• Title, Summary, Keyword: 캐비티압력

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Analysis of Cavity Pressure for Packing Conditions in Injection Molding of a Deep Depth Product (깊이가 깊은 제품의 사출성형에서 보압조건에 따른 캐비티 내압의 분석)

  • Kim, Dong Woo;Kang, Mina;Kim, Hyeok;Lyu, Min-Young
    • Polymer Korea
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    • v.36 no.6
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    • pp.685-692
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    • 2012
  • Injection molding operation consists of phases of filling, packing, and cooling. The highest cavity pressure is involved in the packing phase among the operation phases. Thus the cavity pressure largely depends upon velocity to pressure (v/p) switchover timing and magnitude of packing pressure. Developed cavity pressure is directly related to stress concentration in the cavity of mold and it may cause a crack in the mold. Consequently control of cavity pressure is considered very important. In this study, cavity pressure was analyzed in terms of v/p switchover timing and packing pressure through computer simulation and experiment. Cavity pressure was increased as the v/p switchover timing was delayed. Residual pressure after cooling phase was observed when the v/p switchover timing was late, which was due to increased pressurizing time for long filling phase. Cavity pressure was increased proportionally with the packing pressure. Residual pressure after cooling phase was also observed, and it was increased with increasing packing pressure. High cavity pressure and residual pressure have been observed at late v/p switchover and high packing pressure. Compared with simulation and experimental results, the profiles of pressures were very similar however simulation could not predict residual pressure. Packing condition was important for the control of cavity pressure and the optimum condition could be set up using CAE analysis.

Estimation of LFT viscosity from CAE analysis with measuring cavity pressure (캐비티 내압 측정 및 CAE해석을 통한 Long Fiber Thermoplastic(LFT)의 점도 추정)

  • Kim, Yong-Hyun;Noh, Seong-Kyu;Kim, Dong-Hak
    • Proceedings of the KAIS Fall Conference
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    • pp.345-348
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    • 2011
  • 본 논문에서는 LFT와 같은 고점도 수지의 점도를 추정하기 위한 방법을 제시하였다. 실제 사출공정에서의 점도를 추정함으로써 신뢰할 수 있는 점도데이터를 제공하기 위한 방법을 제시 하였다. 우선 금형 내에 캐비티 압력을 측정할 수 있는 시스템을 구성하였고, 이 시스템을 이용해서 실제 사출과정에서 나타나는 압력 변화를 측정하는 것이다. 상용화 된 CAE 프로그램(Moldflow)은 사출공정에서 캐비티 내부를 흐르는 수지의 압력변화를 모사할 수 있다. 만약, CAE D/B에 있는 수지의 점도 데이터가 정확하다고 가정하면, 실험에서 측정한 압력 프로파일과 CAE로부터 계산 된 압력 프로파일이 일치해야 한다. 이것이 실험값과 일치하지 않으면 가정한 값을 CAE D/B에 입력해서 일치할 때까지 반복함으로써 신뢰성 있는 점도를 추정 할 수 있다. 한편, LFT에 대하여 적용하여 최적화 된 점도 데이터도 추정할 수 있었다.

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Film Insert Molding of Automotive Door Grip Using Injection-Compression Molding (사출압축성형을 이용한 자동차용 도어그립 필름인서트성형)

  • Lee, Ho Sang;Yoo, Young Gil;Kim, Tae An
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.38 no.7
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    • pp.771-777
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    • 2014
  • Injection-compression molding was used for film insert molding of an automotive door grip using films with three-dimensional embossed patterns. A vacuum mold was fabricated for vacuum-assisted thermoforming of the film, and an injection-compression mold was developed for film insert molding. Three pressure transducers were installed inside the mold cavity to measure cavity pressures. Injection-compression molding experiments under various compression strokes and toggle speeds were performed to investigate their effects on the cavity pressure and heights of the embossed patterns. The compression stroke of 0.9mm and low toggle speed resulted in a higher degree of conservation of embossed patterns. Additionally, the processing conditions for the maximum heights of embossed patterns were almost similar to those for minimum integral value of cavity pressures. The injection-compression molding process presents the opportunity to impart a soft-touch feeling of plastic parts printed with embossed patterns.

A Study on Cavity Pressure and Tensile Strength of Injection Molding (사출성형에서 캐비티압력과 인장강도에 관한 연구)

  • Yoo, J.H.;Kim, H.S.
    • Transactions of the Korean Society of Automotive Engineers
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    • v.2 no.6
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    • pp.110-116
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    • 1994
  • In this research, the tensile strength of molded parts and pressure distribution were analyzed to study the cavity filling stage and packing stage in injection molding. The measurement of cavity pressure was obtained by a data acquisition system with the installation of transducers in the cavity. Molded parts were tested by a universal testing machine to obtain the tensile strength. For the experimental work, the tensile strength of molded parts increased with longer packing time and exact freezing time of the gate was obtained by a cavity pressure curve. In addition, the effect of packing did not occur and tensile strength was almost constant after early 1.5 sec of the freezing time of gate. Density tended to be higher about 0.2% due to a larger degree of mold temperature and melt temperature. Also, changing pressure in the cavity was effectively sensed. Thereafter, the possibility of the development of pattern recognition expert system was confirmed on the basis of the experimental results.

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Frozen Layer Effect on Internal Cavity Pressure during Injection Molding (사출성형 공정에서 고화층이 캐비티 압력에 미치는 영향)

  • Lee H.S.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.474-479
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    • 2005
  • Experimental and theoretical studies of internal cavity pressure during injection molding of a spiral tube cavity were carried out. The frozen layer thickness and the evolution of internal cavity pressure were calculated using a commercial software (C-MOLD). The evolution of the internal cavity pressure was recorded during injection molding of polystyrene into a spiral tube mold. To explain the differences observed between the calculated and measured internal cavity pressure, a pressure correction factor (PCF) was introduced based on the plane stress theory. This factor was determined by analyzing the stress state in the melt and calculating the frozen layer thickness near the mold wall. The corrected and experimental pressures have been compared to validate the applicability of the pressure correction factor.

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Comparison of Molding Characteristics for Multi-cavity Molding in Conventional Injection Molding and Injection Compression Molding (다수 개 빼기 성형에서 일반사출성형과 사출압축성형의 성형특성 비교)

  • Lee, Dan Bi;Nam, Yun Hyo;Lyu, Min-Young
    • Polymer Korea
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    • v.38 no.2
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    • pp.144-149
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    • 2014
  • Large residual stresses are remained in the conventional injection molded products because of the high cavity pressure in packing phase during injection molding process. Conventional injection molding (CIM) invokes distribution of cavity pressure and it has a limitation to obtain product with uniform physical property. Multi-cavity conventional injection molding contains quality deviation among the cavities since flow imbalance occurs during filling phase. Injection compression molding (ICM) is adopted to overcome these limitations of CIM. In this study, molding characteristics of CIM and ICM have been investigated using multi-cavity injection mold. Researches were performed by both experiment and computer simulation through observations of birefringence for transparent resins, polycarbonate and polystyrene in CIM and ICM. As a result, low and uniform birefringence and mold shrinkage were showed in the specimens by ICM that could give a uniform cavity pressure. Deviation of physical property among the specimens in multi-cavity mold shown in CIM was significantly reduced in the specimens by ICM. Through this study it was concluded that the ICM in multi-cavity molding was valid for molding products with uniform property in an individual cavity and also reduced property deviation among the cavities.

A Potential-Based Panel Method for the Analysis of a 2-Dimensional Partially Cavitating Hydrofoil (양력판 이론에 의한 2차원 수중익의 부분 캐비티 문제 해석)

  • Chang-Sup,Lee
    • Bulletin of the Society of Naval Architects of Korea
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    • v.26 no.4
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    • pp.27-34
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    • 1989
  • A potential-based panel method is formulated for the analysis of a partially cavitating 2-dimensional hydrofoil. The method employs dipoles and sources distributed on the foil surface to represent the lifting and cavity problems, respectively. The kinematic boundry condition on the wetted portion of the foil surface is satisfied by requiring that the total potential vanish in the inner flow region of the foil. The dynamic boundary condition on the cavity surface is satisfied by requiring that the potential vary linearly, i.e., the velocity be constant. Green's theorem then results in a potential-based boundary value problem rather than a usual velocity-based formulation. With the singularities distributed on the exact hydrofoil surface, the pressure distributions are predicted with more improved accuracy than the zero-thickness hydrofoil theory, especially near the leading edge. The theory then predicts the cavity shape and cavitation number for an assumed cavity length. To improve the accuracy, the sources and dipoles on the cavity surface are moved to the newly computed cavity surface, where the boundary conditions are satisfied again. It was found that five iterations are necessary to obtain converged values, while only two iterations are sufficient for engineering purpose.

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An experimental study for prediction of the fluctuating pressure induced by a cavitating propeller (캐비티가 발생한 프로펠러의 변동압력 추정을 위한 실험적 연구)

  • K.S. Kim;I.S. Moon;K.Y. Kim;I.H. Song;J.T. Lee
    • Journal of the Society of Naval Architects of Korea
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    • v.36 no.1
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    • pp.47-52
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    • 1999
  • The influence of propeller revolution on measurement of fluctuating pressure is almost minimized in the KRISO cavitation tunnel and the measurement accuracy of fluctuating pressure acting on a flat plate due to a cavitating propeller is improved. The measurement data for Sydney Excess propeller is compared with the measurement results of other research institutes loading to the conclusion that KRISO data is so stable and reasonable. The fluctuating pressure data measured on a model ship and the prototype ship is compared with the data measured on the flat plate. The solid boundary factor, derived from a calculation based on a lifting surface theory, is applied to predict full scale pressure level from the experimental data on the flat plate, showing quite reasonable agreement with full scale data.

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CAE Simulation Study an Filling Imbalance in Multi-Cavity Injection Molding (다수 캐비티 사출성형에서 충전 불균형 현상에 관한 시뮬레이션)

  • Jeon, Kang-Il;Kim, Dong-Hak
    • Proceedings of the KAIS Fall Conference
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    • pp.678-681
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    • 2009
  • 사출성형은 열가소성수지의 가공법으로써 정밀도나 고품질의 제품을 효과적으로 생산하는데 널리 이용되며 플라스틱은 현재 광범위하게 사용되고 있는 공업재료 중의 하나이다. 과거에는 플라스틱을 일회용품 및 외장재로 사용하였다. 그러나 산업기술이 발전하며 플라스틱은 금속을 대체 할 수 있는 재료로서 사용할 수 있다는 인식의 변화로 점차 기계요소용 재료로 사용되고 있으며 기계요소용 재료로 사용됨에 따라 플라스틱 제품이 정밀한 부품으로 사용되기 위해서는 금형의 가공뿐만 아니라 사출성형 시 용융수지가 금형의 각 캐비티에 균형적으로 충전되는것이 요구된다. 이러한 요구조건을 만족하기 위해서는 각 캐비티의 가공치수는 매우 높은 정밀도를 유지해야 하며, 각 캐비티에서의 충전과 냉각도 동일한 상태를 유지해야 한다. 충전 불균형은 성형품의 품질에 큰 저해 요인으로서 플라스틱 제품의 치수성, 밀도, 외관품질, 강도 등에 불균일한 결과를 가져오는 요인으로 지적되고 있다. 실제로 충전 불균형은 충전 단계에서 런너 내에서 발생하는 불균일한 전단분포에 기인하여 발생되므로 점도변화에 영향을 주는 수지의 물성, 런너의 배열과 같은 외부 요인과 사출압력, 사출속도, 수지온도, 금형온도와 같은 성형공정 조건에 의한 요인에 의한 충전 불균형의 양상이 달라지게 된다. 본 연구는 다수 캐비티 금형에서 충전 불균형 현상에 대한 원인을 검토하고 실제로 사출성형을 실시하기 전 사출성형해석 소프트웨어를 이용하여 시뮬레이션을 하여 다수 캐비티에 대한 충전 패턴을 미리 예측하여 보았다.

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Comparative Analysis of Injection Molding Process by On-line Monitoring in Cylinder of Injection Molding Machine and in Cavity of Mold (사출성형기 실린더와 금형 캐비티의 실시간 모니터링을 이용한 사출성형공정 비교 분석)

  • Park, Hyung-Pi;Cha, Baeg-Soon;Tae, Jun-Sung;Choi, Jae-Hyuk;Rhee, Byung-Ohk
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.34 no.10
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    • pp.1513-1519
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    • 2010
  • Recently, on-line process monitoring systems using sensors are being extensively used to produce highquality products. However, the difficulty in installing the sensors within the mold in the cases of micro-molds, optical molds, and molds with complex structures is a serious disadvantage of such process monitoring systems. In this study, the quantitative index of a process monitoring system was evaluated with the mold cavity pressure and the nozzle pressure for the injection molding machine. In order to evaluate the effect of the nozzle pressure, we performed correlation analysis for the weight of the molded product. We also examined the control characteristics of the injection molding machine by analyzing the effect of multistage injection speed, holding pressure, and injection pressure limit on the process monitoring data.