• Title, Summary, Keyword: Injection Molding

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Development of double injection mold for fuel-tube holder (자동차 연료튜브 홀더용 이중사출 금형·성형기술)

  • Kim, Gun-Hee;Yoon, Gil-Sang;Heo, Young-Moo;Jung, Woo-Chul;Shin, Kwang-Ho
    • Journal of the Korea Society of Die & Mold Engineering
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    • v.1 no.1
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    • pp.1-5
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    • 2007
  • Double injection molding process is very efficient molding-method for molding the products which is consist of multi-materials. Fuel-tube holder which is necessary for automobil power train and circulation systems is composed of plastic and rubber materials to minimize the vibration and pulsation noises. In existing process, fuel-tube holder was made by the insert molding process or assembly process after molding. If fuel-tube holder is manufactured by double injection molding process, it may be realize to improve the product quality, efficiency of molding-process and retrenchment of manufacturing cost. In this study, for manufacturing fuel-tube holder by double injection molding process, the analysis of joining characteristics between PA6(polyamide 6) and TPE(thermoplastic elastomer) was executed and the double injectin mold for molding fuel-tube holder with core toggle mechanism was fabricated. Finally, fuel-tube holder was molding using fabricated double injection mold.

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Automated Molding Design Methodology to Optimize Multiple defects in Injection Molded Parts

  • Park, Jong-Cheon;Kim, Byung H.
    • International Journal of Precision Engineering and Manufacturing
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    • v.1 no.1
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    • pp.133-145
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    • 2000
  • Plastic molding designers are frequently faced with optimizing multiple defects in injection molded parts. these defects are usually in conflict with each other, and thus a tradeoff needs to be made reach a final compromised solution. In this study, an automated injection molding design methodology has been developed to optimize multiple defects of injection molded parts. Two features of the proposed methodology are as follows: one is to apply the utility theory to transform the original multiple objective optimization problem into single objective optimization problem with utility as objective function, the other is an implementation of a direct search-based injection molding optimization procedure with automated consideration of process variation. The modified complex method is used as a general optimization tool in this research. The developed methodology was applied to an actual molding design and the results showed that the methodology was useful through the CAE simulation using a commercial injection molding software package. Applied to production, this study will be of immense value to industry in reducing the product development time and enhancing the product quality.

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A Study on the Fiber Orientation and Fiber Content Ratio Distribution during the Injection Molding for FRP (FRP의 사출성형에 있어서 섬유배향상태와 섬유함유율분포에 관한 연구)

  • Kim J. W.;Lee D. G.
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • pp.252-257
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    • 2005
  • Injection molding is a very important industrial process for the manufacturing of plastics objects. During an injection molding process of composites, the fiber-matrix separation and fiber orientation are caused by the flow of molten polymer/fiber mixture. As a result, the product tends to be nonhomogeneous and anisotropic. Hence, it is very important to clarify the relations between separation' orientation and injection molding conditions. So far, there is no research on the measurement of fiber orientation using image processing. In this study, the effects of fiber content ratio and molding condition on the fiber orientation-angle distributions are studied experimentally. Using the image processing method, the fiber orientation distribution of weld-line in injection-molded products is assessed. And the effects of fiber content and injection mold-gate conditions on the fiber orientation are also discussed.

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A Study on the Deflection of Large Mold for Injection Molding (대형 사출금형의 성형시 발생하는 금형 휨에 관한 연구)

  • Hwang, Si-Hyun;Kim, Chul-Gyu;Shim, Soo-Kil;Jeong, Yeong-Deug
    • 한국금형공학회:학술대회논문집
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    • pp.99-102
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    • 2008
  • Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

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Linear Structural Analysis of Standard Plastic Tensile Specimen with Residual Stress Induced by Injection Molding (사출성형과정의 잔류응력을 고려한 표준인장시편의 선형구조해석)

  • Lee D.M.;Han B.K.;Lee Sung-Hee
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.579-580
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    • 2006
  • In this study, an injection mold of tensile test specimen was manufactured by international standard. Pressure and temperature in the cavity of the injection mold was measured by sensors. Simulation of injection molding process was performed with the same condition of experiment and linear structural tensile analysis was also performed with the initial condition of the residual stress induced by injection molding analysis. Normalized elastic coefficient of tensile test was compared with that of structural analysis. It was shown that the residual stress induced by injection molding has an effect on both the experiment of tensile test and linear structural analysis.

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A Study on the Deflection of Large Mold for Injection Molding (대형 사출금형의 성형 시 발생하는 금형 휨에 관한 연구)

  • Hwang, Si-Hyun;Kim, Chul-Gyu;Shim, Soo-Kil;Jeong, Yeong-Deug
    • Journal of the Korea Society of Die & Mold Engineering
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    • v.8 no.1
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    • pp.1-4
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    • 2014
  • Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

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A Searching Method of Optima] Injection Molding Condition using Neural Network and Genetic Algorithm (신경망 및 유전 알고리즘을 이용한 최적 사출 성형조건 탐색기법)

  • Baek Jae-Yong;Kim Bo-Hyun;Lee Gyu-Bong
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.946-949
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    • 2005
  • It is very a time-consuming and error-prone process to obtain the optimal injection condition, which can produce good injection molding products in some operational variation of facilities, from a seed injection condition. This study proposes a new approach to search the optimal injection molding condition using a neural network and a genetic algorithm. To estimate the defect type of unknown injection conditions, this study forces the neural network into learning iteratively from the injection molding conditions collected. Major two parameters of the injection molding condition - injection pressure and velocity are encoded in a binary value to apply to the genetic algorithm. The optimal injection condition is obtained through the selection, cross-over, and mutation process of the genetic algorithm. Finally, this study compares the optimal injection condition searched using the proposed approach. with the other ones obtained by heuristic algorithms and design of experiment technique. The comparison result shows the usability of the approach proposed.

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A Study on the Deformation Optimization of a Plastic Bezel Assembled on the Steering Wheel of an Automobiles (자동차 스티어링 휠에 조립되는 플라스틱 베젤의 변형 최적화에 관한 연구)

  • Han, Seong-Ryoel
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.16 no.5
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    • pp.105-112
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    • 2017
  • In this study, plastics were deformed after molding due to the characteristics of the material. The Taguchi experimental design method was utilized to find the molding conditions that minimized deformation of the plastic bezel to be assembled in an automotive steering wheel. The injection molding conditions applied to the experimental design method are the melt temperature, cavity plate coolant temperature, core plate coolant temperature, and cooling time. Each condition was divided into five levels, and a total of 25 experiments were planned. However, instead of performing 25 actual molding experiments, the injection molding analysis was performed using the Moldflow program, and the deformation values for each molding analysis were obtained. The optimal molding conditions were obtained from these deformation values. The actual injection molding experiment using optimal molding conditions was compared with the deformation amount of the current molded product. The deformation was measured using a precise 3D scanner. The deformation amount of the molded product under optimal molding conditions was 16.1% lower than the deformation amount of the current molded product.

A study on optimum temperature depending on resin of injection molded parts (사출 성형품의 수지에 따른 최적의 온도에 대한 연구)

  • Cho, Sung-Gi;Han, Seong-Ryeol
    • Journal of the Korea Society of Die & Mold Engineering
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    • v.13 no.2
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    • pp.12-16
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    • 2019
  • For optimal injection molding, various molding conditions should be combined well. Therefore, engineers should be thoroughly familiar with mold design, fabrication, and injection molding. The choice of resin among the various molding conditions is closely related to the productivity of the molded part and the deformation after molding, so the engineer must select the appropriate resin. Engineers work on the basis of data provided by resin manufacturers during molding. However, in actual molding work, it is necessary to apply values slightly different from those provided to obtain molded articles of desired performance. In this study, various deformations of molded products were compared with respect to crystalline resin and amorphous resin when molded according to the data provided by the resin maker and molded at the changed values at the work site.

Design of Injection Mold with Cavity Pressure/Temperature Sensors and Molding for Standard Tensile Test Specimen (내압력.온도센서를 갖는 표준 인장시편용 사출금형설계 및 성형)

  • Lee D.M.;Han B.K.;Lee O.S.;Lee Sung-Hee
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.1416-1419
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    • 2005
  • Design and manufacturing of plastic injection mold with cavity pressure/temperature sensors were performed in the present study for tensile test specimen. Standards of mold-base and tensile test specimen were used to design an injection molding system. Cavity pressure and temperature sensors were placed on the side of fixed platen of injection mold machine to prevent them from external impact damage. Injection molding experiments with variations of injection speed and melt temperature were performed and polycarbonate tensile specimens were prepared for the tensile test. It was shown that injection molding processing parameters can have effect on the mechanical properties of the plastic injection molded part.

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