoid should be designed with considering the heat removal performance and the EMC performance. In most cases, these two performances are trade-off. Especially, the metal cover with plastic housing for improving heat removal performance can affect EMC performance by coupling the noise source to harness cable and connector. Therefore, after analyzing the EMC effectiveness of the metal cover, countermeasures for EMC noise reduction should be established. In this paper, by simulating and testing of AHB Gen3 ECU, the influence of the metal cover to EMC performance is analyzed. And based on this result, we propose solutions for EMC noise reduction.

• Journal of the Korea Convergence Society
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• v.2 no.2
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• pp.27-34
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• 2011

This study is making a product for the development of one process worm wheel of making a shape for gear for worm wheel without hobbing manufacturing process. Because of removing a hobbing process, plastic worm wheel for increased productivity and equivalent quality is produced in the result. As the result, this product is selling to Hyundai Mobis, Mando, TRW, KOYO/NSK/Showa(Japan), Delphai(America). The core technology and different strategy are as follows. The technology protection for molding of worm whee is currently patent process "Molding process of helical gear(No. 10-2008-0105908). Further patent procedure for "molding system for positioning decision of inserting boss is currently prepared. As gear molding procedure in hobbing machine without gear machining procedure, most of all, core development technology which is making a gear tooth is main topic. So that, in case of currently developed worm wheel, because core and mold base are not developed in the first procedure, gear is machining in hobbing M/C as the second procedure. In the later, patent for mold base structure will be prepared in this study results.