• Design & Manufacturing
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• v.10 no.1
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• pp.7-11
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• 2016

Sinks occurring in the rib portion of the testing product for the unpainteds are fatal defects at surface quality. In this study, we carried out moldflow analyses for several factors that affect the sinks. The result tells us large important effective factors on sinks by analyzing sink marks estimate. We expect practical use as reference for performing analysis or manufacturing products with rib designs and injection moldings which minimize sink-marks surrounded ribs.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.7
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• pp.111-115
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• 2008

This paper describes the optimization of injection molding conditions to minimize sink marks. Sink marks, which refer to a small depression on the surface opposite a thick wall thickness, are often encounted in injection molded plastic parts. Part geometry, material properties and processing conditions during injection molding can affect the sink mark depth. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique. By actual injection molding using optimized mold and molding conditions, it confirmed that sink mark depth decreased zero compared to 1mm level in the conventional mold and process.

• Design & Manufacturing
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• v.2 no.2
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• pp.33-37
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• 2008

This paper describes the optimization of injection molding conditions to minimize sink marks. Sink marks, which refer to a small depression on the surface opposite a thick wall thickness, are often encounted in injection molded plastic parts. Part geometry, material properties and processing conditions during injection molding can affect the sink mark depth. We designed the runner system which is possible balanced filling to cavities using CAE program and then obtained optimal processing conditions by Taguchi's Robust Design technique. By actual injection molding using optimized mold and molding conditions, it confirmed that sink mark depth decreased zero compared to 1mm level in the conventional mold and process.

• Design & Manufacturing
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• v.12 no.2
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• pp.22-26
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• 2018

In the automotive industry these days, plastic parts have been developed and replaced with plastic parts by maintaining the same function of existing press parts for a variety of reasons. Injection molding plastic parts are subject to molding defects due to various factors, among which the sink marks usually occur in the areas where bosses and ribs are installed. In this study, we analyzed the influence of various factors on the occurrence of sink marks by using the flow analysis of the forming analysis program(Moldflow analysis) using the rib model with the T-shape. Tests have shown that the greatest influence on the sink mark of cosmetic products is the thickness and pressure of the ribs, and the thickness of the basic moulding thickness of the product increases. However, it was considered that the resin temperature and the mold temperature do not greatly affect the occurrence of the sink mark.

• Design & Manufacturing
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• v.2 no.4
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• pp.37-43
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• 2008

Supplementary features in injection molded products, which are boss, rib and snap fit, are mainly located in the products. These features might make molding flow improper in injection processing and consequently give rise to some of molding troubles such as short shot and hesitation. The sink mark on boss parts is generated by the volumetric shrinkage that is caused by both the molding thickness and the closed boss height. The volumetric shrinkage is affected by packing pressure and its amount tends to decrease by increasing the packing pressure. The packing pressure can therefore increase flow rate to a boss part and causes the sink mark depth to increase. As the molding thickness and the closed boss height in the boss part can increase the part volume, these may yield bad solidifying and also extend the molding cycle. In this paper, both the injection molding test and the flow analysis were carried out to investigate the effect of sink marks generated in the boss part of injection molded products.

• Proceedings of the KSME Conference
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• 2001.11a
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• pp.772-777
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• 2001

The gas-assisted injection molding process is often perceived to be unpredictable, because of the extreme sensitivity of the gas. Since a slight change in design or process parameters can significantly change the resulting gas penetration, few designers and molders have the level of experience with the new gas-assisted injection molding process required for the development of new parts. This paper is concerned with the unified molding for a thick cosmetic chest by using gas-assisted injection molding. CAE analysis was carried out to design the part and the gas channel without inducing sink marks. And based on the part weight measurement, the processing parameters to control gas penetration percentage were chosen through the method of design of experiments. A thick cosmetic chest was successfully produced using the gas assist technology. The sink mark issue associated with the conventional injection molded parts was resolved. Weight savings and cycle-time reduction were also achieved.

• Design & Manufacturing
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• v.1 no.1
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• pp.17-21
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• 2007

In the manufacture and processing of large plastic materials, product quality is tested and verified through several techniques such as injection processing, residual stress through injection molding and shrinkage. With regards to the injection molding process, common problems such as inconsistent density is seen when different points of the product are discovered to have varying thickness levels. Sink marks in product are then evident. This occurs when there is poor molding conditions caused about by poor runner and packaging systems incorporated into the process. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique.

• Transactions of Materials Processing
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• v.10 no.5
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• pp.402-410
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• 2001

The gas-assisted injection molding process is often perceived to be unpredictable, because of the extreme sensitivity of the gas. Since a slight change in design or process parameters can significantly change the resulting gas penetration, few designers and molders have the level of experience with the new gas-assisted injection molding process required for the development of new parts. This paper is concerned with the unified molding for a thick cosmetic chest by using gas-assisted injection molding. CAE analysis was carried out to design the part and the gas channel without inducing sink marks. And based on the part weight measurement, the processing parameters to control gas penetration percentage were chosen through the method of design of experiments. A thick cosmetic chest was successfully produced using the gas assist technology. The sink mark issue associated with the conventional injection molded parts was resolved. Weight savings and cycle-time reduction were also achieved.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.9
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• pp.1-8
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• 2020

In this study, the optimal design of the multi-cavity mold layout and packing pressure for the automobile TCU connector cover is determined based on the injection molding analysis and the desirability function method for multi-characteristic optimization. The design characteristics to be optimized are the warpage and sink marks of the product, the scrap of the feed system, and the clamping force. The optimal design is determined by performing injection molding analysis and desirability analysis for design alternatives defined by a complete combination of five mold layouts and six-level packing pressure. The optimal design shows that the desirability values for individual characteristics are quite high and balanced, and the resulting values of individual characteristics are satisfactorily low.

• Proceedings of the KSME Conference
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• 2001.11a
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• pp.766-771
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• 2001

Gas-assisted injection molding is an innovative low-pressure injection molding technique that can provide numerous benefits such as reduced part warpage, excellent surface quality without sink marks, low injection pressure, and greater design flexibility. However, the adoption of gas-assisted injection molding may cause unexpected defects if the gas channel design is not conducted properly. The objective of this paper is to broaden the understanding of gas-assisted injection molding by summarizing the design procedures and experimental results of the gas-assisted injection molding of a 17" flat monitor front cover. The gas channels were designed by using Moldflow(MF/GAS) simulations and a 450 ton injection molding machine with a 5 stage pressure control gas kit was used in the experiments.