• Elastomers and Composites
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• v.55 no.2
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• pp.120-127
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• 2020

In this study, molding shrinkage of PPS resin was investigated. Two types of PPS resins with differing glass fiber and calcium carbonate content were used for this purpose. To observe mold shrinkage, molding conditions based on injection temperature, injection speed, and the position of the cushion were selected. Circular and rectangular specimens were used for the study model. Injection molding simulation was performed to predict the filling pattern and mold shrinkage, and the simulation results were compared with the experimental conclusions. It was observed that the mold shrinkage showed the highest shrinkage (distributed from 0.05% to 0.32%) dependence on the injection temperature, and the lowest shrinkage (distributed from 0.05% to 0.31%) dependence on the injection speed. The role of the position of the cushion in mold shrinkage was difficult to observe. The results of the simulation mostly agreed with the experimental results; however, for some molding conditions, the mold shrinkage in the simulation was overestimated as compared to that in the experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.262-265
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• 2007

Cooling circuit of injection mold affects part quality and cycle time of injection molding process. Examination on mold cooling circuit is usually omitted in part design stage because cooling circuit is designed in the mold design stage. It is desirable to examine mold cooling circuit with respect to part quality in the part design stage. In order to make the examination process convenient and fast, cooling circuit design should be automated without intervention of skilled designer. In this study, optimization of cooling circuit design is automated with commercial softwares; Visual DOC and Moldflow MPI. Effect of initial value for optimization is examined for the optimization result.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.297-300
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• 2008

High pressure is involved during injection molding operation specially packing phase. Cracks in the mold are often occurred by high cavity pressure. In this study, structural analysis of mold has been performed using commercial softwares, Abaqus and Ansys, to investigate cause of crack in the injection mold. Structural analysis contains four cases: stress distribution according to the cavity pressure, stress concentration according to the boundary conditions, stress concentration for inter-locking design of mold, and stress concentration for distributed cavity pressure. Through this study it was observed that the locations of stress concentrations were coincident with locations of crack. Robust mold design is being required to withstand high cavity pressure.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.92-97
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• 2012

Injection mold is a manufacturing process used to produce parts of complicated shape at a low cost. Many factors affect the quality of injection molded part during injection molding process. A study on the optimization of injection mold is progressed by using a simulation software like Moldflow. Filling, packing and cooling phases of injection molding processes are analyzed according to the mold design considering the shrinkage of molded part, the degree of filling rate and the wearing of a mold. Taguchi method is applied to analyze the significance of processing parameter and the dynamic characteristics according to the variation of processing parameters. From the results, the mold temperature and packing pressure influenced the shrinkage of injection molded part.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.1
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• pp.34-39
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• 2011

Temperature control of a rubber injection mold is important for the dimensional accuracy of product. The main objective of this paper is to optimize the arrangement of heaters by FEM and optimal design method. Firstly, 3-dimensional transient heat transfer analysis was carried out for a square specimen mold. Results of FE analysis are a good agreement with the experimental results, showing about 1.22~7.22% error in temperature distribution. Secondly, we suggested the optimal method about an arrangement of heaters of rubber injection mold by using the optimal design technique. Distances between heater's center and the contact surface of mold, distances between heater's center and symmetric surface were considered as design variables. And the variances between the temperatures of cavity surfaces and their average temperature were used as the objective functions. Applying the optimal solution, the temperature variation was improved about 52.9~88.1 % compared to the existing mold. As a result of sensitivity analysis for design variables, design variables parallel to the direction of the split plane in mold affect the largest on the surface temperature variation in mold cavity.

• Transactions of Materials Processing
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• v.14 no.6 s.78
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• pp.570-576
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• 2005

Powder Injection Molding(PIM) has recently been recognized as an advanced manufacturing technology for low-cost mass production of metal or ceramic parts of complicated geometry With this regards, design technology of dental scaler tip PIM mold, which has complex shape and small core pin (diameter=0.6mm), with the help of computer-aided analysis of powder injection molding process was developed. Computer-aided analysis for dental scaler tip mold was implemented by finite element method with non-Newtonian fluid, modified Cross model viscosity, PvT data of powder/binder mixture. Compter-aided analysis results, such as filling pattern, weldline formation, air vent position prediction were compared with experimental result, and eventually have been shown good agreement. The core pin (diameter=0.6mm) deflection analysis of dental scaler tip PIM mold during PIM filling process was also investigated before mold fabrication.

• Korean Journal of Computational Design and Engineering
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• v.10 no.3
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• pp.151-161
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• 2005

This paper describes the parting and Boolean operations for a pseudo-solid model of a plastic part, and their application to injection mold design. Here, a pseudo-solid model means a sheet model that looks like a solid model, but its boundary is not closed. When a solid model created in a different CAD system is imported through a standard data exchange file format, in most cases, a pseudo-solid model may be created due to tolerance or some other problems. However, most existing mold design systems based on solid modeling kernels require a complete part solid model. Therefore, mold designers have to do time-consuming healing operations to convert a pseudo-solid to solid. To eliminate or reduce the healing pre-process for mold design, in this paper, we proposed the parting and Boolean Operations on pseudo-solid part models. This paper also describes their detailed implementation and a case study.

• Korean Journal of Computational Design and Engineering
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• v.10 no.6
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• pp.381-391
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• 2005

The design methodology of injection molding die has been changed from two-dimensional drafting to three-dimensional solid modeling, which is due to many advantages over the conventional methodology in terms of design modification and data associativity. In addition to the solid modeling capability, it is required for a mold designer to utilize a database management system that facilitates efficient mold design. In the paper presented is the implementation of a software program which automatically generates three-dimensional mold-bases including standard parts and slider parts, conforming to given geometric constraints. It is based on a commercial CAD system (Unigraphics NX) along with related API (application program interface) libraries. The research is expected to reduce design efforts and simplify construction of a complex three-dimensional mold-base model that is comprised of standard parts and slider parts, by use of the three-dimensional database and automatized geometric dimensioning.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.29-35
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• 2011

In the design of the injection molding process, various parameters including mold design parameters and molding conditions should be investigated to improve part quality. The mold temperature is one of important processing parameters that affect the flow characteristics, surface appearance, part deformation, mechanical properties, etc. Numerical analyses have been used to predict the temperature distribution of the mold under the given cooling or heating conditions. However, conventional analyses have been performed by assuming that the mold material is a single solid even though a number of plates are assembled to construct an injection mold. In the present study, a numerical approach considering the thermal contact resistance is proposed to provide more reliable prediction of the mold temperature distribution by reflecting the heat-resistance between assembled mold plates.

• Design & Manufacturing
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• v.2 no.5
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• pp.21-24
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• 2008

On this study, injection molding product of rectangular tray structure with thickness 0.25mm and aspect ratio(length/thickness) approximately 150 conducted. Technical aspects were reviewed on mold-die design and injection molding conditions. To have a thin-membraned plastic part, short-shot, shrinkage, twist, whitening and flash problems were considered and resolved. After measuring products, validity of this study and future improvement were discussed.