[논문]사출성형 해석과 선호함수법에 기초한 자동차 TCU 커넥터 커버의 금형 레이아웃 및 보압의 최적 설계

박종천; 유만준

doi:10.14775/ksmpe.2020.19.09.001

사출성형 해석과 선호함수법에 기초한 자동차 TCU 커넥터 커버의 금형 레이아웃 및 보압의 최적 설계
Optimal Design of Mold Layout and Packing Pressure for Automobile TCU Connector Cover Based on Injection Molding Analysis and Desirability Function Method 원문보기

한국기계가공학회지 = Journal of the Korean Society of Manufacturing Process Engineers, v.19 no.9, 2020년, pp.1 - 8

박종천 (금오공과대학교 기계공학과) , 유만준 (금오공과대학교 대학원 기계공학과)

Abstract ▼ AI-Helper

In this study, the optimal design of the multi-cavity mold layout and packing pressure for the automobile TCU connector cover is determined based on the injection molding analysis and the desirability function method for multi-characteristic optimization. The design characteristics to be optimized are the warpage and sink marks of the product, the scrap of the feed system, and the clamping force. The optimal design is determined by performing injection molding analysis and desirability analysis for design alternatives defined by a complete combination of five mold layouts and six-level packing pressure. The optimal design shows that the desirability values for individual characteristics are quite high and balanced, and the resulting values of individual characteristics are satisfactorily low.

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제안 방법

In this study, injection molding simulations are performed for design alternatives defined by a complete combination of five mold layout designs and six-level packing pressure, and the optimal design is determined by the desirability analysis. The optimal design shows that the desirability values for individual design characteristics are balanced and fairly high and that the values of the individual design characteristics sufficiently meet the design tolerances.
In this study, to determine an optimal design of the mold layout and packing pressure, we established 30 design alternatives given by a full factorial combination of the five mold layouts and six-level packing pressure and performed the injection molding analysis and desirability analysis for each design alternative. The six levels of packing pressure for the maximum injection pressure were 80%, 100%, 150%, 200%, 250%, and 300%.
This study determines an optimal design of multi-cavity mold layout and packing pressure for molding of TCC based on injection molding simulation analysis and preference analysis. The design characteristics chosen to determine the multi-cavity mold layout (or mold layout) and packing pressure are the warpage and sink marks of the TCC, the scrap of the feed system, and the clamping force.
The design characteristics selected to evaluate the productivity of the TCC are the scrap of the feed system and the clamping force. The scrap is the weight of the gate, runner, and sprue determined after molding.
The evaluation criteria chosen in this study to determine the optimal TCC mold layout are the product’s formability and productivity.
The automobile transition control unit (TCU) connector cover (TCC) is a component for protecting the terminals of the interface portion of the automobile TCU connector parts from foreign objects and external shocks. This study determines an optimal design of multi-cavity mold layout and packing pressure for molding of TCC based on injection molding simulation analysis and preference analysis. The design characteristics chosen to determine the multi-cavity mold layout (or mold layout) and packing pressure are the warpage and sink marks of the TCC, the scrap of the feed system, and the clamping force.

대상 데이터

2, a finite element model was generated and injection molding analysis was performed. The four products consisted of a total of 144,512 triangular elements of the dual domain type,^[12] and the feed system (i.e., gates, runners, and sprues) consisted of 132 to 3401-dimensional elements of the beam type.
8mm. The material of the TCC is polypropylene (PP), and the weight is 7.65g.

성능/효과

1. Based on the injection molding analysis and desirability function method, the optimal design of the multi-cavity mold layout and packing pressure for the automobile TCC was determined.
2. The warpage and sink marks of the product, scrap of the feed system, and clamping force were selected as the design characteristics to be optimized, and the multiple design characteristics were optimized by using the overall desirability function that incorporates the individual desirability functions of the design characteristics.
3. The injection molding analysis and the desirability analysis were performed for design alternatives defined by a complete combination of five mold layouts and six levels of packing pressure. As a result, the combination of the mold layout of Case #2 and the packing pressure of 200% was determined as the optimal design with the best integrated desirability of 0.
4. The optimal design produced satisfactory results in desirability and values for individual design characteristics: The desirability values of the warpage, sink mark, scrap, and clamping force were 0.70, 0.85, 0.72, and 1.0, respectively, which was fairly balanced with significant levels. The design characteristic values were expected to be 0.
0 for warpage, sink mark, scrap, and clamping force, respectively, so it was found that the level and balance of individual desirability values were quite high. Accordingly, the values of the design characteristics were expected to be 0.061mm, 0.003 mm, 2.79g, and 27.02ton for warpage, sink mark, scrap, and clamping force, respectively, and they showed satisfactory results. In addition, the optimal design has an advantage over other designs in terms of economics of mold production: The mold layout design has fewer runner branches than Case #4 and #5, so it is expected that the outer dimensions of themold will be smaller and thus the cost of mold material and tooling will be lower.
The injection molding analysis and the desirability analysis were performed for design alternatives defined by a complete combination of five mold layouts and six levels of packing pressure. As a result, the combination of the mold layout of Case #2 and the packing pressure of 200% was determined as the optimal design with the best integrated desirability of 0.77.
In the optimum design, the desirability values for individual design characteristics were 0.70, 0.85, 0.72, and 1.0 for warpage, sink mark, scrap, and clamping force, respectively, so it was found that the level and balance of individual desirability values were quite high. Accordingly, the values of the design characteristics were expected to be 0.

참고문헌 (12)

Yao, D., "Direct Search-Based Automatic Minimization of Warpage And Weldlines in Injection Molded Parts," A Thesis for a Master, University of Massachusetts, pp. 1-135, 1998.
Liao, S. J., Chang, D. Y., Chen, H. J., Tsou, L. S., Ho, J. R., Yau, H. T. and Hsieh, W. H., “Optimal process conditions of shrinkage and warpage of thin-wall parts,” Polymer Engineering and Science, Vol. 44, No. 5, pp. 917-928, 2004.

상세보기
Erzurumlu, T. and Ozcelik, B., "Minimization of warpage and sink index in injection-molded thermoplastic parts using Taguchi optimization method," Materials and Design, Vol. 27, pp. 853-861, 2006.

상세보기
Zhou, J. and Turng, L.S., “Adaptive Multiobjective Optimization of Process Conditions for Injection Molding Using a Gaussian Process Approach,” Advances in Polymer Technology, Vol. 26, No. 2, pp. 71-85, 2007.

상세보기
Mehat, N. M. and Kamaruddin, S., “Multi- Response Optimization of Injection Moulding Processing Parameters Using the Taguchi Method,” Polymer-Plastics Technology and Engineering, Vol. 50, No. 15, pp. 1519-1526, 2011.

상세보기
Azaman, M. D., Wang, X., Zhao, G. and Wang, G., "Research on the Reduction of Sink Mark and Warpage of the Molded Part in Rapid Heat Cycle Molding Process," Materials and Design, Vol. 47, pp. 779-792, 2013.

상세보기
Derringer, G. and Suich, R., “Simultaneous Optimization of Several Response Variables,” Journal of Quality Technology, Vol. 12, No. 4, pp. 214-219, 1980.

상세보기
Derringer, G., “A Balancing Act: Optimizing a Product's Properties,” Quality Progress, Vol. 27, No. 6, pp. 51-58, 1994.

상세보기
Del Castillo, E., Montgomery, D. C., and McCarville, D. R., "Modified Desirability Function for Multiple Response Optimization," Journal of Quality Technology, Vol. 28, No. 3, pp. 337-336, 1996.
Malloy, R. A., Plastic Part Design for Injection Molding, Hanser/Gardner Publishers Inc., Cincinnati, pp. 75-84, 1994.
Park, J. C., Yu, M. J., and Park, K. Y., “Design of Feed System and Process Conditions for Automobile Lamp Garnish Lens with Injection Molding Analysis,” Journal of the Korean Society of Manufacturing Process Engineers, Vol. 18, No. 11, pp. 1-8, 2019.

원문보기 상세보기
Shin, N. H., Oh, H. S. and Kang, S. G., The Optimization of Injection Molding Process by CAE, Daekwangseorim, Seoul, pp. 327-422, 2010.

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