• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.706-709
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• 2005

Despite geometrical balanced runner system, filling imbalances between cavity to cavity have always been observed in multi-cavity injection mold. These filling imbalances are results from non-symmetrical shear rate distribution within melt as it flows through the runner system. It has been possible to decrease filling imbalance by optimizing processing conditions, but it has not completely eliminated this phenomenon during the injection molding processing. This paper presents a solution of these filling imbalances by using runner core pin which creates a symmetrical shear distribution within runner and the effects on filling imbalance when modifying a shape of runner core pin. As a result of using runner core pin, a remarkable improvement in reducing filling imbalance was confirmed. In addition we investigated how filling imbalances were affected by shape of runner core pin.

• Design & Manufacturing
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• v.2 no.5
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• pp.16-20
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• 2008

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing; However, even though geometrically balanced runner is used, filling imbalances have been observed. In these day, the CAE has been used widely in injection molding. However, CAE with fusion mesh can't indicate such as jetting, flow mark and filling imbalance in multi cavity mold. In this study, we investigated the filling imbalance according to runner shapes by CAE analysis. As a result in CAE, in case of binary branch runner system, filling imbalance was indicated between cavity to cavity, but the flow pattern of each cavity uniformed in unary branch runner system.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.98-102
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• 2009

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalance has been observed. Filling imbalance could be decreased by modifying processing conditions such as injections rate, mold temperature, injection pressure, melt temperature that are related to shear, viscosity. In this study, a series of experiment was conducted to investigate filling imbalance variation when modifying runner layout and polymer and to determine which processing condition influences as the primary cause of filling imbalance in geometrically balanced runner system. The filling imbalance was decreased up to result range of $3{\leq}DFI{\leq}8(%)$ by using a new runner system for balanced filling.

• Transactions of Materials Processing
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• v.15 no.1 s.82
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• pp.47-56
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• 2006

It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially when the family-mold has a volumetric difference between two cavities. In this study, the cavity-filling imbalance was confirmed by the temperature and the pressure sensors, and a variable-runner system was developed for balancing the cavity-filling. Experiments of balancing the cavity filling was carried out in the family-mold with the variable-runner system, and balancing the cavity-filling was confirmed by changing the cross-sectional area of a runner in the variable-runner system with the temperature and pressure sensors. The influence of the injection speed to the balancing-capability of the variable-runner system was also examined in the experiment.

• Design & Manufacturing
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• v.6 no.1
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• pp.52-57
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• 2012

Aspect of filling imbalance that is originated from imbalanced share rate in runner is changed by material property, runner layout that are factors of changing viscosity and by injection pressure, injection speed, melt temperature and mold temperature that are injection conditions. In this paper, we made a study of runner system that is one of factor of filling imbalance and Sharp Conner Effect and Groove Corner Effect that are recently released. The study are showed that filling rate of between inside and outside cavity was influenced on shape of runner. Also, we suggested runner system for filling imbalance by adapting the two effects at multi cavity of unary branch type and theoretical investigated flow in the Shrap Conner runner type.

• Design & Manufacturing
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• v.1 no.1
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• pp.13-16
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• 2007

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalance have been observed. Filling imbalance could be decreased by modifying processing conditions such as injections rate, mold temperature, injection pressure, melt temperature that are related to shear, viscosity. In this study, a series of experiment was conducted to investigate filling imbalance variation when modifying runner layout and polymer and to determine which processing condition influences as the primary cause of filling imbalance in geometrically balanced runner system.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.2
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• pp.60-65
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• 2012

This paper deals with an CAE analysis and optimization of injection molding for a mobile phone cover. Two design goals are established in the optimization; one is to switch over the feed system from cold runner to hot runner for the purpose of reducing material costs, and the other is to minimize the warpage in order to improve product quality. By the full-factorial experiments for design parameters, we showed that the cold runner design could be changed to the hot runner design by replacing the current resin with a new resin of higher fluidity. In addition, we could significantly reduce the warpage of the cover product under the hot runner system by optimizing packing pressure and packing time.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.329-332
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• 2008

Flow imbalance among the cavities was often observed in multi-cavity mold. The flow imbalance affects on the dimensions and physical properties of melded articles. First of all, the origin of flow imbalance is geometrical imbalance of delivery system. However, even the geometry of delivery system is balanced the cavity imbalance is being developed. This comes from the temperature distribution in the cross-section of runner, which is affected by the operational conditions. In this study, experimental study of flow imbalance has been conducted for various injection speeds. This study also suggests new runner design to eliminate flow imbalance in multi-cavity injection mold. Simulation and experimental results showed suggested new designed runner could eliminate or reduce flow imbalance in multi-cavity injection mold.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.10
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• pp.144-149
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• 2008

Configuration of filling imbalance which is originated from imbalanced share rate of melt on runner is changed by runner layout, runner shape, material property, injection pressure, injection speed, melt temperature and mold temperature. In this paper, we conducted a study of runner layout and shape that are main factors of filling imbalance. Other factors such as the sharp corner effect and the groove corner effect are recently released were also considered. The results of study are showed that filling rate of between inside and outside cavity was influenced on shape of runner. Especially, this study suggests a new runner system for filling balance by adapting the two effects of unary branch type runner at multi cavity mold and theoretical investigated flow in the sharp corner type runner.

• Transactions of Materials Processing
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• v.15 no.9 s.90
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• pp.641-647
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• 2006

During the injection molding process an excessive packing can occur in the smaller volume cavity because of volumetric difference of the family-mold. It causes warpage by increased residual stress in the product and flesh by over packing. In this study, we used a variable-runner system for the filling balance of the cavities by changing the cross-sectional area of a runner, and confirmed the filling imbalance by temperature and pressure sensors. We carried out experiments to examine the influence of types of resins such as LDPE/ABS/PA6,6 on the filling balancing of the system, in order to help mold designers, who can easily adopt the variable-runner system to their design. We also examined filling imbalance in the system with CAE analysis.