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Man-Jun Yu(유만준),Jong-Cheon Park(박종천) 한국기계가공학회 2021 한국기계가공학회지 Vol.20 No.12
In this study, the optimal feed system and process conditions that can simultaneously minimize each warpage occurring in the two shape features of the 2P Header HSG, a connector part for automobiles, were determined through injection molding simulation analysis. First, we defined each warping deformation of the two features geometrically and quantified them approximately using the injection molding simulation data. For design optimization, a full factorial experiment was conducted considering the feed system, resin temperature, and packing pressure as design variables, and a follow-up experiment was conducted based on the analysis of the average warpage. In this study, an optimal design was generated considering both the warpage result and resin-saving effect. In the optimal design, the warpages of the two shape features were predicted to be 0.18 and 0.29 mm, and these warpages were found to meet the allowable limit of warpage, which is 0.3 mm, for part assembly.
진공확산접합을 이용한 형상적응형 냉각채널을 가진 화장품 용기용 사출금형의 제작 및 시험사출
유만준(Man-Jun Yu),박종천(Jong-Cheon Park) 한국기계가공학회 2020 한국기계가공학회지 Vol.19 No.3
In this study, an injection mold with conformal cooling channels was designed and manufactured for use in the production of a thick plastic cosmetic container that required high gloss surfaces. A cooling analysis verified the design of the conformal cooling channel for the cosmetic container, and also showed that the cooling efficiency was superior to that of the straight cooling channel. Slide cores designed with the conformal cooling channel were manufactured using the Layers Parting method and vacuum diffusion bonding. Subsequent test injection and quality inspection showed no problem in the appearance and dimensional accuracy of the produced product. The cycle time for product production was about 110 seconds, sufficient for mass production.
Man-Jun Yu(유만준),Jong-Cheon Park(박종천) 한국기계가공학회 2023 한국기계가공학회지 Vol.22 No.7
The objective of this study is to minimize warpage at the opening of an injection-molded component for automobile door locking mechanism by optimizing the cooling channel design and molding conditions. Experiments were initially conducted using Taguchis orthogonal array and the face-centered central composite design method, followed by statistical analysis to determine the optimal design conditions for the peripheral cooling channels and molding conditions. A simulation experiment was conducted to validate the predicted optimal design conditions, which yielded a warpage of 0.8319 mm. To further reduce the warpage, serial- and baffle-type cooling channels were installed between the head and opening of the product. A full factorial experiment was conducted to optimize the design variables for each channel type. The internal cooling channels significantly reduced the fluctuation of the mold surface temperature to maintain the allowable warpage limit of 0.7 mm. Comparisons of the warpage values confirmed that baffle-type internal cooling channels provided more uniform cooling and effectively reduced warpage compared with serial-type channels.
충전해석에 의한 Plug Cover Housing 금형의 피드시스템 설계
박종천(Jong-Cheon Park),유만준(Man-Jun Yu) 한국기계가공학회 2018 한국기계가공학회지 Vol.17 No.5
In this study, the optimum design of mold feed systems is determined for plug cover housing (PCH), which is a cover-assembly product that protects the wiring of automobile connectors. The design goal is to achieve the filling balance of the resin in the left and right covers while avoiding the occurrence of weld lines in the hinge as much as possible. For the optimization, an orthogonal array experiment and a main effect analysis of the design factors are performed, and the factors that cause the interactions with the two design characteristics are selected as the design variables. We present some design alternatives, i.e., some combinations of the design variables, and analyze the filling-simulation results, expected molding risk, and cost economics to select an optimum design solution among the design alternatives. In the optimal solution, the weld line is generated at a position outside the hinge, and the filling balance is also acceptable, showing that both design goals can be satisfied simultaneously despite conflicting with each other.
Jong-Cheon Park(박종천),Man-Jun Yu(유만준),Ki-Yoon Park(박기윤) 한국기계가공학회 2019 한국기계가공학회지 Vol.18 No.11
In this study, we design the feed system and process conditions for a lamp garnish lens of an automobile. For this purpose, four design alternatives are presented and injection molding simulation analyses are performed. The optimal feed system is selected by considering the formability of the product and the cost of mold manufacture. The product formability is assessed by the weld line, warpage, sink mark and the maximum injection pressure, whereas the mold-making cost is estimated by the number of valve gates in the hot runner system. To improve the product formability, process conditions are optimized using an experimental design approach named one-factor-at-a-time. No weld line is generated as a result of the optimization. In addition, it is found the warpage and sink mark are reduced while the maximum injection pressure is increased, compared with those before the optimization.
곡선형 형상적응형 냉각채널을 갖는 금형 코어 제작을 위한 DMT 공정개발
한지수(Ji Su Han),유만준(Man Jun Yu),이민규(Min Gyu Lee),이윤선(Yoon Sun Lee),김우성(Woo-Sung Kim),이호진(Ho Jin Lee),김다혜(Da Hye Kim),성지현(Ji Hyun Sung),차경제(Kyoung Je Cha) 한국기계가공학회 2019 한국기계가공학회지 Vol.18 No.11
The cooling rate and the uniformity of mold temperature, in the injection molding process, possess great influences on the productivity and quality of replications. The conformal cooling channel, which is of a uniform spacing from the mold cavity by the metal additive manufacturing process, receives much attention recently. The purpose of this study is to develop a mold core with a curved conformal cooling channel for a pottery-shaped thick-wall cosmetic container through the hybrid method of direct metal tooling (DMT) process. In this study, we design a mold core that contains the curved cooling channel for the container. A method that divides the cavity is proposed and the DMT process is carried out to form the curved cooling channel. The test mold core, with the curved conformal cooling channel, has been fabricated by the proposed method to confirm the feasibility of the design concept. We show that no leakage is observed for the additive manufactured test mold core, and its physical properties demonstrate that it can be sufficiently used as the injection mold core.
Jong-Cheon Park(박종천),Man-Jun Yu(유만준) 한국기계가공학회 2020 한국기계가공학회지 Vol.19 No.9
In this study, the optimal design of the multi-cavity mold layout and packing pressure for the automobile TCU connector cover is determined based on the injection molding analysis and the desirability function method for multi-characteristic optimization. The design characteristics to be optimized are the warpage and sink marks of the product, the scrap of the feed system, and the clamping force. The optimal design is determined by performing injection molding analysis and desirability analysis for design alternatives defined by a complete combination of five mold layouts and six-level packing pressure. The optimal design shows that the desirability values for individual characteristics are quite high and balanced, and the resulting values of individual characteristics are satisfactorily low.
Jong-Cheon Park(박종천),Man-Jun Yu(유만준) 한국기계가공학회 2024 한국기계가공학회지 Vol.23 No.4
In designing runner systems for family molds, achieving balanced resin filling across product cavities is essential for uniform quality assurance. This study aims to develop two-stage optimization algorithms that integrate with injection molding analysis software, specifically for designing runner systems that ensure a filling balance in family molds. The first stage employed a modified complex method to generate various runner system design alternatives with balanced filling. In the second stage, the signal-to-noise ratio was used to select a robust design alternative that maintained the filling balance, even under varying molding conditions, as the optimal design. The developed optimization algorithm was applied to design a runner system for family molds used in producing injection-molded components for automotive heating, ventilation, and air conditioning (HVAC) systems. This study focused on a runner system for a rotary bar and decorative knob plate. The resulting optimal design demonstrated a robust filling balance between the two product cavities, maintaining consistency despite fluctuating process variables.