DSI 성형을 이용한 금속/플라스틱 복합 부품 제조에 관한 연구

하석재,차백순,고영배,Ha, Seok-Jae,Cha, Baeg-Soon,Ko, Young-Bae 한국금형공학회 2020 한국금형공학회지 Vol.14 No.4

Various manufacturing technologies, including over-molding and insert-injection molding, are used to produce hybrid plastics and metals. However, there are disadvantages to these technologies, as they require several steps in manufacturing and are limited to what can be reasonably achieved within the complexities of part geometry. This study aims to determine a practical approach for producing metal/plastic hybrid components by combining plastic injection molding and metal die casting to create a new hybrid metal/plastic molding process. The integrated metal/plastic hybrid injection molding process developed in this study uses the proven method of multi-component technology as a basis to combine plastic injection molding with metal die casting into one integrated process. In this study, the electrical conductivity and ampacity were verified to qualify the new process for the production of parts used in electronic devices. The electrical conductivity was measured, contacting both sides of the test sample with constant pressure, and the resistivity was measured using a micro ohmmeter. Also, the specific conductivity was subsequently calculated from the resistivity and contact surface of the conductor path. The ampacity defines the maximum amount of current a conductive path can carry before sustaining immediate or progressive deterioration. The manufactured hybrid multi-components were loaded with increasing currents, while the temperature was recorded with an infrared camera. To compare the measured infrared images, an electro-thermal simulation was conducted using commercial CAE software to predict the maximum temperature of the power loaded parts. Overall, during the injection molding process, it was demonstrated that multifunctional parts can be produced for electric and electronic applications.

3D 분말사출성형공법을 활용한 티타늄 웰빙주얼리 개발에 관한 연구

이형규(Hyung Kyu Lee) 한국디자인문화학회 2009 한국디자인문화학회지 Vol.15 No.3

본 논문은 3D 분말사출성형기법을 활용한 티타늄 웰빙주얼리의 제작 가능성을 제시함으로 티타늄 주얼리 디자인의 다양화 및 시장의 확대, 국제 시장 경쟁력 강화의 방안을 탐색하기 위한 것이다. 본 연구의 범위는 티타늄에 관한 일반적 개요, 티타늄 가공기술 및 시장현황, 3D분말사출성형기법 이며 이를 활용하여 티타늄 웰빙주얼리 개발가능성을 타진해 보고자한다. 연구방법은 인터넷을 이용한 국내외 정보D/B 및 네트워크 검색, 논문과 단행본을 포함한 도서 출판물 등 문헌 조사를 중심으로 티타늄에 관한 일반적 개요 및 주얼리 시장 분석을 하였다. 또한 시제품을 통해 티타늄 3D분말사출성형기법을 이해하고 3D 분말사출성형기법의 티타늄주얼리 응용 가능성을 탐색하였다. 티타늄은 많은 매장량과 재료가 가진 물리적 장점에도 불구하고 1950년대 이후에야 상업적으로 사용되어진 희유금속이며 그 이유는 금속정련 방법 및 가공공정의 어려움 때문이었다. 그러나 최근 기계가공환경이 발전하면서 첨단 기술공법이 개발되어 여러 산업분야에서 티타늄의 물리적 특성이 활용되고 있다. 티타늄의 여러 가지 장점 중에서 친생체적이며 내구성이 강하고 가벼운 특징은 티타늄 웰빙주얼리를 개발하기에 매우 적합한 요소이다. 이는 귀금속 중심의 주얼리 시장에 다변화를 가져올 수 있으며 티타늄 가공 기술을 발전 확장시켜 다른 제품에도 확장 적용시킬 수 있을 것이다. 따라서 본 논문에서는 오늘날 티타늄 주얼리가 주목 받을 수 있는 타당성과 3D분말사출성형기법을 활용한 주얼리 제작의 필요성을 제시하고자한다. This paper is intended to propose methods for diversification of titanium jewelry design and for expansion of the market and reinforcement of international market of titanium jewelry by suggesting potential manufacture of titanium wellbeing jewelry utilizing 3D metal injection molding. This study looked into general introduction, processing technique and market situations of titanium and examined 3D metal injection molding and titanium wellbeing jewelry development possibility utilizing it. As study methods, potential application of titanium jewelry of 3D metal injection molding was sought by understanding titanium 3D metal injection molding through a prototype and by analyzing a titanium jewelry market. Also, this study was focused, through internet, on investigation of literatures such as home and abroad D/B and network search, and publications including theses and a separate volume. In spite of lots of reserves and its physical merits, titanium is a rare metal that has been commercially used since 1950s, because of difficulty in refining and processing it. Recently, however, as mechanical processing environment develops, the latest manufacturing method was developed, so that the physical features of titanium are being used. in many industrial fields. Organism-friendly, durable and light features of titanium among its many merits are very convenient for titanium wellbeing jewelry to be developed. These features may cause a variety of changes in the jewelry market centered on precious metal, advancing titanium processing skill which would be further applied to other products. Accordingly, this paper propose the validity of titanium jewelry worthy of note today and the necessity of jewelry manufacture utilizing 3D metal injection molding.

A study on compound contents for plastic injection molding products of metallic resin pigment

박영환,Gyu-Sang Lee,곽재섭 대한기계학회 2016 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.30 No.12

Injection molding process is widely used for producing most plastic products. In order to make a metal-colored plastic product especially in modern luxury home alliances, metallic pigments which are mixed to a basic resin material for injection molding are available. However, the process control for the metal-colored plastic product is extremely difficult due to non-uniform melt flow of the metallic resin pigments. To improve the process efficiency, a rapid mold cooling method by a compressed cryogenic fluid and electricity mold are also proposed to decrease undesired compound contents within a molded plastic product. In this study, a quality of the metal-colored plastic product is evaluated with process parameters; injection speed, injection pressure, and pigment contents, and an influence of the rapid cooling and heating system is demonstrated.

Effect of Oxygen on Mechanical Properties of Metal Injection Molded Titanium and Titanium Alloy

Doi Kenji,Hanami Kazuki,Tanaka Hideki,Teraoka Tsuneo,Terauchi Shuntaro 한국분말야금학회 2006 한국분말야금학회 학술대회논문집 Vol.2006 No.1

Mechanical properties of metal injection molded titanium and titanium alloy parts were investigated in this study. Material powders with low oxygen content and spherical shape were obtained by electrode induction-melting gas atomization which could melt and atomize titanium and titanium alloy bars with no touch on crucible or tundish. Tensile specimens were fabricated from obtained powders by metal injection molding process. Tensile strength of the specimens increases with increasing oxygen content. This result corresponds to a tendency of wrought metal.

금속사출성형기법을 이용한 플랜지 제작기술에 관한 연구

이동길,장경천,정민관,김명호,김일수 한국공작기계학회 2008 한국공작기계학회 춘계학술대회논문집 Vol.2008 No.-

MIM(Metal Injection Molding) that is a kind of PIM(Powder Injection Molding) is using in optical communication field, display field, several fields such as semi-conductor field because ceramic has superior physical properties. Also, mold's optimization that can produce high precision flange that is one of main parts of optical communication field is greatly required. The objective of this paper is to study the suitability of design and capability analysis for the MIM and process that can mass-produce the flange using in a mold by conduct the experiments as well as the flow analysis. It was filling time 0.5-1.5 second, injection pressure 11.0-12.5 MPa range for the injection parameters that cause high effect to injection derived from optimum condition by flow analysis. Yield that is more than gravity 7.495 that establish by target as result that analyze gravity of products at investigated injection conditions was 99.01 % and process capability was construed by 3.83 sigma level. Also, the average gravity and standard deviation was 7.6151 and 0.0511 respectively. The measured dimensions were all good results within the established target showing that concentricity, roundness, and density were 27.43 ㎛, 18.64, and 97.63%.

휴대폰 중간면의 인서트 사출성형공정에 관한 연구

민병현(Byeong-Hyeon Min),김병곤(Byeong-Gon Kim),예상돈(Sang-Don Ye) 한국산학기술학회 2022 한국산학기술학회논문지 Vol.23 No.4

휴대폰 외관의 미려함과 견고함을 확보하기 위해 고정밀 기능 부품들이 결합된 휴대폰 중간 면에 금속 부품과 플라스틱 수지를 결합한 인서트 사출 성형을 하였다. 휴대폰 중간면은 PBT(Polybutylene terephthalate) 보강재로 유리섬유 40% 함유 플라스틱 수지를 사용해 인서트 사출을 진행했다. USB 홀의 전체 길이는 성형품의 체적 수축으로 인한 치수 관리 위치로 사용되었다. 기존의 공정능력을 분석하여 USB 단자 전장 치수의 안정성 확보와 사이클 타임 축소를 통한 생산성 향상의 두 가지 목표를 연구 방향으로 설정하였다. USB 단자의 전장 치수의 관리 규격인 8.49±0.04 mm를 만족하면서 사이클 타임을 55초에서 33초로 22초 단축하는 사출성형공정조건을 최적화하였다. 양산 단계에서의 최적화 검증으로 장기공정능력지수 Zlt는 4.22σ, 단기공정능력지수 Zst는 4.89σ, Zshift는 0.67σ를 도출하였으며, 개선 전 공정능력과 비교하여 Zlt는 3.03σ 높아지고 Zshift는 0.57σ 낮아지는 등 기술력과 관리력에 대한 공정능력이 향상되었음을 확인하였다. The middle surface of a mobile phone, where high-precision functional parts are combined, is usually insert injection molding to achieve beauty and rigidity of the mobile phone"s exterior. In particular, injection molding can combine metal parts and plastic resin in the middle surface of a mobile phone effectively. This study insert injection molded the middle surface of a mobile phone from a plastic resin containing 40 % glass fiber as reinforcement in polybutylene terephthalate (PBT). The length of the USB hole was used as the measure in managing dimensional changes in the molded product due to its volumetric shrinkage. Next, two goals were set for further research after analyzing the existing process capability. These goals include securing the stability of the USB terminal"s overall dimensions and improving productivity by reducing cycle time. Subsequently, fixing the average target value for the length of the USB terminal to 8.49 mm minimized the average dimensional deviation. In addition, optimized insert injection molding conditions shortened the cycle time from 55 seconds to 33 seconds . The long-term process capability index Zlt was 4.22 σ, the short-term process capability index Zst was 4.89 σ, and the Zshift was 0.67σ for the optimized insert injection molding. Hence, the capability of the insert injection molding in terms of technology and management has improved with the proposed modifications.

금속사출성형기법을 이용한 플랜지 제작기술에 관한 연구

이동길(D.G. Lee),장경천(K.C. Jang),정민관(M.G. Jung),김명호(M.H. Kim),김일수(I.S. Kim) 한국생산제조학회 2008 한국생산제조시스템학회 학술발표대회 논문집 Vol.2008 No.5

MIM(Metal Injection Molding) that is a kind of PIM(Powder Injection Molding) is using in optical communication field, display field, several fields such as semi-conductor field because ceramic has superior physical properties. Also, mold's optimization that can produce high precision flange that is one of main parts of optical communication field is greatly required. The objective of this paper is to study the suitability of design and capability analysis for the MIM and process that can mass-produce the flange using in a mold by conduct the experiments as well as the flow analysis. It was filling time 0.5~1.5 second, injection pressure 11.0~12.5 ㎫ range for the injection parameters that cause high effect to injection derived from optimum condition by flow analysis. Yield that is more than gravity 7.495 that establish by target as result that analyze gravity of products at investigated injection conditions was 99.01 % and process capability was construed by 3.83 sigma level. Also, the average gravity and standard deviation was 7.6151 and 0.0511 respectively. The measured dimensions were all good results within the established target showing that concentricity, roundness, and density were 27.43 ㎛, 18.64, and 97.63%.

Microstructure and High Temperature Oxidation Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Powder Injection Molding Process

Yeun‑Ah Joo,Young‑Kyun Kim,윤태식,Kee‑Ahn Lee 대한금속·재료학회 2018 METALS AND MATERIALS International Vol.24 No.2

This study investigated the microstructure and high temperature oxidation property of Fe–Cr–B metal/ceramic compositemanufactured using powder injection molding process. Observations of initial microstructure showed a unique structurewhere α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performedat 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented paraboliccurves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identifiedCr2O3and SiO2at 900 and 1000 °C. In addition to Cr2O3and SiO2,CrBO3and FeCr2O4formed due to phase decompositionof boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidationmechanism of Fe–Cr–B metal/ceramic composite manufactured using powder injection molding, and the possibility of itsapplication as a high temperature component material was also discussed.

Innovations in Micro Metal Injection Molding Process by Lost Form Technology

Nishiyabu Kazuaki,Kanoko Yasuhiro,Tanaka Shigeo 한국분말야금학회 2006 한국분말야금학회 학술대회논문집 Vol.2006 No.1

The production method of micro sacrificial plastic mold insert metal injection molding, namely process has been proposed to solve specific problems involving the miniaturization of MIM. Two types of sacrificial plastic molds (SP-mold) with fine structures were used: 1) PMMA resist, 2) PMMA mold injected into Ni-electroform, which is a typical LIGA () process. Stainless steel 316L feedstock was injection-molded into the SP-molds with multi-pillar structures. This study focused on the effects of metal particle size and processing conditions on the shrinkage, transcription and surface roughness of sintered parts.

Process chain analysis of the dimensional integrity in a metal-insert polymer smart phone baseplate - from die casting to polymer injection molding

Kai Jin,김태산,김낙수,김병곤 대한기계학회 2015 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.29 No.4

Given the rapid development of die casting and polymer injection molding technologies, injection molding with metal-insert products,such as smart phone baseplate, can be widely produced and used. Injection molding usually has a complicated shape and high precision. Residual stress and related warping, local bending, and shrinkage are the key problems that affect the final product quality. These defectsare generated because of temperature change, pressure, and cooling regime. In this research, finite element method was carried out toprocess chain analysis from die casting to polymer injection molding. This method predicted the residual stresses during the packing andcooling stages of die casting and polymer injection molding. The reason of distortion after ejection as well as the magnitude and distributionof distortion were also analyzed. To verify the calculated distortion after ejection, we compared the numerical analysis results withthe experimental results that were measured by 3D scanning technology. The calculated deformation was consistent, and the residualstress was formed because of the different thicknesses of the sheets that resulted in different cooling rates, causing thermal stresses tobecome unevenly distributed. After the ejection, the uneven residual stress caused local distortion.