• Polymer(Korea)
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• v.36 no.6
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• pp.677-684
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• 2012

Injection molding process is a popular polymer processing involving plasticizing and enforcing the material flow into the mold. A polymer material shrinks according to temperature variations during the shaping process, and subsequently molding shrinkage developed. Developed deflections or warpages after molding process in part are caused by residual stress relaxation contained in the part. Adding inorganic materials or fibers such as glass and carbon to control shrinkage and enhance warpage resistance are common. In this study, warpages according to part design have been investigated through experiment. Warpages for molding conditions and mold designs such as gate locations were measured. Warpages along flow direction and perpendicular to the flow direction were also measured. Warpages near gate and far from gate were compared. Glass fiber reinforced crystalline polymers, PP and PA66 have been used in this experiment. Glass fiber reinforced crystalline polymers showed large warpage compared with glass reinforced amorphous polymers. Warpages in crystalline polymers were less influenced by molding conditions compared with amorphous polymers, however warpages of crystalline polymers significantly depend on part design.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.9 no.6
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• pp.1726-1732
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• 2008

Injection molding is one of plastic forming technology which can easily mass-produce plastic parts with various and even complex shape. The technology has lots of difficulties in making a good part due to phase change of material, high applied pressure, and fast melt flow speed in the cavity. To overcome the problems, they had to make trial and error method until the CAE(Computer Aided Engineering) could be a tool for concurrent engineering. In this paper, we investigate the optimal design for a plastic DVD tray part by systematic approach of the commercial CAE program. In design, we should consider two objectives which are both dimensional stability and cost-down. The dimension of the part is crucial because the tray should carry a DVD correctly, but the part is too thin to injection-mold easily. In order to improve the moldability, the mold is designed in the form of stack mold which is a kind of 4 hot runner system. In first, we changed the stack-mold system with one hot-runner to cost down, and decided the optimal position of the gate. After that, we investigate the effect of both the layout of cooling channels and the cooling temperature on the shrinkage of the DVD tray. A optimal simulation approach, the gate design is 2Gate#3 and the layout is Case2 cooling line as the optimal temperature of $70^{\circ}C$. The Moldflow and PC+ABS are used for the CAE program and material respectively.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.10
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• pp.1549-1554
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• 2010

Recently, plastic screws have replaced metal screws because of the former's light weight, thermal and electrical insulating properties, and anticorrosion characteristics. Plastic screws are usually produced by injection molding, which involves material shrinkage during the solidification of the polymer. This shrinkage results in the degeneration of the dimensional accuracy. In the present study, the effect of injection-molding conditions on the dimensional accuracy of plastic screws was investigated through a numerical simulation of injection molding; on the basis of this simulation, we could determine the mold-design parameters. The design of experiment was applied in accordance with the numerical analysis in order to optimize the injection-molding conditions with a view to improving the dimensional accuracy of the precision plastic screw.

• Asian-Australasian Journal of Animal Sciences
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• v.32 no.11
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• pp.1763-1775
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• 2019

Objective: The influence of konjac gel level on fermentation process and product qualities were assessed to evaluate the feasibility of using it as fat analog in Northeastern Thai fermented sausage (Sai Krok E-san). Methods: Five treatments of fermented sausages were formulated by replacing pork backfat with 0%, 7.5%, 22.5%, and 30% konjac gel. The changes in lactic acid bacteria (LAB) and important physicochemical properties of samples were assessed during 3 days of fermentation. After the end of fermentation at day 3, water activity ($a_w$), instrumental texture, color, microbial counts, and sensory evaluation were compared. The best product formulation using konjac for replacing pork back fat were selected and used to compare proximate composition and energy value with control sample (30% pork backfat). Results: An increase in konjac gel resulted in higher values of LAB, total acidity, and proteolysis index with lower pH and lipid oxidation during 3 days of product fermentation (p<0.05). It was noted that larger weight loss and product shrinkage during fermentation was observed with higher levels of konjac gel (p<0.05). The resulting sausage at day 3 with 15% to 30% konjac gel exhibited higher hardness, cohesiveness, gumminess, springiness, and chewiness than control (p<0.05). The external color of samples with 22.5% to 30% konjac gel were redder than others (p<0.05). Mold, Salmonella spp., Staphylococcus aureus, and Escherichia coli in all finished products were lower than detectable levels. Product with 15% konjac gel had the highest scores of sourness linking and overall acceptability (p<0.05). Conclusion: The product with 15% of konjac gel was the optimum formulation for replacing pork backfat. It had higher sensorial scores of sourness and overall acceptability than control with less negative impact on external appearance (product shrinkage) and weight loss. Moreover, it provided 46% fat reduction and 32% energy reduction than control.

• Journal of Korea Foundry Society
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• v.37 no.1
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• pp.1-13
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• 2017

The purpose of this study is to increase the part recovery rate (to more than 70%) during the casting of a ductile cast iron turbo charger housing using a heater around the riser. Before creating a casting mold, various runner and riser systems were designed and analyzed with a casting simulation analysis tool. The design variables were the heater temperature, top insulation, riser location, riser diameter and the riser shape. During the feeding from the riser to the part, the reverse model was better than the forward model. When heating the riser (above $600^{\circ}C$), solidification of the riser was delayed and the feeding effect was suitable compared to that without heating. At a higher heating temperature, less solidification shrinkage and porosity were noted inside the part. On the basis of a casting simulation, eight molds were fabricated and casting experiments were conducted. According to the experimental conditions, external and internal defects were analyzed and mechanical properties were tested. The ultimate tensile strength and elongation outcome were correspondingly more than 540MPa and 5% after a heat treatment. In addition, a maximum part recovery rate of 86% was achieved in this study.

• Journal of the Korean Ceramic Society
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• v.49 no.6
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• pp.592-600
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• 2012

Conventional methods for preparing ceramic bodies, such as cold isostatic pressing, gypsum-mold slip casting, and filter pressing are not completely suitable for fabricating large and thick ceramic plates owing to disadvantages of these processes, such as the high cost of the equipment, the formation of density gradients, and differential shrinkage during drying. These problems can be avoided by employing a pressure-vacuum hybrid slip casting approach that considers not only by the compression of the aqueous slip in the casting room (pressure slip casting) but also the vacuum sucking of the dispersion medium (water) around the mold (vacuum slip casting). We prepared the alumina formed bodies by means of pressure-vacuum hybrid slip casting with stepwise pressure loading up to 0.5 MPa using a slip consisting of 40 vol% solid, 0.6 wt% APC, 1 wt% PEG, and 1 wt% PVA. After drying the green body at $30^{\circ}C$ and 80% RH, the green density of the alumina bodies was about 56% RD. The sintered density of an alumina plate created by means of sintering at $1650^{\circ}C$ for 4 h exceeded 99.8%.This method enabled us to fabricate a $110{\times}110{\times}20$ mm alumina plate without cracks and with a homogeneous density, thus demonstrating the possibility of extending the method to the fabrication of other ceramic products.

• Resources Recycling
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• v.21 no.6
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• pp.12-22
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• 2012

This study investigated a utilization technology of light burned dolomite. light burned dolomite ($CaMg(CO_3)_2$) generated in furnace (steel manufacturer) is an alternative to quick lime. Using light burned dolomite has an effect on reducing the consumption of fluorite slag MgO concentration in supersaturated solution by prolonging the life of softening effect. Armophous MgO, not containing periclase is formed by firing dolomite under $800^{\circ}C$. It has larger surface area and higher reactivity than periclase, and also shows better expansion effect than quicklime. Due to those effects, therefore, armophous MgO produced from light burned dolomite is used as an alternative expansion agent in mortar. In the experiment, characteristics of light burned dolomite were compared to those of existing expansion agents such as anhydrite and quicklime. Then, each expansion and shrinkage rates were measured over a period of about 3 months in both of 1m Jis mold at labscale and apartment mortar flooring at field scale. In the result, it was observed that light burned dolomite in mortar flooring more compensates for the expansion and shrinkage rates than the existing expansion agents, showing low expansion rate of below 0.05% and also decreases the crack.

• 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 for Precision Engineering
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• v.31 no.1
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• pp.9-13
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• 2014

The molding process can be divided into five separate steps: plastification, injection, holding, cooling, and finally ejection. In the plastic injection molding, the effect factor such as mold temperature, injection speed, packing pressure and inhomogeneous cooling under packing process affects both the article dimension and physical characteristics. Especially, the packing pressure is the most critical factor to affect molded articles quality among the packing parameters. In this paper, the CAE simulation considering the molding condition is performed to predict the faulty cause which appears in the packing process between cavities of injection molding machine. From the results of CAE simulation, the packing phenomena according to the product form and the gate position was investigated to improve the article quality and minimize the various molding defects. The effect of packing pressure and gate number on the injection molding was discussed.

• Transactions of Materials Processing
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• v.24 no.6
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• pp.437-442
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• 2015

The development of polishing technology has enabled the production of injection molds with high quality surfaces and shapes. For products such as mobile phones which require high quality performance the use of plastic materials has many constraints such as shrinkage and deflection. The purpose of the current research is to use reverse engineering in order to find and analyze the data of a selected aspherical lens and then creating a process to design an improved lens. Additionally, the improved lenses are subject to molding analysis. In order to solve this problem, the lens construction program, Zemax, was used to analyze and optimize performance. In the case of optimization, the object was to eliminate spherical aberration and to find good MTF data. The result of the optimization data was similar to the MTF data found from a random lens. Specific resin and analysis conditions were selected and CAD modeling was done to enhance the injection molding analysis.