• Design & Manufacturing
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• 제14권4호
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• pp.65-70
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• 2020

Partial reinforcement of sheet metal parts with CFRP patch is a technology that can realize ultra-lightweight body parts while overcoming the high material cost of carbon fiber. Performing these patchworks with highly productive press equipment solves another issue of CFRP: high process costs. The A-pillar is the main body part and has an undercut shape for fastening with other parts such as roof panels and doors. Therefore, it is difficult to bond CFRP patches to the A-pillar with a general press forming tool. In this paper, a flexible system that applies uniform pressure to complex shapes using ceramic particles and silicone rubber is proposed. By benchmarking various A-pillars, a reference model with an undercut shape was designed, and the system was configured to realize a uniform pressure distribution in the model. The ceramic spherical particles failed to realize the uniform distribution of high pressure due to their high hardness and point contact characteristics, which caused damage to the CFRP patch. Compression equipment made of silicone rubber was able to achieve the required pressure level for curing the epoxy. Non-adhesion defects between the metal and the CFRP patch were confirmed in the area where the bending deformation occurred. This defect could be eliminated by optimizing the process conditions suitable for the newly developed flexible system.

• Design & Manufacturing
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• 제18권3호
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• pp.71-80
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• 2024

Sink marks are a common defect that occurs due to differences in shrinkage in areas with significant thickness variations in injection-molded parts. In this paper, we investigated the reduction of sink marks and the improvement of gas venting in injection molding processes using External Gas Injection (EGI). A mold was designed with considerations for EGI core pins, O-ring grooves to prevent gas leakage, and ejector-pin sealing. The sink marks were then examined through a series of experiments. When the delay time for injecting compressed air was set to 2.2 seconds, the depth of the sink marks was minimized. However, when the delay time was either too short or too long, the depth of the sink marks increased. There was almost no difference in the depth of the sink marks at discharge pressures of 30 and 50 bar of compressed air, but the sink marks were significantly reduced at a discharge pressure of 70 bar. Under the conditions of a 2.2-second delay time and a supply pressure of 70 bar, the smallest depth, 0.594 ㎛, was observed when the supply time was between 6 and 7 seconds. This represents a reduction of approximately 94% compared to the sink mark depth of 10.078 ㎛ observed with conventional injection molding. To verify the gas venting effect of compressed air injection, an experiment was conducted using non-dried PC. The silver streaks that appeared on the exterior of the molded part were completely eliminated when the air supply pressure was set to 20 bar. This indicates that by injecting compressed air into the mold cavity before injecting the resin, the appearance quality of the injection-molded part can be improved without the need to dry the resin in advance.

• 한국주조공학회지
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• 제35권4호
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• pp.80-87
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• 2015

The Al die casting process has been widely used in the manufacturing of automotive parts when the process requires near-net shape casting and a high productive rate. However, porosity arises in the casting process, and this hampers the wider use of this method for the creation of high-durability automotive components. The porosity can be controlled by the shot condition, but, it is critical to set the shot condition in the sleeve, and it remains difficult to optimize the shot condition to avoid air entrapment efficiently. In this study, the 4.5 mm, 2.0 mm plate die castings were fabricated under various shot conditions, such as plunger velocities of 0.7 m/s ~ 3.0 m/s and fast shot set points of the cavity of -25%, 0%, 25%, and 50%. The mold filling behavior of Al melts in the cavity was analyzed by a numerical method. Also, according to the shot conditions, the results of numerical analyses were compared to those of die-casting experiments. The porosity levels of the plate castings were analyzed by X-ray CT images and by density and microstructural analyses. The effects of the porosity on the mechanical properties were analyzed by tensile tests and hardness tests. The simulation results are in good general agreements with the die-casting experimental results. When plunger velocity and fast shot set point are 1.0 m/s and cavity 25% position, castings had optimum condition for good mechanical properties and a low level of porosity.

• Design & Manufacturing
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• 제13권2호
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• pp.17-21
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• 2019

In this study, selective laser sintered 3D printing mold core and metal core were used to investigate the difference of the thickness shrinkage from the gate of the injection molded part at a constant interval. SLS 3D printing mold core was made of nylon-based PA2200 powder and the metal core was manufactured by conventional machining method. As the PA2200 powder material has low strength, thermal conductivity and high specific heat characteristics compared with metal, molding conditions were set with the consideration of molten temperature and injection pressure. Crystalline resin(PP) and amorphous resin(PS) with low melting temperature and viscosity were selected for the injection molding experiment. Cooling time for processing condition was selected by checking the temperature change of the cores with a cavity temperature sensor. The cooling time of the 3D printing core was required a longer time than that of the metal core. The thickness shrinkage of the molded part compared to the core depth was measured from the gate by a constant interval. It was shown that the thickness shrinkage of the 3D printing core was 2.02 ~ 4.34% larger than that of metal core. In additions, in the case of metal core, thickness shrinkage was increased with distance from the gate, on the contrary, in the case of polymer core showed reversed aspect.

• 대한기계학회논문집A
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• 제37권1호
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• pp.113-119
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• 2013

뿌리기술로 불리는 생산기반기술은 국내 주력기간산업과 미래유망산업 관련 제품의 품질 및 생산성을 좌우하는 핵심기술로서 제조산업의 주류를 이루는 중소기업의 경쟁력 강화를 위한 최적의 생산기반기술 관련 지식의 공유 및 확산은 매우 중요하다. 그러나, 생산기반기술은 현장 경험과 숙련 정도에 의존도가 높은 공정기술이기 때문에 이를 지식의 형태로 표준화하여 시스템적으로 공유하기 어렵다. 본 연구에서는 대표적인 모바일 핵심부품 중 하나인 휴대폰 외장부품 제조를 위해 공통적으로 필요한 부품 설계, 금형설계, 금형가공, 사출성형공정 최적화, 표면처리 등의 주요 기반기술의 표준화 및 정보화를 수행하였다. 또한, 이를 쉽게 축적, 공유하도록 하기 위하여 지식저작도구, 의미기반 데이터베이스, 웹 포털 서비스로 구성된 웹 기반 지식공유 시스템을 구축하였다.

• Design & Manufacturing
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• 제13권1호
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• pp.55-60
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• 2019

Smart-phone in the recently released high-end applied to the camera module is equipped with the most features auto focusing camera module. Also, auto focusing camera module is divided into voice coil motor, encoder, and piezo according to type of motion mechanism. Auto focusing camera module is composed of voice coil motor (VCM) as an actuator and leaf spring as a guide and suspension. VCM actuator is made of magnet, yoke as a metal, and coil as a copper wire. Recently, the assembly as yoke and magnet is made by human resources. These process has a long process time and it is difficult to secure quality. Also, These process is not economical in cost, and productivity is reduced. Therefore, an automatic assembly as yoke and magnet is needed in the present process. In this paper, we have developed an automatic assembly device that can automatically assemble yoke and magnet, and performed verifying performance. Therefore, by using the developed automatic assembly device, it is possible to increase the productivity and reduce the production cost.

• Design & Manufacturing
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• 제12권2호
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• pp.16-21
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• 2018

Recently, as the demand for high-precision parts increases due to industrial development, a machine tool system for ultra-precision machining and polishing has been actively developed. As a result, there is an increasing demand for ultra-precision surface roughness along with dimensional processing. However, due to the increase in processing time due to the demand for ultra-precise surfaces and enormous facility investment, it is difficult to secure competitiveness. The polishing process using the abrasive film in super precision machining has been applied to machines, electronic devices, aerospace, and medical fields. Super finishing using the abrasive film which is applied in the industrial field recently can achieve high surface roughness in a short time. Super finishing using the abrasive film which is applied in the industrial field recently can achieve high surface roughness in a short time. Also, application of industrial field is increasing due to advantages such as low noise and low dust. Recently, researches on stainless steel having strong resistance to corrosion, heat resistance, heat resistance, toughness and weldability have been actively conducted with respect to the nuclear energy industry or marine development. Therefore, in this study, surface roughness and residual stress were measured after SUS304 polishing using dynamic analysis of film polishing apparatus and polishing film.

• Design & Manufacturing
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• 제14권1호
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• pp.42-48
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• 2020

Titanium alloy has been in the spotlight as a core material in high-tech industries that require high strength and light weight because it has excellent strength and corrosion resistance and strength is higher than that of steel. Therefore, in various industries, existing steel products are intended to be replaced with titanium alloys. Titanium alloys can cause cutting tool breakage during cutting, and heat generated during cutting does not dissipate, accumulates in tools and workpieces, resulting in large wear and tear on thin workpieces. In addition, since titanium alloy is a metal with high chemical activity, the wear of the tool becomes more severe when the cutting speed is high, so machining of titanium bolt through cutting is very disadvantageous in terms of productivity. Therefore, the production of bolts using titanium alloys is being produced through a forging process to improve productivity and product quality. In this paper, hot forging molding analysis was performed on bolts used for fastening automobile parts using Ti-6Al-4V alloy, which is the most commonly used titanium alloy.

• Design & Manufacturing
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• 제14권2호
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• pp.62-68
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• 2020

Recently, research on precise parts required in aerospace, ship, and automobile industries has been actively conducted. In this paper, electron beam drilling machining parameters were selected and experiments were conducted to compare processing characteristics analysis according to machining parameters through machining experiments of a vaporization amplification sheet to which STS 304 was applied. Also, as a result of measuring the machining. As the thickness gradually increased, it was confirmed that the electron beam could not reach the vaporization amplification sheet and thus melted on the surface of the material. As a result of the experimental analysis, it was analyzed that the vaporization explosion reaction of the vaporization amplification sheet was not normally performed due to the working distance (WD) according to the material thickness.

• Design & Manufacturing
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• 제13권1호
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• pp.5-12
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• 2019

In this paper, we studied the micro tool deflection, micro cutting with low temperature, and deformation of micro ribs caused by cutting forces. First, we performed an integrated machining error compensation method based on captured images of tool deflection shapes in micro cutting process. In micro cutting process, micro tool deflection generates very serious problems in contrast to macro tool deflection. To get the real images of micro tool deflection, it is possible to estimate tool deflection in cutting conditions modeled and to compensate for machining errors using an iterative algorithm correcting tool path. Second, in macro cutting fields, the cryogenic cutting process has been applied to cut the refractory metal but, the serious problem may be generated in micro cutting fields by the cryogenic environment. However, if the proper low temperature is applied to micro cutting area, the cooling effect of cutting heat is expected. Such effect can make the reduction of tool wear and burr formation. For verifying this passibility, the micro cutting experiment at low temperature was performed and SEM images were analyzed. Third, the micro pattern was deformed by the cutting forces and the shape error occurred in the sidewall multi-step cutting process were minimized. As the results, the relationship between the cutting conditions and the deformation of micro-structure during micro cutting process was investigated.