폴리머 디지털몰드 사출성형에서 코어의 열팽창 및 변형에 관한 연구
A Study on the Thermal Expansion and Deformation of Cores in Injection Molding with Polymer Digital Mold
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In this study, the dimensional changes in the core due to thermal deformation that occurs when applying the injection molding process to a polymer digital mold manufactured using an additive manufacturing method was investigated. Digital mold design was performed for the ASTM D638 standard tensile specimen shape, and the P3-type Origin One equipment capable of molding IND403, a high-elasticity photopolymer with excellent dimensional stability of HDT80, was used to manufacture the designed polymer core. After assembling the mold using the additive polymer core as a mold insert, injection molding experiments were performed with ABS resin. During the experiment, expansion of the polymer core was observed and injection molding analysis and structural analysis were performed in parallel to precisely analyze the cause. The results of the precision analysis confirmed that the heat source generated during the injection molding process increased the temperature of the polymer core which caused thermal deformation toward the open surface while the upper and lower polymer cores were restrained and then deformation occurred toward the cavity portion with less restraint resistance due to mutual contact pressure during the mold closing process. A novel polymer core was designed that can withstand injection molding pressure without excessive thermal expansion. It was shown that proposed design of additive polymer core was very effective in thermal expansion during the injection molding experiments.
Abstract
In this study, the dimensional changes in the core due to thermal deformation that occurs when applying the injection molding process to a polymer digital mold manufactured using an additive manufacturing method was investigated. Digital mold design was performed for the ASTM D638 standard tensile specimen shape, and the P3-type Origin One equipment capable of molding IND403, a high-elasticity photopolymer with excellent dimensional stability of HDT80, was used to manufacture the designed polymer core. After assembling the mold using the additive polymer core as a mold insert, injection molding experiments were performed with ABS resin. During the experiment, expansion of the polymer core was observed and injection molding analysis and structural analysis were performed in parallel to precisely analyze the cause. The results of the precision analysis confirmed that the heat source generated during the injection molding process increased the temperature of the polymer core which caused thermal deformation toward the open surface while the upper and lower polymer cores were restrained and then deformation occurred toward the cavity portion with less restraint resistance due to mutual contact pressure during the mold closing process. A novel polymer core was designed that can withstand injection molding pressure without excessive thermal expansion. It was shown that proposed design of additive polymer core was very effective in thermal expansion during the injection molding experiments.