Optimization for the prepreg compression molding of notebook computer cover using design of experiment and finite elemen
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Optimization for the prepreg compression molding of notebook computer cover using design of experiment and finite element method Ho‑Sang Kim1 · Won‑Gi Lee1 · Chan‑Hee Lee1 · Kyoung Don Lee1 Received: 5 March 2020 / Accepted: 24 August 2020 © Springer Nature Switzerland AG 2020
Abstract Composite materials can be successfully applied to the manufacturing process in the consumer electronics field and can drastically reduce the weight of the several parts. For this reason, it is important to predict the shape change after carrying out compression molding of composite material and to determine the key parameters of the manufacturing process. In this paper, the compression molding process of a notebook computer cover using composite materials was analyzed by the finite element method. In addition, the signal-to-noise ratio has been calculated for the warpage deformations that occurred on the surface of the notebook computer cover. The design of experiment method was applied to determine the optimal parameters in the process. Levels of the optimal process factors were selected for minimum warpage deformation and to verify the proposed method; a physical notebook computer cover was manufactured using these optimal conditions. Experimental results, including those on warpage deformations, show that the proposed method can be useful in the manufacturing of lightweight notebook computer covers using a compression molding machine. Keywords Compression molding process · Design of experiment · Finite element method · Fiber behavior · Mold shape
1 Introduction Recently, the demand for light and robust components has exploded with the development of commercial portable electronic devices. For this reason, methods for manufacturing electronic components using light and durable composite materials as replacements for existing metal parts are widely used. In particular, a portable notebook computer cover is known to be an effective component that gives weight reduction through the introduction of composite materials, as exemplified in many industrial fields [1–3]. To make mechanical parts using composite materials, many manufacturing methods including autoclaving, injection molding, resin transfer molding, and prepreg compression molding have been used. These have several advantages and disadvantages in terms of productivity
and part strength, respectively. Usually, the notebook computer cover has a thin, flat, and curved shape and is required to have a flat surface for mechanical rigidity. In addition, it should be easy to assemble for mass production and have aesthetic characteristics. In order to satisfy these conditions, the prepreg compression molding method can be applied to fabricate the notebook computer cover. In this method, to manufacture a product, prepregs are stacked according to an arrangement, pressurized and cured through a mold (warm mold) heated by a hot plate, and finally cooled and demolded. Since this method uses a prepreg in which resin is probed on carbon fiber, it has the advantage of shortening the pr
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