cae - cheric * †** , 402-751 253 ... as a result, the optimum condition based on the above...
TRANSCRIPT
HWAHAK KONGHAK Vol. 41, No. 5, October, 2003, pp. 577-584
CAE� ��� ���� ��
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(2001, 9- 7. /0, 2003, 8- 4. 12)
Application of CAE in Injection Molding Process
Beomho Kim*, Woojin Jang, Junghoon Kim, Junghwan Cho, Yung-Hoon Park** and Soonja Choe†
Department of Chemical Engineering, Institute of Polymer Science and Engineering, Inha University, 253 Yonghyun-dong, Nam-gu, Incheon 402-751, Korea
*Hyundai Engineering Plastics Co., Ltd., 1233 Tongjung-li, Seokmun-myun, Tangjin-gun, Chungnam 343-856, Korea**Dept. of Polymer Science and Technology, Sunchon National University, 315 Maegok-dong, Sunchon, Chonnam 540-742, Korea
(Received 7 September 2001; accepted 4 August 2003)
� �
���� ���� � � � ��� �� �� ���� �� ���� ��� ��� � ! "#$%�, A��
29” TV backcover& '(�� )�� *+, ��- .$� /0 12� 3 )�� 45& 67��� �89: Mold
Flow�� CAE software(S/W)& �;9< =>�(? @A9B�. C� D)� E�� FGH 0IJG K(local database)�
LM DN OP- QRS K(standard database) �� @AT�& UV WX9B�. Y T� 29” TV backcover ����
- .$� => Z[�? @\9� ]9<, => �^_ `a9b 67� 45b 4cd 9: =>� e� 67� 45
b fd9< �(�, .$� =>gh? i�9B�. DE� local databaseH �j� standard database �� @A T�&
UV9<, DE FG_ �\ k:, lG 7m� no_ �p qrsG Zi9:, 4 _$ database �� @A T�b U
t 9B�.
Abstract − Injection molding process is influenced by the injection conditions such as various thermal history and deforma-
tion processes that affect mechanical properties of the fabricated product. The design of the 29-inch TV backcover modifiedwith the alteration of the thickness of special parts. Then the flow analysis was performed using the CAE S/W of the Mold
Flow Company. In addition, the analysis was performed using the measured viscosity(local database) at various shear rates and
the results were compared with those using the standard database. In order to reduce the unbalanced flow of the molten resin,the thickness of the part, where the flow speed was slow, increased, while that of the part, where the flow speed was fast,
reduced. As a result, the optimum condition based on the above modification of the special part of TV backcover is selected in
terms of idealized flow pattern. In addition, the analyses based on the local database and the standard database showed no dis-tinctive difference, although the measured viscosity was slightly higher and the temperature distribution was broader than by
the standard database.
Keywords: Injection Molding, CAE (Computer Aided Engineering), Filling Phase Analysis, Packing Phase Analysis
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�"f ���� �'� ��{7 ±²"� ��{� ���� PQ�
��� °Î# §�� �Ï"SF. Bakerdjian� Kamal[13], White³
Dee[14]� f� ��xy� UK µk� �"f �`��' ����
PQ� ��� ÐÑ ÒFÓ §�� °Î� �B� JÔ"SF.
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���# ·� ¸¹� � =��' Õ�����# ¦�³ Õ�Ö
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� �`� a= �Q�� `�Ù� ¦� �p�� Ú�"SF.
Malguarnera M[17]� ¬+2� �� ��xy' PQ� ���
°Î# §�� �Ï"S�, Chung� Ryan[18], Sanschagrin[19]� 9:
; =>� ±²� �� �i7 Ú�"\� �Û{K ¸¹� W�' µ
� ��� 0Î"�Ü l�"SF. Kamal� Lafluer[20]# :M¦ ·Ý
� ¡}� Ä× a= ��� W�"S�T, Wang M[21, 22]� a= w
Õ��� ¸¹� �l"� `�Ù, ¦�, =>' ·�� °Î# §��
Ú�"S�T, Þß a= ���� => �à� á�>� °Î# §��
�"SF. â³ E� Ú� ��7 ãU� GIL, ASAHI CHEMICAL,
CADMOULD, CINPRESS, MOLDFLOW M ��# W�( ä��å
� IJ"S�, �Û{æ ¸¹� W�"f µ� ����� ¡�K x
y� df"f W�"# Ú�7 QÀ _m"� �F.
ÑK H�� ç# ���� �� z�'>� Úáæ °è�x� z
{³ éê ¥>� ë�{"P â"f, � ��`'� °�� M�
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� �� �K �� z�� É"� �� ®¯ �2� î'# a
=W� M' �F. â� W�� �"f �ïð ��7 ¼> Ø�� �
("f z�W�� "\ ñ� ò �� ���� z�¯� �´7 ±²
ó �F.
ª Ú���# A�� 29” TV backcover ¢Q�\� �("f �'
Â� âγ , ��lô, 8�� ¦� M ����� §�� °Î#
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z� ¢�"� ë�� ��xy� õbF. '7 âK W��#
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� ¸ö"SF. ÍK µ�� `�À�� Ä+ ²�æ ·�(local
database)³ .6�� Þ�� dfK ·�Ø(standard database)
� �K W�� :÷ øã"SF. MOLDFLOW software# Fig. 1� ¡
}W�� Fig. 2� a=W� flow chart� ùô� È�F.
2. �� ��
2-1. �� ��
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áûæ Pª�2 � 3!R� �`��, :�, (5 ��7 �"f �"
#$, 01�2 �34 (56� �ü!Q# 10−7 m2/sec ��'F.
(5# â�� ¡}(pseudoplastic flow)6'T, ¡}W�� â"
f ·�# ¦�³ `�Ù N� Ôl"SF. ÍK �� ��� '()
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Ellis model �&� Second order model[16, 23] M� �("SF. �3
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#$, �� z{7 Q!ó þ# ÿD� �D� ̧ È �(ó �# Tait
Fig. 1. Flow charts for computation of filling phase analysis.
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D´ É�R (1)� '("SF.
(1)
C# 0.0894'�, v0(T)# =>' 00 þ :6�'F. ÿD� �D�
UK �� FB� E' gi_F.
if, T>Tt (2)
if, T<Tt (3)
if, T>Tt (4)
if, T<Tt (5)
if, T>Tt (6)
if, T<Tt (7)
��� ̀ '¦� Tt� =>� 0¶ Ç�N+� ��"\ FB R (8)
� EF.
(8)
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ÿ6�� �6� D' z{KF.
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Equation of Continuity: (9)
Equation of Momentum: (10)
Equation of Energy:
(11)
�&�, ' W�� '(æ Pª ��� FB� EF.
- incompressible fluid: =0 (12)
- generalized Newtonian fluid: τ = η( ) (13)
- constant thermal conductivity: κ (14)
' R�� ρ# (5��, # :6�, # �>�À�, τ# `�¥
>, P# pressure, Cp# :�, β# tu� ü/Q, κ# �`��, η#aP ·�, # `�Ù'�, τ=η 'F.
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9:; ��d3' Õ�)#$ ��)# lô tc# FB� E' �ï
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���� "f 2nd order ·� É�R� Ai ��i_ master curve��
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Rosand�� Advanced Capillary Extrusion Rheometer� ²�"SF.
2-5. Filling Balance
Filling balance# flow balance³ runner balance� ��F. Flow balance
# �� K �`'� ��`�� d éê¥>' Ò¤� !P)#
��� z�'� PQ� H� ""7 ÉKF. 1\� ò4# ���
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3. ��� ��
ª Ú���# ���� ��� ë�{7 µ�"P â"f MOLDFLOW
�� ̀ ò ~&P2 MF/VIEW7 �("S�T, Solver�# MF/FLOW,
v T p,( ) v0 T( ) 1 C ln 1p
B T( )------------+
–
=
v0 T( ) b1 1, b2 1, T+=
v0 T( ) b1 s, b2 s, T+=
B T( ) b3 1, exp b– 4 1, T( )=
B T( ) b3 s, exp b– 4 s, T( )=
v T p,( ) 0=
v T p,( ) b7exp b8 Tb9p–( )=
Tt p( ) b5 b6p+=
∂ρ∂t------ ∇ ρv⋅( ) 0=+
∂∂t---- ρv( ) ρg ∇ τ⋅[ ] ∇ ρvv⋅[ ]–+=
ρCp∂T∂t------ v ∇T⋅+
βT ∂P∂t------ v ∇P⋅+
ηr·2 κ∇2T+ +=
∇ v⋅r· r·
v g
r· r·
tch2
π2α---------
TX TM–
TP TM–------------------
ln=
TX TM–
TP TM–------------------
ln
Fig. 2. Flow charts for computation of packing phase analysis.
HWAHAK KONGHAK Vol. 41, No. 5, October, 2003
580 ��������������� ����
MF/COOL, MF/WARPM� �("SF.
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Ù��� 3ó"P â"f 01� ���� W�� �()# %�� �
� �´� shell mesh7 �("SF.
W�� ���# ��� ZP³ aspect ratio(%�� ���� %��
� '[# �/ & z� UK ' <'� :� �W (Ñ)#$, ��
)4� *�"\ aspect ratio# +©� W� lô' P"]��
� *�"r� W� ��� Ä+ ��"� ��"SF. � ±�, ¡}
w Õ� W�� jÑ# 1.5, z� w �xW� jÑ# 1.3 �'� ,â
�� ¢�"SF. �&"f â� xy� -� ��K surface� ,ä[, ¾
¿, �' M� ¸¹.K ò �(ó � $'�, ����P� �s
w ���� ��xy� �("f W�"SF. ��� ô/ß �0"\,
` ~& ��2 ¸¹.(modelling)� ��3ó(meshing), W� ��2
��É�R ¡�(derivation of element equations), ��É�R x1
(assembly of element equations), jQxy� ¢�(application of boundary
conditions) w l,2R� W�(solution of system equations)� ��
~&"f 3,*�'Ø(display results)� h�F[23].
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§�� g# 242 5ê, �' âÎ w , ����� P"c
� �´, ·� w ¡} Ç�� âÎ M��, ª Ú���# �'Â
âγ , ��lô, 8� ¦� M ����� §�� °Î# z��
��"�, ¸¹� d3� ÈO z{� �K � ¡}� z� ¢�
"f ë� ��xy� õbF.
ÍK, CAE +.� 6�K �34� �� Þ�(�`��, :�, (5
��, ÅÆ�¦�, ñ�¦� M)� áûæ ¼>$'� ���, ª Ú
�� �(æ ä��å2 MOLDFLOW��# �34 (56� Pª�
� 3!R� �`��, :�, (5��7 '("f �"�, 01�2 �
34 (56� � 3!��# 10−7 m2/sec7 �("SF. Shear stress,
τzx=η(dvx/dz)��, :� D η# aP·�(apparent viscosity), À�
�à2 dvx/dz# `�Ù'F.
ÍK (5# â�� ¡}�� ��"S�r� ¡}W�� â"
f ·�# ¦�³ `�Ù� N� Ôl"SF.
4. � ��
4-1. ��� �� � ��
�(æ ̧ ¹2 A�� 29” TV backcover� ̧ ¹ �D w ��� Fig. 3�
Table 1� �l"SF. ��� ZP# �� 651.6 mm è� 573.3 mm <
' 325.6 mm'T, ' ��� 7d8³ 7�¯� �� 2212.3 cm3³
2.1 kg'F. 89:°;� �¡} HIPS(high impact polystyrene)7
�("S�, Fig. 3� <�ö�� �ï� 3 hot runner system� �("
f 7 g¼"SF. Fig. 3� ö=� �ï� �³ E' � d3� Ä
+ ÈO7 ú&"S�T, � d3> ÈO# Table 1� �iÈ�F.
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�'Â�d� ��æ # ¡}"?' @� A�� 4� BCd §
D�� ë5 �`' '[i� )#$ �` lô> � ¡}EF
� Fig. 4� �l"SF. � G`ß �`"#$(Fig. 4(d)) HI l
ô� 3.455V'T Fig. 4(a), (b)³ E' `1��� ��� D�d� :
"f "�d� J� �`)T, Þß Fig. 4(c)��# ÌM"� �`)
"# ®ÌM ¡}� K �F.
¡}' â��~L 9:;� $�dM ÌM"� �`)
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`l��, ��� PQ� H�� ¡l�# ,â�� FB� 3� É
�� ÈO7 z{lì ¸¹� ¡}EF� Ä× ®Ì�� W�"��
"SF.
• CASE 1: Ppí� UK ¡}W�
• CASE 2: � ¡}' DU��� �� d3� ÈO7 *�
• CASE 2: ÈO *�: 2.8 mm→3.3 mm: D� ( ·Ñ², O\ "� ��)
• CASE 3: � ¡}' DU��� N× d3� ÈO7 ��
• CASE 2: (ÈO ��: 2.8 mm→2.5 mm: D� ��, ( ·Ñ ²\ ��)
Fig. 3. Shape of the model used in this study.
Table 1. Characteristics of the 29” TV monitor backcover
Dimensions Length 651.0 mmWidth 573.3 mm Height 325.6 mm
Thickness (by color) Green 3.0 mm Cyan 2.0 mmBlue 2.8 mm Purple 3.5 mmYellow 1.5 mm Gray 2.25 mm
Volume & weight Gross Volume: 2212.28 [cm3]Gross Weight: 2.06 [kg]
Used resin Kumho chemicals: High flowing HIPSApplication gate 3 SIDE-GATE system (red)
Fig. 4. Flow pattern of the molten resin.
���� �41� �5� 2003� 10�
CAE� ��� ����� ��� 581
• CASE 4: CASE 2³ CASE 3� P1�´� ¡}� Q¾, ��
• CASE 2: (ÈO *�: 2.8 mm→3.3 mm: D� ( ·Ñ², O\ "� ��)
• CASE 2: (ÈO ��: 2.8 mm→2.5 mm: D� ��, ( ·Ñ ²\ ��)
R � :÷S� UK W���7 Fig. 5³ Table 2� �l"S#$,
ªL� ¸¹2 CASE 1� :"f ¸¹ ÈO� z{7 º CASE 2, 3
w 4� ¡}EF' �D)�B� afg� �F. � ���� CASE 4
� ¡}' �/ Ñ"f '7 ë5 í�� ?T"SF. l�� �` ¶
'7 4èß �UaP â"f Fig. 6� CASE 1� CASE 4� lô>
¡}EF� :÷V�l"S#$, 3V j� )�� þ� ¡} EF' D
�ß í���� �D)�B� ü2 ó �F.
4-3. $% & '! "#
4-3-1. ¦�3Á
¡}W��� Q!K � ̀��� � ̀'ò� ¦�3Á7 �� Fig. 7
� Fig. 8� �ï �F. ' ¸¹�� Q!K ¦� 3Á# 216.9oC��
231.1oC �'� � ¶� 0 14.2oC� �i� :÷� s9"SF. 01
��� �` � ¦�3Á# 8�� � ¡¼)# Ûô � âÎ� �
ï�# ¦�3Á2$ � ¶'# U/ 20oC '"'i! KF. ¦� ¶
'� Z\, ¡}"?� W¶� *�N� H�, ��� Xá� §�
� °Î# weld line� ��� PQ� H�' ú+_F. (5� ¡
}�� tu� ·�� �p"#$ ·�# ¦�� N'r� 8�� i
Fig. 5. Flow pattern in each CASE.
Fig. 6. Flow pattern upon injection time.
Table 2. Comparison of the flow analysis in each CASE
CASE 1 CASE 2 CASE 3 CASE 4
used resin HIPS HIPS HIPS HIPSmold temperature 50 oC 50oC 50oC 50oCresin temperature 230oC 230oC 230oC 230oCinjection time 3.426s 3.359s 3.414s 3.365smolding pressure (MPa) 59.85 64.62 62.01 65.84temperature distribution (during filling) 217.5oC-231.2oC 217.3oC-231.1oC 218.4oC-231.2oC 216.9oC-231oCtemperature distribution (after filling) 174.9oC-239oC 184.9oC-239.7oC 182.5oC-239.3oC 204.3oC-235.9oCShear stress (MPa) 0.26-0.53 0.35-0.53 0.24-0.47 0.31-0.39Shear rate (1/s) 12883-75036 379075 19996-77902 239913.23clamp force (tonne) 1678.3 1661.9 1723.4 1705.6
HWAHAK KONGHAK Vol. 41, No. 5, October, 2003
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Fig. 9. Air trap.
Fig. 10. Experimental local and standard database (shear rates vs. vis-cosity at 220oC).
Fig. 11. Comparison of flow pattern by the standard and local database.
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