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진카이,김낙수,Taesan Jeong,김태산,김병곤 한국정밀공학회 2014 International Journal of Precision Engineering and Vol. No.
With the rapid development of injection molded parts in different fields, products such as injection molded part with metal-insert areusually requested to have high precision and complicated shape. During producing process, residual stresses and deformations suchas warping, local bending and shrinkage are produced due to temperature change, pressure and cooling regime during packing andcooling stages. In this research, numerical analysis of residual stress generated during the packing and cooling stages of injectionmolding process was carried out. And the magnitude and distribution of final distortions were predicted, which were consistent withexperimental measurement. So we came to the conclusion that the residual stresses were formed due to different temperature gradient,causing thermal stresses become uneven distribution. After ejection, the uneven residual stress caused local distortion. Furthermore,the residual stresses were formed due to the process parameters. Besides finding the reason of distortion, another task was to minimizethe distortion. So that optimal design was taken to design important parameters such as melt temperature, die temperature, packingpressure and packing time. The results by optimal design showed that it could reduce the deformation of product effectively.
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김태산,진카이,김낙수,김병곤 대한기계학회 2015 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.29 No.7
During the manufacturing process of die casting baseplate, residual stresses and deformations, such as warping, local bending andshrinkage, are produced due to the changes of temperature, pressure and cooling regime during the packing and cooling stages. Using theElastic-plastic model of AZ91D magnesium alloys at different temperature, a numerical analysis model for the die casting baseplatewhich combines with the influence of residual stresses generated at the packing and cooling stages was built. To verify the numericalresults, 3D scanning technology was used that measured the deformation of the whole baseplate and drew a deformation pattern. Throughcomparison, it is concluded that the calculated deformations were consistent with that of measurement. Furthermore, the residual stresseswere generated differently due to the process parameter change, so that the optimal design was taken for mold temperature, packing pressureand packing and cooling regime. Through optimal design, baseplate deformation was reduced effectively.
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