인서트 변형을 고려한 배터리 케이스 사출 성형 해석

안동규(Dong-Gyu Ahn),김대원(Dea-Won Kim) 대한기계학회 2008 대한기계학회 춘추학술대회 Vol.2008 No.11

The objective of this paper is to investigate into the influence of the injection conditions on the insert deformation and the wall thickness of the injection part using the three-dimensional injection molding analysis. Full three-dimensional insert model was added to the injection molding analysis model to consider the effects of insert deformation during the injection molding process. In order to obtain the optimum injection molding condition with a minimum insert deformation, degree of experiments were utilized. From the results of the analyses, it was shown that the optimum injection condition is injection time of 1.6 sec, injection pressure of 30 ㎫a and packing time of 15 sec. In addition it was shown that the wall thickness is approached to target thickness when the core deformation is considered in the injection molding analysis.

사출압축성형을 이용한 자동차용 도어그립 필름인서트성형

이호상(Ho Sang Lee),유영길(Young Gil Yoo),김태안(Tae An Kim) 대한기계학회 2014 大韓機械學會論文集A Vol.38 No.7

자동차용 도어그립을 대상으로 하여 3 차원 엠보 패턴이 인쇄된 필름을 적용한 인서트성형을 구현하기 위하여 사출압축성형을 사용하였다. 진공금형을 제작하여 필름 열성형을 하였으며, 필름인서트성형을 위하여 사출압축금형을 개발하였다. 3 개의 압력센서를 설치하여 금형 캐비티압력을 측정하였으며, 다양한 압축스트로크와 토글속도에 대한 사출압축성형 실험을 수행하여, 공정조건이 캐비티 압력과 엠보 패턴의 높이에 미치는 영향을 고찰하였다. 압축스트로크 0.9mm 와 느린 토글속도에서 엠보 패턴의 유지율이 높게 나타났다. 또한 엠보패턴이 최대 높이를 갖기 위한 공정조건은 캐비티 압력의 적분값이 최소가 되는 조건과 거의 동일하였다. 사출압축성형을 사용하여 엠보 패턴이 인쇄된 소프트한 촉감을 갖는 플라스틱 제품을 구현할 수 있다. 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.

FEM 캐리어의 사출조건에 따른 인서트사출해석 신뢰성에 관한 연구

박지열(Jiyeol Park),하태준(Taejun Ha),김용수(Yongsoo Kim) 한국자동차공학회 2019 한국자동차공학회 학술대회 및 전시회 Vol.2019 No.11

현재 자동차 부품 중 사출제품은 고도의 기술향상으로 제품 개발에서 양산적용까지는 안정적이지만 제품을 얻기까지는 많은 비용이 들고 시행착오의 반복으로 시간이 과도하게 발생하기도 한다. 따라서 CAE(Computer Aided Engineering) 기술을 접목시키면 개발하고자 하는 제품의 예상되는 문제점들을 미리 분석하여 최적의 설계를 얻을 수 있다. 최근에는 해석 기술의 발달로 실제 사출성형공정을 재현하여 충진, 보압, 변형까지의 단계적 상태 결과를 예측할 수 있게 되었다. 그러나 설계단계에서 해석을 통해 기본적인 게이트 위치 및 수량, 사출압력, 형체력에 대해서는 참고 개선반영이 이루어지고 있으나 변형에 대해서는 시험사출결과를 통해 개선되는 경우가 다반수다. 본 연구에서는 현재 사출해석조건을 적용 시 해석결과를 실제 제품결과와 비교하여 충진 끝단 유동패턴 및 사출압력, 변형경향까지 확인 후 현 수준을 파악할 것이다. 그리고 사출해석조건을 세분화 및 정확성을 개선하여 해석결과를 통해 유동 패턴 및 사출압력, 변형 경향의 개선 여부를 확인 검증하고 현장에서 조사 및 측정된 정보들을 해석입력조건으로 가공하기 위한 정의방법과 해석결과 신뢰성 향상을 제시하고자 한다.

Al-Insert 사출성형을 이용한 자동차 내장재 부품 개발에 관한 연구

노태정(T.J. Lho),김진영(J.Y. Kim),강동중(D.J. Kang),김종학(J.H.Kim),김기일(G.Y.Kim) 한국정밀공학회 2005 한국정밀공학회 학술발표대회 논문집 Vol.2005 No.10월

Generally, Aluminum is superior to durability, light, and characteristics of the material are embossed luminant. So, these characteristics of aluminum will be used automobile interior parts by aluminum injection moulding. Especially, The external of Aluminum plate is engraved differing pattern by roller working. This working can use any longer and be seen gracefully. This is the reason why aluminum insert moulding is used. This feature of research can be characterized by simple process to customize aluminum sheet of blanking and forming process with internal parts of configuration if products are injected by aluminum sheet. Besides, to analysis completed Automobile interior parts to be concerned volumetric shrinkage, best gate location, fill time analysis and so on through the mold-flow before the aluminum insert moulding is worked.

Numerical Analysis of the Filling Stage in Insert Injection Molding of Microfluidic Chip with Metal Electrodes

이봉기(Bong-Kee Lee),나승식(Seung-Sik Na) Korean Society for Precision Engineering 2015 한국정밀공학회지 Vol.32 No.11

In the present study, a numerical investigation of an insert injection molding process was carried out for the development of thermoplastic microfluidic chip plates with metal electrodes. Insert injection molding technology enables efficient realization of a plastic-metal hybrid structure and various efforts have been undertaken to produce novel components in several application fields. The microfluidic chip with metal inserts was proposed as a representative example and its molding process was analyzed. The important characteristics of the filling stage, such as the effects of filling time and thickness of the part cavity, were characterized. Furthermore, the detailed distributions of pressure and temperature at the end of the filling stage were investigated, revealing the significance of metal insert temperature.

스크림 인서트 PAB Door 일체 크래시패드 개발

이민경(Minkyeong Lee),최재섭(Jaeseob Choi),최성식(Sungsik Choi) 한국자동차공학회 2017 한국자동차공학회 학술대회 및 전시회 Vol.2017 No.11

본 논문은 PAB 전개압 및 사이즈 증대에 대응하여 크래시패드의 에어백 전개부 강건화 구조의 개발 및 검증 과정에 대해 설명하고자 한다. 발포 타입의 크래시패드를 대상으로 개발된 본 제품은 스킨, 발포폼, 크패시패드 코어로 구성되며, 크래시패드 코어는 스크림을 인서트하여 PPF 소재로 사출한다. 스크림은 메쉬타입의 직물 소재로, PAB 전개시 도어 힌지를 강화하는 역할을 한다. 크래시패드 코어 사출시, PAB Chute 측벽 및 도어 형상이 모두 성형되어, 별도의 PAB Chute가 필요 없다. 또한 인몰드 스코링 구조 및 스크림 패턴을 적용하여, PAB 전개라인을 제작하는 스코링 공정을 삭제하였다. 제작된 제품은 북미 사양 PAB를 장착하여 전개성능 검증을 완료하였다.

자동차부품용 알루미늄인서트 사출성형공정 구현에 관한 연구

노태정(Tae-Jung Lho),김경수(Kyung-Soo Kim) Korean Society for Precision Engineering 2008 한국정밀공학회지 Vol.25 No.5

Generally a plastic injection molding is a manufacturing process used to produce the various parts of complicated shape at low cost. The objective of this study is to implement a new plastic injection molding process with inserted Aluminum sheet, which is highly durable, light and luminous. Moldflow analysis and simulation of plastic injection molding process with inserted Aluminum sheet were carried out in order to predict optimal molding operation conditions. The experimental results in the AI-inserted plastic injection molding process were compared with the simulation results by Moldflow. Durability and reliability test results for trial products were satisfied to adopt the AI-inserted plastic injection molding process developed as manufacturing of automobile interior parts.

수치해석을 이용한 냉장고용 유리선반 성형용 인서트 금형의 개선

한성렬(Seong-Ryeol Han) 한국기계가공학회 2016 한국기계가공학회지 Vol.15 No.6

Refrigerator glass shelves are manufactured by Insert Injection Molding. The current process of injection of glass into the mold induces movement of the core, on urethane springs. Defects in the product can result from too low a force being transmitted from the springs. To solve this problem, the force on the moving core and the injection molding pressure were subjected to numerical analysis. Based on this, the number of urethane springs as well as their hardness was changed to improve the situation. The number of springs was changed from 6 to 4. The diameter of the springs was increased from Ø75 to Ø100, and the hardness was increased from 70 (shore A) to 90 (shore A). These improvements caused the force on the molding core to increase by approximately 65,442 N. The proportion of defects decreased by 66%.

초발수 곡면표면 실리콘 사출금형성형기술

이성희(Sung-Hee Lee),강정진(Jeong Jin Kang),이종원(Jong-Won Lee),홍석관(Seok-Kwan Hong),고종수(Jong Soo Ko),이제훈(Jae-Hoon Lee),노지환(Jiwhan Noh) Korean Society for Precision Engineering 2012 한국정밀공학회지 Vol.29 No.1

In this study, silicone injection molding technology with curved thermoplastic insert was developed to produce super-hydrophobic surface. Thermoplastic insert part and injection mold design of base plastic cover were performed to produce cost effective hydrophobic surface part. An optimization process of part thickness for thermoplastic insert part was performed with transient thermal analysis under silicone over-molding process condition. Structural thermal analysis of silicone injection mold was also performed to obtain uniform temperature condition on the surface of micro-patterned mold core. Super-hydrophobic surface for the silicone injection molded part with thermoplastic insert could be verified from the measurement of contact angle. It was shown that the averaged contact angle was over 140°.

크롬메탈 필름 일체형 라디에이터 그릴 사출성형 공정개발

박홍석(Hong-Seok Park),김정호(Jung-Ho Kim),Thanh-son Tran,Xuan-Phuong Dang 대한기계학회 2009 대한기계학회 춘추학술대회 Vol.2009 No.11

Most of automotive plastic parts are injection molding product because injection molding is one of the most useful polymer processing method. Specially, film insert molding is a new injection molding technique in which molten polymer is injected into the cavity after some films are precisely attached to the mold wall. In this study, we suggest the best possible method to fix the chrome films to one side of the mold walls, and moreover, we develop inside pins to fix the films in the mold. Furthermore, inside pins are considered to reduce an overflow of molten polymer when the plastic resin is introduced into the cavity. In addition, we suggest the optimum parameter for radiator grill with chrome metal film in injection molding process.