• 한국정밀공학회지
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• 제26권3호
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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.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 춘계학술대회 논문집
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• pp.569-574
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• 2002

As consumer's desire becomes various, agility of mold manufacturing is most important factor for competence of manufacturer. In common works to use commercial CAM system to generate tool path, some decision making process is required to produce optimal result of CAM systems, The paper proposes a methodology for computer-assisted tool selection procedures for various cutting type, such as rough, semi-rough and finish cuts. The system provides assist-tool-items for machining of design model part of injection meld die by analyzing sliced CAD model of die cavity and core. Also, the generating NC-code of the tool size is used to calculate machining time. The system is developed with commercial CAM using API. This module will be used for optimization of tool selection and planning process.

• 소성∙가공
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• 제15권9호
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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.

• 한국생산제조학회지
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• 제20권6호
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• pp.811-816
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• 2011

We develop a plastic object lens for blu-ray disc playing pick-up module as morethan 0.85 numerical aperture in this research. We design plastic object lens for blu-ray disc playing pick-up module's each factor's in balanced and made our designed lens by injection molding. Furthermore, by correction designing in mold-core, we optimization our lens efficiency as world grade; wave front aberration $0.028{\lambda}$. RMS, light axis differential 0.3967arcmin. We can manufacture localized blu-ray disc's pick-up lens's component and by this fact we obtain international competitiveness. The result of this research will be very helpful to develop a single objective lens for 3 different wavelength of laser diodes in playing and recording pick-up module.

• 한국공작기계학회논문집
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• 제17권4호
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• pp.112-118
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• 2008

In order to meet the optical performance in the process of the micro lens manufacturing with plastics, it is important to embody accuracy in shape and surface roughness to the intended design. Since it is difficult to machine exactly the mold core of lens fit to the designed shape, in this paper, a simple program using MATLAB is developed for shape correction of the mold core after first machining it. This program evaluates correction parameters(aspheric coefficients and curvature) and generates aspheric NC data for compensating the core surface in prior machining process. The program provides the way to manufacture plastic injection molding lens with aspheric shape of high precision, and is expected to be effective for correction and to shorten the processing time.

• 산업공학
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• 제13권4호
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• pp.591-598
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• 2000

In this paper, an efficient algorithm is proposed to find parting lines(PL) and generate parting surfaces(PS) for an injection mold design. We used a Face-Edge Graph which can be made by B-rep information of solid model. The graph is useful for finding the peripheral-loop edges for PL and the inner-loop edges for hole-patch. The PS can be generated automatically by selecting pre-defined direction lines. We can create a core and cavity molds by trimming the raw stock block with the PS and the upper/lower faces of a product model. We implemented proposed method with Unigraphics API functions and C language, and tesed on Unigraphics V15.

• Design & Manufacturing
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• 제13권1호
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• pp.36-41
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• 2019

A large plastic molding requires an injection molding with a large clamping force. However, it could not be prepared in the manufacturing at any time. In order to solve the problem, the injection molding analysis study was conducted on the back cover of 55 inch LED TV. The study compared the case of applying the existing flow system such as hot runner, the improvement of the hot runner lay-out and the precise control of the gate operation time, From the results of using the improved flow system, it was found that the welding and the clamping force were considerably improved as compared with before the improvement. In particular, the clamping force was reduced by 50% compared with before the improvement.

• 한국생산제조학회지
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• 제22권2호
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• pp.248-255
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• 2013

The objective of this study is to optimize the Metal Injection Molding(MIM) process with design of experiments(DOE) and numerical analysis. To derive the optimal process condition, experiment or numerical analysis was performed under various process conditions. To analyze the interaction among influential factors contributing to the temperature at flow front and response surface in MIM, both central point and axial point were added to the full factorial design with 2 levels and 5 factors and then their impacts on response variable in 43 experimental conditions were analyzed and the significance was evaluated. As a result, sprue, runner, and gate were completely filled in about 0.247 seconds after injection, the front part of the green body was filled in about 0.3344 seconds, the green body except gate, etc changed to almost solid state in about 3.29 seconds, the Packinging pressure was completed in about 6.29 seconds, and the green body inside and outside and sprue, etc became solid in 13.2 seconds. The impact of individual or reciprocal action of factors on the temperature at flow front was analyzed through regular probability, test statistics, main effect, and interaction effect. As a result, of a total of 31 combinations of factors, 9 unit factors and reciprocal actions were significant, and the screening was also possible. A proper regression equation was drawn with regression analysis and response surface design on the response variable of temperature at flow front, and the applicability could be verified.

• 산업공학
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• 제18권1호
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• pp.73-81
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• 2005

Injection molding has been widely used in producing plastic parts in large quantities. However, its productivity mainly depends on the expertise and experience of skilled workers because of the difficulty and complexity to determine a robust injection molding condition which is not influenced by the minor operational variation of an injection molding machine and produces good parts continuously. This study analyzes the defect types of the parts and proposes a support system to assist users in determining the robust process condition. The support system calculates the start condition from the information of an injection mold, the injection molding machine, the resin used, and the part. Through the iterative step which updates the condition using the defect information of the part tested, users can obtain the initial condition which produces the part without any problem for the first time. The support system also assists users in obtaining the robust condition from the initial condition using the technique of experimental design. To prove the validity of the support system, this study implements it in the control panel of the injection molding machine.

• 한국정밀공학회지
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• 제21권11호
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• pp.163-170
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• 2004

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, however, numerical analysis based on solid elements has been reported as more reliable approach than shell -based one. The present work covers three-dimensional injection molding simulation using MP1/Flow3D and relevant deformation analysis of an injection molded plastic lens based on solid elements. Numerical analysis has been applied to the injection molding processes of an aspheric lens for a photo pick-up device. The reliability of the proposed approach has been verified in comparison with the experiments.