• 대한기계학회논문집A
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• 제28권6호
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• pp.826-837
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• 2004

Rotational molding is a plastics processing technique that is ideally suited to producing relatively large, hollow, seamless parts which are partially or totally enclosed. Designers of plastic parts turn to rotational molding to produce small or large parts of unusual shape that cannot be produced as one piece by other processes, e.g., blow molding and thermoforming. In this paper, in order to enhance the quality of rotational molding plastic products, 1) surface features for the plastic products are characterized by using an image analysis system, 2) maximum tensile strength for the plastic products that are made of materials that consist of Samsung-Atofina R90lU, pigments and two different kinds of calcium carbonate (OMYA CaCO$_3$) is measured and compared with each other by using an Instron universal testing machine, 3) thickness for the plastic products is non-destructively measured to investigate the quality of the plastic products by using an A-scan ultrasonic tester.

• Design & Manufacturing
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• 제16권3호
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• pp.1-8
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• 2022

In this study, an artificial neural network(ANN) was constructed to establish the relationship between process condition prameters and the qualities of the injection-molded product in the injection molding process. Six process parmeters were set as input parameter for ANN: melt temperature, mold temperature, injection speed, packing pressure, packing time, and cooling time. As output parameters, the mass, nominal diameter, and height of the injection-molded product were set. Two learning structures were applied to the ANN. The single-task learning, in which all output parameters are learned in correlation with each other, and the multi-task learning structure in which each output parameters is individually learned according to the characteristics, were constructed. As a result of constructing an artificial neural network with two learning structures and evaluating the prediction performance, it was confirmed that the predicted value of the ANN to which the multi-task learning structure was applied had a low RMSE compared with the single-task learning structure. In addition, when comparing the quality specifications of injection molded products with the prediction values of the ANN, it was confirmed that the ANN of the multi-task learning structure satisfies the quality specifications for all of the mass, diameter, and height.

• 한국정밀공학회지
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• 제31권1호
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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.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.269-272
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• 2004

The present study used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding process of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design & molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors, as critical ones influencing on the quality and productivity, of which is summarized as design guidance. The main contribution factors for cycle time can be sequentially enumerated as follows; hot spot, part thickness, coolant inlet temperature, melt temperature cooling line layout, etc.. As a first step critical factors of the design process of current monitor housing were investigated. And the optimal and better critical factors found in the first step were applied to a new product proving our process was correct. Moldflow software was used for injection molding simulation, and Minitab software for the statistical analysis. Finally, the productivity was increased by about 33 percents for our specific case.

• 소성∙가공
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• 제16권1호
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• pp.3-8
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• 2007

Novel compression molding system for preform has been developed in this study. The preforms for injection blow molding and injection stretch blow molding are being manufactured by injection molding. However it contains gate mark that affects the bottom crack in the PET bottle. The compression molded preform does not contain gate mark, thus the appearance quality of bottle has been increased and the residual stress near gate(bottom of the bottle) has been reduced. The thickness distributions, haze, and transmittance are well accepted for the preform. Also, flow characteristics of the resin between a core and cavity could be analyzed through computer simulation.

• 폴리머
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• 제38권2호
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• pp.193-198
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• 2014

렌즈 그리고 DVD 등과 같은 성형품들은 우수한 광학적 특성을 필요로 한다. 일반사출성형 공정은 캐비티 내에 압력이 높고 큰 온도변화를 포함하게 되어 성형품에 큰 잔류응력이 남아 광학적 품질이 저하된다. 따라서 이와 같은 제품들은 성형 시 잔류응력을 최소화하기 위해 캐비티 내의 압력을 낮게 그리고 균일하게 조절할 수 있는 사출압축성형 공정을 사용하는 경우가 많다. 본 연구에서는 실험을 통하여 사출압축 성형품에 영향을 주는 성형인자를 분석하였다. 다수 캐비티 금형을 이용하여 캐비티 간 품질편차도 고찰하였다. 실험에 사용한 재료는 투명수지인 PC와 PS이었다. 사출압축성형의 실험에서 공정변수로는 압축거리, 압축속도, 압축력 그리고 압축지연시간을 이용하였다. 실험결과, 사출압축성형 공정 변수 중 압축력과 압축지연시간 그리고 압축거리가 광학적 특성에 크게 영향을 미쳤으며 그 정도는 수지에 따라 다르게 나타났다. 이러한 현상은 사출압축성형 시 수지마다 유동성에 따라 최적의 성형조건이 있음을 의미하는 것이다.

• 한국기계가공학회지
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• 제20권12호
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• pp.129-135
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• 2021

Injection molding is a manufacturing method of melting the polymer resin and injecting it into a mold to molding it into the desired form. Due to the short molding time and outstanding formability, complex products can be shaped with high precision and it is the most widely used polymer molding method. However, there may be areas that are not filled depending on the location of the injection gate where polymer resin is injected. Formability is determined by deformation and surface precision due to the impact of residual stress after molding. Hence, choosing the location of the injection gate is very important and molding analysis of injection molding is essential to reduce the cost of the mold. This study evaluated the injection formability based on the location of the injection gate of the vertical machining center ATC tool port using injection molding analysis and the results were compared and analyzed. Injection molding analysis was conducted on filling, packing, and deformation according to the location of the gate of the ATC tool port. From each injection gate location, filling time, pressure, and maximum deformation were compared. At gate 2, conditions of molding time and the location of the gate were far superior in production and quality. Gate 2 produced the smallest deformation of 0.779mm with the best quality.

• 한국생산제조학회지
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• 제6권1호
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• pp.84-91
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• 1997

In producing moldings by using an injection mold, several variables such as the metal mold and the condition of injection molding should be selected properly in order to obtain good quality of moldings. In this study, focussed are the mechanical properties of injection moldings, since many researches on injection have been focussed mainly on the molding quality, injection pressure, and bulk temperature but the properties of injection moldings have not been studied extensively. The mechanical properties of present injection moldings can be improved simply by changing the molding material and the injection conditon without changind the metal mold. To have the final products meet the specified molding quality and mechanical properties at the same time, the bulk temperature of injection, pressure variation, volumetric shrinkage, stress, and cooling should be analized by CAE(computer aided engineering) after injection mold design. In this paper, the effects of dischare condition on mechanical properties of injection moldings are studied by testing the moldings which are injected by varying injection conditions.

• Composites Research
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• 제36권3호
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• pp.186-192
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• 2023

최근, 철도차량 분야에서는 경량화 및 운송 효율화를 위해 복합재 활용에 대한 관심이 높아지고 있다. 이에 따라 다양한 차량 부품에 복합재를 적용하고자 하는 연구 및 상용화 개발이 활발히 이루어지고 있으며, 복합재 적용에 대한 품질 검증을 위해 완성품의 기계적 성능 평가와 같은 사후 측정을 중심으로 평가가 이루어지고 있다. 하지만, 제작 품질에 큰 영향을 미치는 요소인 복합재 성형 과정에서 발생하는 열과 응력에 대한 분석은 미비한 상황이다. 따라서, 본 연구에서는 철도차량용 복합재 부품의 성형 품질을 검증하기 위하여 가장 활발히 사용되는 복합재 내장재 패널 2종(라미네이트 패널, 샌드위치 패널)에 대한 성형 품질 분석을 진행하였다. 이를 위해 복합재 내부 적용에 용이한 FBG 광섬유 센서를 이용하여 성형 과정 동안 온도 및 변형률 변화를 모니터링 하고, 성형 완료 후 발생하는 잔류 변형률 값을 측정하였다. 결과적으로, 과열 현상과 과도 잔류응력이 발생하지 않은 것을 확인함으로써 철도차량용 복합재 내장재 패널의 우수한 성형 품질을 검증하였다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.183-186
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• 2007

The injection molding process has high accuracy and good reproducibility that are essential for mass production at low cost. Conventional molding processes typically use the water-based mold heating and air cooling methods. However, in the nano injection molding processes, this semi-active mold temperature control results in the several defects such as air-flow mark, non-fill, sticking and tearing, etc. Therefore, in order to control temperature of the molds actively and improve the quality of the molded products, the novel nano injection molding system, which uses active heating and cooling method, has been introduced. By using the Peltier devices, the temperature of locally adiabatic molds can be controlled dramatically and the quality of the molded patterns can be improved.