• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.497-498
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• 2006

Powder Injection Molding (PIM) has recently been recognized as an advanced manufacturing technology for low-cost mass production of metal or ceramic parts of complicated geometry. With this regards, design technology of dental scaler tip PIM mold, which has complex shape, with the help of computer-aided analysis for powder injection molding process was developed. Compter aided analysis results, such as filling pattern, weldline formation, and air vent position prediction were investigated and eventually showed good agreements with experimental results.

• Transactions of Materials Processing
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• v.14 no.6 s.78
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• pp.570-576
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• 2005

Powder Injection Molding(PIM) has recently been recognized as an advanced manufacturing technology for low-cost mass production of metal or ceramic parts of complicated geometry With this regards, design technology of dental scaler tip PIM mold, which has complex shape and small core pin (diameter=0.6mm), with the help of computer-aided analysis of powder injection molding process was developed. Computer-aided analysis for dental scaler tip mold was implemented by finite element method with non-Newtonian fluid, modified Cross model viscosity, PvT data of powder/binder mixture. Compter-aided analysis results, such as filling pattern, weldline formation, air vent position prediction were compared with experimental result, and eventually have been shown good agreement. The core pin (diameter=0.6mm) deflection analysis of dental scaler tip PIM mold during PIM filling process was also investigated before mold fabrication.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.102-109
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• 1998

In this study, the side panels were developed using the laser-welded Tailored Blanks (TB) with both the same thickness and the different thickness. At first, the formability of the same thickness T.B was investigated to be compared with one of the non welded panel with respect to weldline movements and strain distribution on blank during the stamping. Based on these results, we selected candidates of T.B with different thickness for stamping experiments. That is, we determined the weld line positions and the die step. Then we made some stamping tryouts with selected types of blank designs to investigate the formability of T.B with different thickness. During the tryouts, the wrinkles were found in the a-pillar lower region which is under the deformation mode of the shrink flange. In the b-pillar region, the fractures were found also, these defects have been reduced and corrected by controlling the blank design and the die faces and process pamameters.

• Transactions of Materials Processing
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• v.12 no.5
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• pp.465-472
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• 2003

Engineering design can be viewed as a decision making process, which involves the nonlinear tradeoffs task among the multiple conflicting attributes and considers the robustness of design. In order to obtain best engineering design, methodology for accurate assessment of his/her preference about the multiple attributes is required. Conventionally, intuitive procedures based on lottery questions are used to elicit the designer's preference structure: however, they can lead to inconsistent and inexact preference results due to the rank reversal problems derived from the designer's big cognitive burden. In this paper, alternatively, a design methodology based on multiattribute utility function through the pairwise comparison among alternatives is presented. The proposed procedure is applied to an actual injection mold design with the aid of the CAE simulation and the result is discussed.

• Transactions of the Korean Society of Automotive Engineers
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• v.19 no.1
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• pp.66-72
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• 2011

Injection pressure is an important factor in filling procedure for injection molded parts. In addition, weldlines should be avoided to successfully produce injection molded parts. In this study, we optimally obtained injection molding process parameters that minimize injection pressure. Then, we determined the thickness of the part to avoid weldlines. To solve the optimization problem proposed, we employed MAPS-3D (Mold Analysis and Plastics Solution-3 Dimension), a commercial CAE tool for injection molding analysis, and PIAnO (Process Integration, Automation, and Optimization) as a commercial PIDO (Process Integration and Design Optimization) tool. We integrated MAPS-3D into PIAnO, automated the analysis and design procedure, and performed optimization by employing PQRSM (Progressive Quadratic Response Surface Method) equipped in PIAnO. We successfully obtained optimization results, which demonstrates the effectiveness of our design method.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.1
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• pp.62-75
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• 2001

The design and manufacture of injection molded polymeric parts with desired properties is a costly process dominated by empiricism including repeated modification of actual tooling. This paper presents and expert design evaluation system which can predict the mechanical performance of a molded product and diagnose the design before the actual mold is machined. The knowledge-based system synergistically combines a rule-based expert system with CAE programs. An iterative boundary pressure reflection method(IBPR) is developed to automate the cavity filling simulation program and to predict thermo-mechanical properties of a molded part precisely. Mathematical models of weldline and frozen-in molecular orientation are established to determine the spatial variation of microstructural anisotropies of a molded part from the result of cavity filling simulation. The strength ellipse is devised as and index which represents th spatial distribution of the microstructural anisotropies of a molded part, Heuristic knowledge of injection molding, flow simulation, and mechanical performance prediction is formalized as rules of an expert consultation system. The expert system interprets the analytical results of the process simulation, predicts the performance, evaluates the design and generates recommendations for optimal design alternative.

• Journal of the Korean Society for Precision Engineering
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• v.33 no.12
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• pp.1021-1030
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• 2016

The runner system of the injection mould and the injection volume of the injection molding process greatly affect the quality of the produced part. The goal of this paper is the design of the runner system and the prediction of the injection volume for the injection moulding of a housing part of small-size air cleaner to improve the formability through the three-dimensional injection moulding analysis. The effects of the runner system of the mould on the injection moulding characteristics are investigated. From the results of the investigation, a proper design of the runner system with uniform filling characteristics and the minimized defect formation is obtained. In addition, the influence of the moving distance of the screw on filling characteristics, weldline formation and deformation characteristics is examined. From the results of the examination, an appropriate moving distance of the screw for the housing part of small-size air cleaner is estimated.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.8
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• pp.1097-1103
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• 2010

Injection pressure, an important factor in the filling procedure, should be minimized to enhance injection molding quality. In addition, warping deformation and weld lines, which are representative failures, should be avoided to enhance injection molding quality. To improve injection molding quality, the design procedure for an automotive fog blank cover is divided into two stages. In the first stage, we optimally obtain injection molding process variables that minimize injection pressure and warping deformation by using design of experiments, approximation and optimization techniques equipped in PIAnO (Process Integration, Automation and Optimization), a commercial PIDO (Process Integration and Design Optimization) tool. Then, we determine the thickness of the automotive fog blank cover that enables us to avoid generating weld lines. The design results we obtain in this study are found far better than those of the initial design, which demonstrates the effectiveness of our design method.

• Elastomers and Composites
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• v.44 no.4
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• pp.358-365
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• 2009

High-frequency induction is an efficient way to rapidly heat mold surface by electromagnetic induction. In the present work, high-frequency induction heating is applied to injection molding of a mobile phone cover in order to eliminate weldlines by efficiently raising the mold temperature. Through the induction heating experiments, the maximum temperature of $143^{\circ}C$ is obtained on the mold surface in 3s of heating, which is higher than the glass transition temperature of the resin material. An injection molding experiment is then performed with the aid of induction heating, from which we can successfully remove all the weldlines of the mobile phone cover. The effect of induction heating conditions such as the heating power and the heating time on the surface appearance is experimentally investigated.

• Composites Research
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• v.12 no.2
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• pp.70-81
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• 1999

Resin transfer molding(RTM) as a composite manufacturing process is currently of great interest in the aerospace industry requiring high performance composite parts. In this study, an analysis of mold filling in the RTM process was carried out by numerical simulation using finite element/control volume technique. Experimental work for the visualization of resin flow through fibrous preform was also conducted in order to quantitatively measure the permeabilities of the fiber mats and to evaluate the validity of the developed numerical code. The different types of fiber mats and silicon oils were selected as reinforcements and resin materials, respectively. The effects of fibrous preform structure, mold geometry, and preplaced insert on the flow front patterns during mold filling were examined by integrating the model predictions and experimental results. The flow fronts predicted by numerical simulation were in good agreement with those observed experimentally. However, according to the regions of the mold, some deviations between predicted and observed flow fronts could be found because of non-uniform fiber volume fraction. Weldline locations for the resin flow through round insert preplaced in the mold could be qualitatively deduced based on predicted flow fronts.