• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2005.04a
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• pp.45-46
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• 2005

• Korean Chemical Engineering Research
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• v.48 no.4
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• pp.490-498
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• 2010

The optimum mold design and the optimum process condition were constructed upon executing process simulation of rubber injection molding with the commercial CAE program of MOLDFLOW(Ver. 5.2) in order to solve the process-problems of K company relating to air-traps and short-shots. The former occurs at the cavity edge of torque-rod-bush and the latter takes place for the injection molding of dynamic dampers. As a result the process problem relating to air traps was solved by optimizing edge-angle and the number of gates to prevent the flow congestion of flow-front and to make the flow-front movement unaffected by congestion. For dynamic dampers of K company the unmolded flaw caused by their unfilled cavity was corrected by installing the air-vent at the confronting locations of both upstream and downstream of flow-front where air traps frequently occur. Besides the unmolded flaws were rectified by altering the position of gate from the upper to the middle or by increasing the number of gates. Thus the process problems of K company relating to air-traps and short-shots of torque-rod-bush and dynamic dampers, respectively, were solved by proper altering of mold design with process simulation of rubber injection molding.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.4
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• pp.144-150
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• 2005

Gas-assisted injection molding (GAIM) process is reducing the injection pressure during mold filling required as well as the shrinkage and warpage of the part and cycle time. Despite of these advantages, this process introduces new parameters and makes the application more difficult because the process interacts between gas and melt during injection molding process. Important GAIM factors that involved in this process include gas penetration design, locations of gas injection points, shot size, gas injection delay time as well as common injection molding parameters, gas pressure and gas injection time. In this study, the experiments were conducted to investigate effects of GAIM process variables on the gas penetration for PP and ABS moldings by changing gas injection point. Taguchi method was used fer the design of experiment. When the gas was injected at cavity's center, the most effective factor was shot size. When the gas was injected at cavity's end, the most effective factor was melt temperature. Injection speed was also an effective factor in GAIM process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.5
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• pp.113-118
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• 2017

In this paper, we propose a design procedure for determining the gate position robust to changes and inherent fluctuations in the process conditions during injection molding. To evaluate the robustness of the gate position, the signal-to-noise ratio is used, and noise conditions are implemented using orthogonal arrays, where the process variables are considered as noise factors and possible process fluctuations are set as the levels of the noise factors. To show the usefulness of the proposed robust design procedure, we apply it to a computer CPU baseplate. As a result, it is shown that a robust gate position can be determined that reduces the average warpage deflection by 2.4% and 1.7%, and the variance by 3.4% and 5.1%, compared to the two initial gate positions.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.443-448
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• 2008

Fiber reinforced injection molded parts are widely used in recent years because of their improved properties of materials such as specific stiffness, specific strength, and specific toughness. The demand for products with high precision is increasing and it is important to minimize the warpage of the products. The warpage of short-fiber reinforced product is caused by anisotropy induced by fiber orientation as well as the residual stresses induced during the molding process. In order to reduce the warpage of the part, it is important to achieve successful mold design, processing control, and part design. In the present study, the design of gating system, molding condition, and part structure were carried out and verified with numerical analysis using a commercial CAE code Moldflow. The numbers and locations of gates were iteratively determined, and the molding conditions which can decrease the warpage of the part were investigated. Finally, slight structural modification of the part was conducted to reduce the locally concentrated warpage.

• Proceedings of the KAIS Fall Conference
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• 2001.11a
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• pp.139-143
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• 2001

In injection molded parts, the ribs require more complicated mold cavities and cores. But it is necessary for the parts to attach the ribs for assembly, moldability and other functional purposes. To design them appropriately considering structural strength and injection molding, the profound knowledge that includes moldability, causal effects on the properties of the part is needed. This paper describes the design methodology which enables easy, simple, time and cost-effective design for the features.

• Design & Manufacturing
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• v.17 no.1
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• pp.64-69
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• 2023

This paper explores the impact of gate shape changes on the size and density of foamed cells in microcellular foam injection molding. Five different gate shapes were examined while varying the amount of nitrogen gas(N2) injected for foaming. Analysis of the results showed that while average values did not change significantly, deviation values decreased by approximately 65% for cell size and 56% for density when 3.5wt% of nitrogen gas was injected in the film gate. Further analysis was conducted to verify this phenomenon, revealing that the contact area between the gate and product had the greatest impact. Our findings indicate that to ensure uniform generation of foamed cells in microcellular foaming product design, a gate with a wide contact area should be secured.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.46-51
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• 2012

Injection pressure, an important factor in filling process, should be minimized to enhance injection molding quality. Injection pressure can be controlled by valve gate open timing. In this work, we decided the valve gate open timing to minimize the injection pressure. To solve this design problem, we integrated MAPS-3D (Mold Analysis and Plastic Solution-3Dimension), a commercial injection molding CAE tool, to PIAnO (Process Integration, Automation and Optimization), a commercial PIDO (Process Integration, and Design Optimization) tool using the file parsing method. In order to reduce computational cost, we performed an approximate optimization using meta-models that replaced expensive computer simulations. At first, we carried out DOE (Design of Experiments) using OLHD (Optimal Latin Hypercube Design) available in PIAnO. Then, we built Kriging models using the simulation results at the sampling points. Finally, we used micro GA (Genetic Algorithm) available in PIAnO. Using the proposed design approach, the injection pressure has been reduced by 13.7% compared to the initial one. This design result clearly shows the validity of the proposed design approach.

• Korea-Australia Rheology Journal
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• v.16 no.1
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• pp.27-33
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• 2004

Application of gas assisted injection molding has been expanded during last two decades because of many advantages such as design flexibility, dimensional stability, reduction of machine tonnages, and so on. However, the surface defects including hesitation mark and gloss difference are observed for thick parts. Difficulties in lay-out of the gas channel and processing condition are another disadvantages. Liquid gas assisted injection molding(LGAIM), in which a liquid with a boiling point lower than the temperature of the polymer melt is injected into the melt stream, and travels with the melt into the mold where it vaporizes and pushes the melt downstream and against the cavity walls to create hollow channels within the part, is a good alternative of the conventional gas assisted injection molding especially in manufacturing simple and very thick parts. Though this is a new frontier of the innovation in the injection molding industry, there is no guideline for the design and processing conditions. In this paper, theoretical analysis has been made to describe the hollow formation dynamics in LGAIM. This model provides an insight into LGAIM process: explains why LGAIM has advantages over conventional gas assisted injection molding, and gives a guideline for the design and processing conditions.

• IE interfaces
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• v.13 no.2
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• pp.157-165
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• 2000

In this paper, an efficient method is proposed to place the cooling lines(CLS) and ejector pins(EPS) of mold design. The other components of mold, except CLS and EPS, can be generated automatically by batch processing. But the placements and sizes of CLS and EPS depend on the shapes of a part, so that the design works of CLS and EPS should be processed interactively. Using the pre-defined reference points, the positions of CLS and EPS can be determined interactively. By the proposed method, the interference occurred during placing CLS and EPS can be avoided, and the proper lengths of them can be calculated automatically. The information of the positions and lengths are stored in BOM database for generating a machining data. The proposed method is implemented with Unigraphics API functions and C language, tested on Unigraphics V15.