In this study, the injection pressure of 31 MPa and clamping force of 1,000 kN toggle electric injection molding machine were used to measure the load transmitted to the frame during injection molding and to use it as the design basis data. In general, the toggle structure is composed of a movable plate, tie bars, crossheads, toggle links, toggle pins, base plates, etc and The material is spherical graphite cast iron(FCD 400). In this study, it was found that there was a 1.3% safety factor by calculating the clamping force in the structure of the five-point toggle link system. In addition, Expected static bottom load, Expected dynamic additional load, Maximum expected additional load, and Maximum weight load were measured using tensile measurements and presented as important basic design data of the assembly.

Injection molding is extensively used for mass production of plastic products. Over the years, the plastic products have been manufactured in a variety of colors, materials and mechanical properties to fulfill the market demand. The purpose of this study is to identify the relation between the color of resin and the product quality. To proceed this study, different colored PBT specimens have injection molded, and mechanical properties were compared. Tensile tests and bending tests have carried out to study mechanical properties of the specimens, and differentials have occurred in tensile strength, bending strength and tensile elongation by their respective color. And the red specimens were broken during the bending test. The experimental results reveal that the color of the resin influences the mechanical strength of the injection molded product. As a result, the color of resin should be considered when setting parameters for injection molding in order to improve the product quality.

Due to the development of plastic materials, injection molding products are limitlessly used. The colours of the plastic material also, have been developed to meet the needs of customers. The purpose of the present study is to verify the shrinkage of the injection-molded PC and PBT specimens in different colours. In this study, red, white, black and transparent colours were selected for PC resin. Also blue, red and black colours were selected for PBT resin. 50 specimens were produced per each colour, and measured after cooling-off. The P-value, the test statistic of the measurements in every direction of PC and PBT specimens were below 0.05 except the PBT specimen’s thickness. The rate of shrinkage for the length and thickness of PC specimens were 0.48% and 3.9% that obtained 4.4 times as big as the gap those between those two rates. The shrinkage in PBT were about 1.45% for the length and 5.08% for the thickness which had 3.6 times as big as the gap. This experimental results obtained that the colour of the resin (PC and PBT) effects its shrinkage. Consequently, the colour of the resin must be concerned in the event of injection-molding.

Smart phones are currently the most popular electronic devices with high volume production activities driven by high demand and requirements for rapid turnaround time. The changes of displacement were analyzed according to a variable of the gate size and runner system. The radial type and gate with large size were shown that better results in displacement. While the design and production of lenses, the key component of a camera, still need to be improved, the current technology has run into its limit with regard to trends in size and weight reduction. In this study, an injection molding analysis was performed on plastic lenses that are widely employed for smart phone cameras. Specifically, the displacement of lenses at the time of injection molding was studied by varying the gate size and runner system.

The ribs of the injection molded article are a necessary shape in order to maintain the rigidity without increasing the material cost. The ribs on the outside of the molded article in the form of a housing are located on the side of the cavity inside in the mold. This paper proposes slotting by machining side-ribs. The slotting was performed through CNC control along the edge profile of the rib width. The machining time and the roughness of the machined surface were compared to verify the machining efficiency and the practicality of the machining method as a side-rib machining method.

Warpage of injection molded product is caused by non-uniform shrinkage and residual stress. A method of removing uneven molding shrinkage and residual stress is to remove the defective factor to Uniform cooling of products. Warpages for part designs have been investigated in this study according to the injection molding conditions for amorphous ABS and crystalline PP by the rapid cooling and heating system. Experimental results showed that the crystalline resin was more warped than amorphous resin, Warpages have been observed in the regions of the part, near gate region and flow direction region.

This study investigates application cases of facility management system model for enhancing facility productivity of industry filed around medium and small facility processing companies and finds the inefficiency of the existing management model. Following items are researched to seek out methods and measures to maximize facility productivity through empirical analysis by exploring and establishing a new management model. First, the empirical analysis, it is found that the overall equipment efficiency index used for facility productivity management in the companies has a difficulty being used as the index for it in actual medium-small processing companies. Second, a new facility management system model applying standard cycle time is suggested among facility management index system to measure facility productivity. Third, the empirical analysis is used to verify that developed facility management system model is a useful method to manage the facility productivity by applying the model to actual medium-small processing companies. Finally, it is necessary to implement comparison analysis on whether actual productivity enhancement induces a distinctly different result by using a new facility management index system model to be inhibited in this study.

An injection unit is the important part which guide the melted resine into the mold. Once injection molding is performed, there will be a pressure of 33 MPa built up inside of injection cylinder body. It was confirmed that the crack occurs by internal stress on the 9 mm material when the machine is used for long time. Because the cylinder rod has material thickness of 9~12 mm during manufacturing process on the cylinder body, there would be 3 mm thickness differences. In this experiment, IDEAS, a computer aided structure analysis software, is used to present the optimized design condition. Insert rod with inner diameter of 9 mm was set as a normal and vary 3 mm in x, y axis direction. When the internal pressure of 33 MPa occurs at the injection unit, fix the x and y direction and find out the stress acting only in z axis. It was confirmed that the stress of 45~82 N/mm 2 was built up when the left of cylinder body had been set 9 mm by using a structure analysis. Also, it has been verified the thickness of the material on the left need to be greater and equal than 12 mm to prevent a material crack by an internal stress.

The purpose of this study was to explore olfactory sensitivity of odors from injection molding processing. To do this, the experiment was carried out in an injection molding factory, and participants were exposed to the environment where odor-substances (Formaldehyde, Benzene, Toluene, Ethylbenzene, Xylene, Styrene) exist. In addition, we used the subjective scale using semantic adjectives as an olfactory sensitivity. As a result, the assessment structure of olfactory sensitivity was composed of eight factors (irritant, thermal, tense, unique, like-dislike, active, stable, masculine), and the main factor which was irritant characteristics explained 20% of the total olfactory sensibility. These results suggested that odors from injection molding processing would cause more negative emotional responses than the flavor which is mainly used in olfactory sensitivity. This study, as a basic study of the improvement in a factory environment for the efficiency of work, has limits in that it was conducted to the extent of identifying the olfactory sensitivity structure of those who were at a laboratory and who were exposed to the environment of odor substance induced in the injection molding processing. Therefore, for the method of removing malodorous substance, the effect of materials which can neutralize it, and the comparison of a direct performance in the environment where negative sensitivity structure exists, a series of studies which aim to improve the environment of injection molding factories, such as performance assessment in the environment of a factory and an office need to be conducted. It is expected that when these studies are put together, the improvement guidelines will be provided as a type that can maximize the effectiveness of work in the factory environment where injection molding processing is done.

This study was developed the rapid heating and cooling device using peltier module for uniform cooling. make the rapid heating and cooling device(RCHD), for traditional water cooling device(TWCD) method and the rapid heating and cooling method warpage were compared and were analyzed and the materials used crystalline PP polymer. various warpage were compared for the process parameters such as packing pressure, packing time, mold temperature. in the crystalline PP polymer, TWCD method has higher warpage than RCHD method and show the result to be a bit more uniform cooling. RCHD method has higher warpage than TWCD method as cooling time and packing time increases and TWCD method has higher warpage than RCHD method as mold temperature increases.

Recently as the manufacturers want competitiveness in dynamically changing environment, they are trying a lot of efforts to be efficient with their production systems, which may be achieved by diminishing unplanned operation stops. The operation stops and maintenance cost are known to be significantly decreased by adopting proper maintenance strategy. Therefore, the manufacturers were more getting interested in scheduling of exact maintenance scheduling to keep smooth operation and prevent unexpected stops. In this paper, we proposedan integrated maintenance approach in injection molding manufacturing line. It consists of predictive and preventive maintenance approach. The predictive maintenance uses the statistical process control technique with the real-time data and the preventive maintenance is based on the checking period of machine components or equipment. For the predictive maintenance approach, firstly, we identified components or equipment that are required maintenance, and then machine parameters that are related with the identified components or equipment. Second, we performed regression analysis to select the machine parameters that affect the quality of the manufactured products and are significant to the quality of the products. By this analysis, we can exclude the insignificant parameters from monitoring parameters and focus on the significant parameters. Third, we developed the statistical prediction models for the selected machine parameters. Current models include regression, exponential smoothing and so on. We used these models to decide abnormal patternand to schedule maintenance. Finally, for other components or equipment which is not covered by predictive approach, we adoptedpreventive maintenance approach. To show feasibility we developed an integrated maintenance support system in LabView Watchdog Agent and SQL Server environment and validated our proposed methodology with experimental data.

Molding trouble in injection-molded parts is caused by change of complexed molding product and molding process condition, etc. Warpage, which is one of the molding trouble, acts as possible factor which results in defect in assembly. In this study, a mold was designed to produce specimens with rib parallel to flow direction, specimens with rib perpendicular to flow direction and specimens without rib. This work researched change of warpage according to injection molding condition such as packing pressure, packing time, resin temperature in crystalline polymers(PP). Flat shape with ribs showed higher warpage than flat shape without ribs. The Specimens with ribs that are located perpendicular to the flow direction.