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사출 성형 해석의 이해와 사출 성형 불량 Solution
(Injection Molding Analysis & Solution of Injection Molding Problem)
김 웅 이니츠(Initz) Research Engineer, Ph. D. in Mechanical Engineering [email protected]
Contents
1. Injection Molding Analysis is... 1-1 : General Result of Injection Molding Analysis 1-2 : Special Analysis of Injection Molding 1-3 : DOE with Injection Molding Analysis 1-4 : Molding Window with Injection Molding Analysis 2. Solution of Injection Molding Problem 2-1 : FlowMark Solution 2-2 : (Sprue)Sticking Solution 2-3 : Silver Streak Solution 2-4 : SinkMark Solution 2-5 : Warpage Solution 3. Injection Molding – Structural Coupling Analysis
0. Characteristics of PPS
PPS JV Company
1-1. Injection Molding Analysis
Temp. at Flow Front Fill Time
Fiber Orientation Tensor Time to reach Ejection Temp.
1-1. Injection Molding Analysis
Pressure at end of fill Shear Rate
1-1. Injection Molding Analysis
SinkMark Ave. Volume Shrinkage
1-1. Injection Molding Analysis
Warpage (X10) Pressure at Injection Location
1-1. Injection Molding Analysis
1-2. Special Injection Molding Analysis
Gas Assisted Molding Analysis Over Molding Analysis
Insert Molding Analysis
Core Shift Analysis
1-3. DOE with Injection Molding Analysis
▶ Variable Injection Molding Condition ▶ DOE of Analysis
- Fill Time - Time to reach Ejection Temp. - Temp. at Flow Front
▶ Result
1-4. Molding Window with Injection Molding Analysis
▶ Recommend Injection Molding Condition
or Unknown Injection Molding Condition
Fill Time
Short Shot Problem
Temp. at Flow Front
▶ Molding Window Injection Molding Condition
2-1. FlowMark Solution
▶ Flow Mark : Gate 또는 제품의 좁은 유로를 통과하면서 냉각된 수지가 Cavity내에서 다시 냉각되어져 높은 점도로 되고 다시 차가 운 금형 표면에 의해 고화되어 Flow와 같은 무늬가 발생하는 사출 불량. 주로 Gate 주위 혹은 Gate에서 먼 영역에서 Flow Mark가 발생한다
▶ Injection Molding Conditions Solution
Injection Molding Condition
Flow Mark Problem (Shear Rate)
L M H L H
Injection Speed #
mm/s
Injection Pressure #
MPa
Melting Temp. # °C
V/P Switch # mm
▶ Modify Design Solution
Original Design Advanced Design
2-2. (Sprue)Sticking Solution
▶ Injection Molding Conditions Solution
▶ Modify Design Solution
Simulation Result
▶ Product ▶ (Sprue)Sticking : Sprue주위의 냉각이 느리거나, 국부적 온도차에 의한 급격한 강성변화가 원인. 사출품이 금형에서 취출되지 않는 불량.
2-3. Silver Streak Solution
Problem
Gate
Injection Molding Condition
Silver Streak Problem (Temp. at Flow & Flow Velocity)
L M H
Injection Speed # mm/s
Dry Condition 1 Hr 4 Hr 8 Hr
Melting Temp. # °C
Screw Speed # mm/s
Solution
▶ Injection Molding Conditions Solution
2-4. SinkMark Solution
- Temp. at Flow Front
Original Design Advanced Design
▶ Product Original Design SinkMark
- Ave. Volume Shrinkage by Cooling System
- Solution Cooling System
고온 저온
▶ Advanced Design of Cooling Channel
상대적 Volume Shrinkage 차이 약 3.0%
상대적 Volume Shrinkage 차이 약 2.2%
▶ Advanced Design Solution
- Ave. Volume Shrinkage
2-5. Warpage(Deformation) Solution
▶ Product & Analysis ▶ Product ▶ Injection Molding
0.165mm 0.088mm
Up : 75℃ Down : 85℃
▶ Injection Molding Conditions Solution
Uniform : 80℃
Gate
(X 10)
3. Injection Molding & Structural Coupling Analysis
Injection Molding & Structural Coupling Analysis
