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Research Papers

Identification of Controlling Parameters on Thermal Deformation of Mobile Device by Injection Molding Process

[+] Author and Article Information
Eunyoung Chang

Department of Mechanical Engineering,
Hongik University, Seoul, 121-791, Korea

Haseung Chung

e-mail: haseung@hongik.ac.kr
Department of Mechanical and System
Design Engineering,
Hongik University,
Seoul, 121-791, Korea

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received March 12, 2012; final manuscript received November 12, 2012; published online January 22, 2013. Assoc. Editor: Allen Y. Yi.

J. Manuf. Sci. Eng 135(1), 011008 (Jan 22, 2013) (9 pages) Paper No: MANU-12-1081; doi: 10.1115/1.4023284 History: Received March 12, 2012; Revised November 12, 2012

Injection molding process is a widely used manufacturing technique to massively produce the components of mobile device with various sizes and complicated geometries. However, the final part quality, especially dimension or geometry, referring to the original design specifications is not often acceptable due to various reasons. This study aims at developing the numerical model to predict the final part quality and subsequently identifying the critical reasons for existing problems. moldflow and abaqus software have been simultaneously used to simulate the injection molding process and thermal deformation arising after ejection step from the mold. In order to validate the model, the deformation predicted by the developed model was compared with experimental results, and both results showed good agreement. We also carried out design of experiment (DOE) to investigate the effect of various processing parameters that affect the final deformation of injection molded product. The developed model and information derived from DOE are expected to provide useful resources to the initial stage of mobile device design.

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References

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Figures

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Fig. 1

Initial CAD design and detection points for both numerical analysis and experiment (a) battery cover and (b) front cover

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Fig. 2

Schematic description of the developed numerical analysis procedure (a) initial CAD design, (b) injection molding process by moldflow, (c) thermal deformation process by abaqus, and (d) deformation measurement by hypermesh

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Fig. 3

Comparison between experimental and numerical result (a) ratio of the averaged height and width of battery cover and (b) size difference between upper and lower position along height of front cover

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Fig. 4

Width dimension of CAD model, experimental and numerical analysis result of battery cover (a) CASE 1, (b) CASE 2, and (c) CASE 3

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Fig. 5

Height dimension of CAD model, experimental and numerical analysis result of battery cover (a) CASE 1, (b) CASE 2, and (c) CASE 3

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Fig. 6

The averaged deformation corresponding to different processing conditions for battery cover (a) case 2, (b) case 3, and (c) case 2 with increased gate number

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Fig. 7

Relative magnitude of main and interaction effects for battery cover

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Fig. 8

Individual effect of (a) mold temperature, (b) Young's modulus, (c) Poisson's ratio, (d) thermal expansion coefficient, and (e) cooling time

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Fig. 9

Relative magnitude of main and interaction effects for front cover

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Fig. 10

Flow chart of hypothetical scenario

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