• 대한기계학회논문집A
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• 제27권1호
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• pp.77-87
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• 2003

The residual stress and birefringence in injection-molded plastic parts can be divided into the flow-induced residual stress and birefringence produced in flowing stage, the thermally-induced residual stress and birefringence produced in cooling stage. However, the physics involved in the generation of the thermally-induced residual stress and birefringence still remains to be understood. Because polymer experiences viscoelastic history near the glass-transition temperature it is hard to model the entire process. Volume relaxation phenomenon was included to predict the final thermally-induced residual stress and birefringence in quenched plastic parts more accurately. The present study focused on comparing the predicted values far thermally-induced residual stress and birefringence with and without volume relaxation behavior (or free volume theory) under free and constrained quenching conditions. As a result, tile residual stress remained as a tensile stress at the center and as a compressible stress near the surface for the free quenching cases. In contract the residual stress remained as a compressible stress at the center and as a tensile stress near the surface fur the constrained quenching cases. The residual birefringence remained as minus values at the center and as plus values near the surface for the free quenching cases. Interestingly the residual birefringence showed minus values in entire zone for the constrained quenching cases. In the prediction of birefringence only the case including free volume theory showed the correct result for the distribution of birefringence in thickness direction.

• 한국세라믹학회지
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• 제51권5호
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• pp.487-491
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• 2014

In this study, we measured the thermally and chemically induced residual stresses on glaze using the photoelastic method. Porcelain with thermally induced residual stress showed compressive stress of 49 MPa for thermal expansion mismatch and a locally fluctuated stress field over the glaze layer due to compensation of compressive stresses around pores. In the case of chemically strengthened porcelain, the compressive stress on the glaze was 151 MPa which was around 3 times higher than the stress on thermally strengthened glaze. The trend of fracture strength of thermally and chemically strengthened porcelains was coincident with that of the residual stress of porcelains.

• 반도체디스플레이기술학회지
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• 제14권1호
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• pp.1-5
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• 2015

This paper deals with the residual stresses developed in an epoxy film deposited on Si wafer. First, chemically induced residual stresses due to the volumetric shrinkage in cross-linking resins during polymerization are treated. The curvature measurement method is employed to investigate the residual stresses. Then, thermally induced stresses are investigated along the interface between the epoxy film and Si wafer. The boundary element method is employed to investigate the whole stresses in the film. The singular stress is observed near the interface corner. Such residual stresses are large enough to initiate interface delamination to relieve the residual stresses.

• Korea-Australia Rheology Journal
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• 제19권4호
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• pp.191-199
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• 2007

Precision injection molding process is of great importance since precision optical products such as CD, DVD and various lens are manufactured by those process. In such products, birefringence affects the optical performance while residual stress that determines the geometric precision level. Therefore, it is needed to study residual stress and birefringence that affect deformation and optical quality, respectively in precision optical product. In the present study, we tried to predict residual stress, final shrinkage and birefringence in injection molded parts in a systematic way, and compared numerical results with the corresponding experimental data. Residual stress and birefringence can be divided into two parts, namely flow induced and thermally induced portions. Flow induced birefringence is dominant during the flow, whereas thermally induced stress is much higher than flow induced one when amorphous polymer undergoes rapid cooling across the glass transition region. A numerical system that is able to predict birefringence, residual stress and final shrinkage in injection molding process has been developed using hybrid finite element-difference method for a general three dimensional thin part geometry. The present modeling attempts to integrate the analysis of the entire process consistently by assuming polymeric materials as nonlinear viscoelastic fluids above a no-flow temperature and as linear viscoelastic solids below the no-flow temperature, while calculating residual stress, shrinkage and birefringence accordingly. Thus, for flow induced ones, the Leonov model and stress-optical law are adopted, while the linear viscoelastic model, photoviscoelastic model and free volume theory taking into account the density relaxation phenomena are employed to predict thermally induced ones. Special cares are taken of the modeling of the lateral boundary condition which can consider product geometry, histories of pressure and residual stress. Deformations at and after ejection have been considered using thin shell viscoelastic finite element method. There were good correspondences between numerical results and experimental data if final shrinkage, residual stress and birefringence were compared.

• 대한기계학회논문집A
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• 제26권11호
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• pp.2342-2354
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• 2002

The present study has numerically predicted both the flow -induced and thermally-induced residual stresses and birefringence in injection o. injection/compression molded center -gated disks. Analysis system for entire molding process was developed based on an ap propriate physical modeling including a nonlinear viscoelastic fluid model, stress-optical law, a linear viscoelastic solid model, free volume theory for density relaxation phenomena and a photoviscoelasticity and so on. Part I presents physical modeling a nd typical numerical analysis results of residual stresses and birefringence in the injection molded center-gated disk. Thermal residual stress was found to be extensional near the center, compressive near the surface and tend to become toward tensional at the surface. A double-hump profile was obtained across the thickness in birefringence distribution: nonzero birefringence is found to be thermally induced, the outer peak is due to the shear flow and subsequent stress relaxation during the filling stage a nd the inner peak is due to the additional shear flow and stress relaxation during the packing stage. Predicted birefringence including both the flow -induced and thermally-induced one becomes quite similar to the experimental one.

• 대한기계학회논문집A
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• 제26권11호
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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.

• 한국정밀공학회지
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• 제14권11호
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• pp.58-68
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• 1997

The residual stresses in injection-molded plastic parts can be divided into two, i.e., the flow-induced residual stress produced in flowing stage and the thermally-induced residual stress produced in cooling stage. Especially, the main source for the defect in the final parts, such as warpage, is known to be the thermally-induced stresses. For the freely quenched samples the structures of residual stresses and bire-fringence have been investigated by many researchers extensively. However, the boundary condition for free quenching was found to be improper to study actual injection molding process. In the present study a datailed structure of the residual stresses and birefringence produced under constrained quenching has been investigated experimentally. In constrained quenched samples a similar pattern but much less stress values than that for the freely quenched samples has been found in the case of the thickness of 1.0 mm. Howvere, in the case of the thickness of 4.0mm, totally different stress profile has been found experimentally. Suprisingly uniform birefringence throughout whole thickness has been found for all the cases of constrained quenching. Finally, to explain the mechanism to produce the final residual stresses and bire-fringence some preliminary numerical results including free volume theory have been introduced briefly.

• 소성∙가공
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• 제16권3호
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• pp.193-200
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• 2007

Simulations of the thermally-induced residual stresses and birefringence in freely quenched plates of polycarbonate were performed by using the linear viscoelastic and photoviscoelastic constitutive equations for the mechanical and optical properties, respectively, and the first order rate equation for volume relaxation. The predictions for the birefringence showed good agreement with experimental measurements. However, for initial temperature close to the glass transition temperature, some differences existed around the surface layer. Based on the simulation, the influences of various cooling conditions on the residual stress and birefringence in plates were investigated. The residual stress and birefringence increased with increasing initial temperature, decreasing coolant temperature and increasing heat transfer coefficient of coolants.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 추계학술대회 논문집
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• pp.258-261
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• 2007

Simulations of the thermally-induced residual stresses and birefringence in freely quenched plates of polycarbonate were performed by using the linear viscoelastic and photoviscoelastic constitutive equations for the mechanical and optical properties, respectively, and the first order rate equation for volume relaxation. The predictions for the birefringence showed good agreement with experimental measurements. Based on the simulation, the influences of various cooling conditions on the residual stress and birefringence in plates were investigated. The residual stress and birefringence increased with increasing initial temperature, decreasing coolant temperature and increasing heat transfer coefficient of coolants.

• 터널과지하공간
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• 제31권6호
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• pp.593-609
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• 2021

본 연구에서는 입자기반 개별요소모델(grain-based distinct element model, GBDEM)을 이용하여 결정질 암석 내 포함된 균열의 열-역학적 거동을 평가할 수 있는 수치해석기법을 제시하고 열에 의한 균열의 미끄러짐 거동을 해석하였다. 이는 DECOVALEX-2023 프로젝트 Task G의 일환으로 수행된 벤치마크 모델링 연구로, Task G는 결정질 암반 내 균열의 열-수리-역학적 복합거동을 해석하기 위한 수치해석기법을 개발하는 데에 목표가 있다. 여기에서는 Voronoi diagram을 이용하여 다면체 개별입자의 집합체로서 해석모델을 생성하고, 입자 및 입자간 접촉에서 발생하는 열-역학적 거동을 개별요소프로그램인 3DEC을 통해 해석하였다. 암석 시험편의 탄성거동을 재현하기 위하여 등가연속체 개념을 적용하여 입자와 접촉의 미시물성을 산정하였으며, 균열에 상응하는 접촉에는 Coulomb slip model을 부여하여 인장강도와 전단강도를 갖는 불연속면을 모사하였다. 경계응력과 열응력에 의한 균열의 거동을 수치적으로 모델링하였으며, 경계조건에 따라 균열의 미끄러짐이 발생하는 열-역학적 메커니즘을 정량적으로 분석하였다. 해석 결과, 본 연구에서 제시한 해석모델이 암석 내 열팽창과 열응력의 증가, 균열 응력과 변위, 경계조건의 영향 등을 합리적으로 재현하고 있음을 확인하였다. 본 연구의 해석모델은 Task G에 참여하는 국외 연구팀들과의 의견 교류와 워크숍을 통해 지속적으로 개선하는 한편, 향후 실내실험에 적용하여 타당성을 검증할 예정이다.