Journal of the Korean Society for Precision Engineering (한국정밀공학회지)

Korean Society for Precision Engineering (한국정밀공학회)
권호 표지
DOI QR코드

DOI QR Code

A Study on the Design of Cooling Channels of Injection Mould to Manufacture a Flat Part with a Partly Thick Volume

부분적으로 후육부를 가지는 평판형 제품의 제작을 위한 사출성형 금형의 냉각채널 설계에 관한 연구

  • 안동규 (조선대학교 기계공학과) ;
  • 박민우 ((주)나라엠엔디 기술연구소) ;
  • 김형수 ((주)우성정공 기술연구소)
  • Received : 2012.05.29
  • Accepted : 2012.06.11
  • Published : 2012.08.01
Download PDF
⟨ Previous Next ⟩

Abstract

The shrinkage and the warpage of the moulded part are influenced by the design of the product and injection mould. In a flat part with a partly thick volume, the warpage of the flat part is created from the difference of the shrinkage between thin and thick regions. The warpage of the flat part with a partly thick volume can be reduced by a proper design of the cooling system in the injection mould. The goal of this paper is to design properly cooling channels of injection mould to manufacture a flat part with a partly thick volume. The conformal cooling channel is adopted to improve cooling characteristics of a region with the thick volume. The linear cooling channels are assigned to the other region. The proper design of the conformal cooling channels is obtained from three-dimensional injection molding analysis for various design alternatives. The moulding characteristics of the designed mould with both conformal and linear cooling channels are compared to those of the mould with linear cooling channels from viewpoints of temperature, shrinkage and warpage of the moulded part using numerical analysis. Injection mould with both conformal and linear cooling channels for the flat part with a partially thick volume is fabricated. In addition, injection moulding experiments are performed using the fabricated mould. From the results of the injection moulding experiments, it has been shown that the designed mould can successfully fabricate the flat part with a partially thick volume.

Keywords

References

  1. Spina, R., "Injection Moulding of Automotive Components: Comparison between Hot Runner System for a Case Study," Journal of Materials Processing Technology, Vol. 155-156, No. 12, pp. 1497-1504, 2004. https://doi.org/10.1016/j.jmatprotec.2004.04.359
  2. Park, K., Sohn, D. H., and Seo, Y. S., "Investigation of Weldline Strength with Various Heating Conditions," J. of the KSPE, Vol. 27, No. 1, pp. 105-112, 2010.
  3. Lee, S. H., Kang, J. J., Lee, J. W., Hong, S. K., Ko, J. S., Lee, J. H., and Noh, J. W., "Slicon Injection Mold & Molding Technology for Super-hydrophobic Curved Surface," J. of the KSPE, Vol. 29, No. 1, pp. 13-18, 2012. https://doi.org/10.7736/KSPE.2012.29.1.013
  4. Dalgarno, K. W. and Stewart, T. D., "Manufacture of Production Injection Mould Tooling Incorporating Conformal Cooling Channels via Indirect Selective Laser Sintering," Proceedings of Institution of Mechanical Engineers Part B: Journal Engineering Manufacture, Vol. 215, No. 10, pp. 1323-1332, 2001. https://doi.org/10.1243/0954405011519042
  5. Ahn, D. G., Park, M. W., Park, S. W., and Kim, H. S., "Design of the Conformal Cooling Channels of the Mould for the Plastic Part of the Refrigerator via Three-dimensional Injection Moulding Analysis," Transactions of the Korean Society of Mechanical Engineers A, Vol. 34, No. 10, pp. 1487-1492, 2010. https://doi.org/10.3795/KSME-A.2010.34.10.1487
  6. Hong, M., Lee, J., and Shin, S., "A Study on the Improvement of Double Injection-molding Keypad Process," Journal of Korean Society of Manufacturing Technology Engineers, Vol. 20, No. 5, pp. 659-665, 2011.
  7. Ahn, D. G., "Application of Laser Assisted Metal Rapid Tooling Process to Manufacture of Molding & Forming Tools - State of the Art," Int. J. Precis. Eng. Manuf., Vol. 12, No. 5, pp. 925-938, 2011. https://doi.org/10.1007/s12541-011-0125-5
  8. Akay, M. and Ozden, S., "Prediction of Process-Induced Warpage in Injection Molded Thermoplastics," Polymer Engineering and Science, Vol. 36, No. 13, pp. 1839-1846, 1996. https://doi.org/10.1002/pen.10579
  9. Yang, S. S. and Kwon, T. H., "Deformation Analysis of Injection Molded Articles due to In-mold Residual Stress and Cooling after Ejection," Proceedings of Spring Annual Meeting of Korean Society of Mechanical Engineers, pp. 251-256, 2001.
  10. Kabanemi, K. K., Vailancourt, H., Wang, H., and Salloum, G., "Residual Stresses, Shrinkage, and Warpage of Complex Injection Molded Products: Numerical Simulation and Experimental Validation," Polymer Engineering and Science, Vol. 38, No. 1, pp. 21-37, 1998. https://doi.org/10.1002/pen.10162
  11. Choi, D. S. and Im, Y. T., "Prediction of Shrinkage and Warpage in Consideration of Residual Stress in Integrated Simulation of Injection Molding," Composite Structures, Vol. 47, No. 1-4, pp. 655-665, 1999. https://doi.org/10.1016/S0263-8223(00)00045-3
  12. Chen, X., Lam, Y. C., and Li, D. Q., "Analysis of Thermal Residual Stress in Plastic Injection Molding," Journal of Materials Processing Technology, Vol. 101, No. 1-3, pp. 275-280, 2000. https://doi.org/10.1016/S0924-0136(00)00472-6
  13. Ferreira, J. C. and Mateus, A., "Studies of Rapid Soft Tooling with Conformal Cooling Channels for Plastic Injection Molding," Journal of Materials Processing Technology, Vol. 142, No. 2, pp. 508-516, 2003. https://doi.org/10.1016/S0924-0136(03)00650-2
  14. Park, C. H., Ahn, H. J., Choi, D. H., and Pyo, B. G., "Two-stage Design Optimization of an Automotive Fog Blank Cover for Enhancing Its Injection Molding Quality," Transactions of the Korean Society of Mechanical Engineers A, Vol. 34, No. 8, pp. 1097-1103, 2010. https://doi.org/10.3795/KSME-A.2010.34.8.1097
  15. Hilton, P. D. and Jacobs, P. E., "Rapid Tooling: Technologies and Industrial Applications," Marcel Dekker Inc., 2000.
  16. Sachs, E., Wylonis, E., Allen, S., Cima, M., and Guo, H., "Production of Injection Molding Tooling with Conformal Cooling Channels Using the Three Dimensional Printing Process," Polymer Engineering and Science, Vol. 40, No. 5, pp. 1232-1247, 1996.
  17. Ahn, D. G., Park, S. H., and Kim, H. S., "Manufacture of an Injection Mould with Rapid and Uniform Cooling Characteristics for the Fan Parts Using a DMT Process," Int. J. Precis. Eng. Manuf., Vol. 11, No. 6, pp. 915-924, 2010. https://doi.org/10.1007/s12541-010-0111-3
  18. Kuo, C. F. J. and Su, T. L., "Optimization of Injection Molding Processing Parameters for LCD Light-Guide Plates," Journal of Materials Engineering and Performance, Vol. 16, No. 5, pp. 539-548, 2007. https://doi.org/10.1007/s11665-007-9088-1
  19. Wang, G., Zhao, G., Li, H., and Guan, Y., "Research on a New Variotherm Injection Molding Technology and Its Application on the Molding of a Large LCD Panel," Polymer-Plastic Technology Engineering, Vol. 48, No. 7, pp. 671-681, 2009. https://doi.org/10.1080/03602550902824549
  20. Jacques, M. S., "An Analysis of Thermal Warpage in Injection Molded Flat Parts Due to Unbalanced Cooling," Polymer Engineering and Science, Vol. 22, No. 4, pp. 241-247, 1982. https://doi.org/10.1002/pen.760220405
  21. Park, S. J. and Kwon, T. W., "Optimal Cooling System Design for the Injection Molding Process," Polymer Engineering and Science, Vol. 38, No. 9, pp. 1450-1462, 1998. https://doi.org/10.1002/pen.10316
  22. Huang, M. C. and Tai, C. C., "The Effective Factors in the Warpage Problem of an Injection-molded Part with a Thin Shell Feature," Journal of Materials Processing Technology, Vol. 110, No. 1, pp. 1-9, 2001. https://doi.org/10.1016/S0924-0136(00)00649-X
  23. Kim, C. H. and Youn, J. R., "Determination of Residual Stresses in Injection-moulded Flat Plate: Simulation and Experiments," Polymer Testing, Vol. 26, No. 7, pp. 862-868, 2007. https://doi.org/10.1016/j.polymertesting.2007.05.006
  24. Shin, J. K., Min, B. K., Kim, Y. J., and Kang, S., "Minimization of Weld Lines in Two Shot Molded Parts with Microlenses," Transactions of Materials Processing, Vol. 13, No. 3, pp. 230-235, 2004. https://doi.org/10.5228/KSPP.2004.13.3.230
  25. Kim, O. R., Cha, B. S., Lee, S. Y., Kim, Y. G., and Woo, C. K., "A Study on the Runner and Gate Consequence of Manufacture Double Shot Molding Using CAE," Transactions of Materials Processing, Vol. 18, No. 2, pp. 160-165, 2009. https://doi.org/10.5228/KSPP.2009.18.2.160
  26. Yoon, G. S., Lee, J. W., Seo, T. I., Kim, Y. J., and Lee, J. B., "A Study on the Analysis of Multi-cavity Co-injection Molding Characteristics by CAE Method," Proceedings of Spring Annual Meeting of Korean Society of Precision Engineering, pp. 451-452, 2011.
  27. Ahn, D. G., Park, M. W., and Kim, H. S., "Selection of Double Shot Moulding Conditions via Injection Moulding Analysis," Proceedings of Spring Annual Meeting of Korean Society of Precision Engineering, pp. 1195-1196, 2010.
  28. Ahn, D. G., Park, M. W., and Kim, H. S., "Design of Cooling System for Multi-Sliced Mould with Volumetric Heat Sink via Three-Dimensional Injection Moulding Analysis," Proceedings of Autumn Annual Meeting of Korean Society of Precision Engineering, pp. 883-884, 2010.
  29. Born, M. and Wolf, E., "Principles of Optics, 7th ed.," Cambridge University Press, pp. 517-521, 1990.

Cited by

  1. A study on the Powder Injection Molding of Translucent Alumina via Flowability Simulation of Powder/Binder Mixture vol.21, pp.3, 2014, https://doi.org/10.4150/KPMI.2014.21.3.215
  2. A Study on Decision of gate location for Injection molding of Automobile air cleaner Upper cover vol.16, pp.7, 2015, https://doi.org/10.5762/KAIS.2015.16.7.4411