• 한국정밀공학회지
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• 제27권1호
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• pp.105-112
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• 2010

Weldlines are generated during the injection molding process when two or more melt flows are brought into contact. The weldlines are unavoidable in the cases of presence of holes or inserts, multi-gated delivery systems, significant thickness change, etc. At the welded contact region, a 'V'-shaped notch is formed on the surface of the molded part. This 'V'-notch deteriorates not only surface appearance but also mechanical strength of the molded part. To eliminate or reduce weldlines so as to improve the weldline strength, the mold temperature at the corresponding weld locations should be maintained higher than the glass transition temperature of the resin material. The present study implements high-frequency induction heating in order to rapidly raise mold surface temperature without a significant increase in cycle time. This induction heating enables to local mold heating so as to eliminate or reduce weldlines in an injection-molded plastic part. The effect of induction heating conditions on the weldline strength and surface appearance of an injection-molded part is investigated.

• 한국산학기술학회논문지
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• 제7권4호
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• pp.554-558
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• 2006

금형산업체의 직무능력 요구에 적응하는 산업현장과 연계된 실무능력 향상을 위한 대학의 금형기술 교육이 필요하다. 특히, 취업 후 회사의 사전교육 없이 직능별 업무에 투입 시킬 수 있는 창의력 있는 우수한 전문기술인을 양성하여 교육의 낭비적 요소를 제거하고 산업체 및 국가의 기술경쟁력을 강화 시키며 학생은 인력수요자인 산업체로부터 요구하는 현장실무에 접근성 높은 교육을 받아 취업이 보장되어야 한다. 또한 산업체는 전문인력 수급의 어려움을 해소 시켜주기 바라고 있다. 이상의 요구를 충족시킬 목적으로 금형산업체와 연계된 금형설계공학전공의 교육과정 개발을 수행하였다.

• 한국CDE학회논문집
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• 제10권3호
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• pp.188-198
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• 2005

There are two types of mold parts, ready-made standard parts and ETO (Engineered-to-Order) parts, the latter are of increasing importance to manufacturers. However, the ETO parts require more engineering support and communication than the ready-made standard parts. Existing e-Catalog modules provide classification structures of products that allow customers to select products based on their needs, and the trade begins with the provided specification. However, machine parts or mold parts have different purchasing patterns. Customers do not purchase the ready-made standard parts offered by an e-Catalog. They usually (1) add own options to the provided specifications or (2) change specification items such as length. To support these trades, a new e-Catalog system is proposed. The proposed system is based on the product design process and the specification selection process in addition to the parts classification structure.

• 동력기계공학회지
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• 제18권3호
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• pp.51-58
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• 2014

Injection molding simulation provided optimized design results by analyzing quality problems while the product is in assembly or in the process of manufacturing with make automobile plastics. Frequent change of design, change of injection molding, repetition of test injection which was held in the old way can now be stopped. And quality upgrade is expected instead. This report deals with the effect which the position of injection molding automobile console gate and number has on product quality including pressure at end of fill, bulk temperature at end of fill, shear stress of end of fill, residual stress at post filling end, product weld lines and warpage results. Simpoe-Mold simulates the complete manufacturing process of plastic injected parts, from filling to warpage. Simpoe-Mold users, whether they are product designers, mold makers or part manufacturers, can identify early into the design stage potential manufacturing problems, study alternative solutions and directly assess the impact of such part modification, whatever the complexity and geometry of such parts, shell part as plain solid parts.

• 소성∙가공
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• 제20권6호
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• pp.450-455
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• 2011

This paper presents an inverse design methodology for the cross section geometry of mold spring with a rectangular cross section as the starting material for a coiling process. The cross-sections of mold springs are universally rectangular, as the parallel sides minimize the possibility of failure under high service loads. Pre-coiled wires are initially designed to have a trapezoidal cross section, which becomes a rectangle by the coiling process. This study demonstrates a numerical exercise to predict changes in the sectional geometry in spring manufacture and to obtain the initial cross section which becomes the exact rectangle desired from the manufacturing process. Finite element analysis was carried out to calculate the sectional changes for various mold springs. Geometrical parameters were the widths at inner and outer radii, the inner and the outer corner radii, and the height. A partial least square regression analysis was carried out to find the main contributing factors for deciding initial design values. The height and the width mainly affected various initial parameters. The initial width at the inner radius was mostly affected by various specification parameters.

• 산업경영시스템학회지
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• 제38권1호
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• pp.44-51
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• 2015

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relations of injection system, casting condition, gate system, and cooling system. According to the various relations of the conditions, the location of product defects was differentiated. High-qualified products can be manufactured as those defects are controlled by the proper modifications of die casting mold with keeping the same conditions. In this research, Computer Aided Engineering (CAE) simulation was performed with the several layout designs in order to optimize the casting layout design of an automotive part (Housing). In order to apply them into the production die-casting mold, the simulation results were analyzed and compared carefully. With the filling process, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflow. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system. The simulation results were also applied into the production die-casting mold in order to compare the results and verify them with the real casting samples.

• Design & Manufacturing
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• 제9권2호
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• pp.30-33
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• 2015

In injection molding, many kinds of defects have occurred because of a characteristic of plastics injection molding. Weld line is one of the defects is formed when separated melt fronts recombine together during the mold filling stage. That is one of problems in injection molding. Weld lines in the appearance of plastics parts can deteriorate visible quality. And most importantly, the local mechanical strength in the weld line area can be significantly weaker. It could be one of the most problems for structural applications. In this study, the mold available two-shot-molding of same polymers have been designed, and a series of experiment about tensile strength in weld line area has been conducted using Taguchi's design of experiment to optimize injection molding conditions decreasing of weld strength and find out a factors affected weld strength in two-shot- molding.

• Design & Manufacturing
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• 제18권2호
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• pp.41-50
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• 2024

In this study, experimental design methods were used to derive optimal process conditions for improving the thickness uniformity of a 0.40 mm, 3.5 inch light guide panel. Process mapping and expert group analysis were used to identify factors that influence the thickness of injection molded products. The key factors identified were mold temperature, mold temperature, injection speed, packing pressure, packing time, clamp force, and flash time. Considering the resin manufacturer's recommended process conditions and the process conditions for similar light guide plates, a three-level range was selected for the identified influencing factors. L27 orthogonal array process conditions were generated using the Taguchi method. Injection molding was performed using these L27 orthogonal array to mold the 3.5 inch light guide plates. Thickness measurements were then taken, and the results were analyzed using the signal-to-noise ratio to maximize the CpK value, leading to the determination of the optimal process conditions. The thickness uniformity of the product was analyzed by applying the derived optimum process conditions. The results showed a 97.5% improvement in the Cpk value of 3.22 compared to the process conditions used for similar light guide plates.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2001년도 춘계학술대회논문집C
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• pp.257-262
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• 2001

This paper describes a specialized CAD system for injection mold design, which has been developed using the application procedure interfaces of Unigraphics. The system consists of modeling modules that are mutually independent and can be accessed without any predefined sequence. In addition, the design process modeling capability proposed in this paper facilitate mold redesign process caused by modification of part shape.

• 한국기계가공학회지
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• 제8권2호
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• pp.53-59
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• 2009

The analysis of injection molding process by CAE is widely used in development of plastic products. That comes from the fact that CAE analysis can reduce trial and error based on optimized design. On this study, by use of MOLDFLOW, the causes of product defects were found and solved by trade-off study. CAE analysis includes Flow-Cool-Warpage Analyses and finally a new mold-die design with better product quality was suggested. On injection molding of round-shaped plastic fan, new mold-die system with 4-tunnel gates located on the edge of a fan disc shows better quality rather than pin-point gate located on the center of a disc. That was effective in terms of flow mark removal and flatness improvement of the product.