When the product is taken out after the injection process, the surface of the product and the mold are attached and to separate them, it is necessary to consider the frictional force between the mold surface and the product surface. Therefore, to reduce the frictional force, a subtraction gradient for the rib shape is generally applied, and a lapping process is performed to improve the surface roughness of the rib shape surface of the processed mold. Therefore, research is needed to improve the surface roughness when processing the rib. In this study, slotting processing was applied to improve surface roughness when processing ribs. Slotting processing is a processing method that removes material through the feed motion of the tool, and processing is possible regardless of the aspect ratio of the processing shape. A slotting tool was developed for rib machining and a comparative experiment with electric discharge machining was performed. Also after processing, the surface roughness and processing time were compared and analyzed, and the improved surface roughness and fast processing time characteristics of the slotting processing compared to electric discharge processing were confirmed.

Recently, the demand for reliability verification is increasing while designing and manufacturing molds using injection molding computer aided engineering(CAE). When performing flow analysis verification, a spiral mold is produced and compared with CAE. Because of the spiral shape, we needed a comparative evaluation with the flow distance of products with different forms. So, we compared the weight and flowed length using CAE. Variables are the change in the width of the spiral shape and the shape of the bar and plate. When the width of the spiral shape is 23mm rather than 15mm, the flow distance flows 30∼70mm more, with a maximum difference of 13%. As a result of comparing the spiral shape and the long square shape with the same width, the spiral shape had a flow distance of 60 to 105mm further, and a difference of up to 28% was found. As a result of comparing the plate shape and the spiral shape with a 15mm width product, the spiral shape has a flow distance of 310∼380mm further, and a difference of up to 82% is different.

In this study, in order of to reflect the mold deformation in the injection molding process to design of mold, the mold deformation was analyzed by performing flow and structural analysis. The 5 inch LGP(light guide plate) mold, platen and tie bar were modeled and applied to the analysis. The result of melt pressure from flow analysis was extracted for use as boundary conditions acting on the mold surface in the structural analysis. In order to evaluate the accuracy of simulation analysis results, injection molding was performed under the process conditions of simulation. As a results, the mold deformation during injection molding tends to be similar that of injection pressure, and it is confirmed that it shows the behavior and properties of melt resins. Compared with the simulation and experiment, the error of the maximum mold deformation in the injection phase was 4.20%.

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.

In this study, porous stainless steel (STS316L) sintered body was fabricated by powder metallurgy method and its properties such as porosity, compressive yield strength, hardness, and permeability were evaluated. 67.5Fe-17Cr-13Ni-2.5Mo (wt%) powder was produced by a water atomization. The atomized powder was classified into size with under 45 μm and over 180 μm, and then they were compacted with various pressures and sintered at 1210oC for 1 h in a vacuum atmosphere. The porosities of sintered bodies could be obtained in range of 20~53% by controlling the compaction pressure. Compressive yield strength and hardness were achieved up to 268 MPa and 94 Shore D, respectively. Air permeability was obtained up to 79 l/min·cm2. As a result, mechanical properties and air permeability of the optimized porous body having a porosity of 25~40% were very superior to that of Al alloy.

It is not easy to predict the shrinkage rate of a plastic injection mold in its design process. The shrinkage rate should be considered as one of the important performances to produce the reliable products. The shrinkage rate can be determined by using the CAE tools in the design produces. However, since the analysis can take minutes to hours, the high computational costs of performing the analysis limit their use in design optimization. Therefore this study was carried out to presume for mutual relation of analysis condition to get the optimum average shrinkage by regression analysis. The results shown that coefficient of determination of regression equation has a fine reliability over 87% and regression equation of average shrinkage is made by regression analysis

Recently, the engineering designer of injection mold has become more and more dependent on the CAE. In the design factors of injection mold, the shrinkage rate should be considered as one of the important performances to produce the reliable products. Therefore, the shrinkage rate can be mostly calculated by the MoldFlow and CATIA in the design process. However, it is not easy to predict the shrinkage rate of a plastic injection mold in its design process because the analysis can take minutes to hours, the high computational costs of performing the analysis limit their use in design optimization. In this study, the surrogate models based on the Taguchi Design in order to optimize the shrinkage rate of bevel gear injection mold is used instead of the original models, facilitating design optimal design.