• Journal of the Korean Society for Precision Engineering
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• v.25 no.9
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• pp.7-13
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• 2008

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.10-16
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• 2013

Ultra-fine planing and micro punching are separately used for improving surface roughness and machining dot patterns, respectively, of metal molds. If these separate machining processes are applied for machining of identical molds, there could be an aligning mismatch between the machine tool and the mold. A hybrid machining system combining ultra-fine planing and micro punching was newly developed in this study in order to solve this mismatch; hybrid process technology was also developed for machining dot patterns on a mirror surface of a metal mold. The hybrid machining system has X, Y, and Z axes, and a cam axis for ultra-fine planing. The cam axis and attachable and removable solenoid actuators for micro punching can make large and small sizes of dot patterns, respectively. Ultra-fine planing was applied in the first place to improve the surface roughness of a metal mold; the measured surface roughness was about 20nm. Then, micro punching was applied to machine dot patterns on the same mold. It was possible to control the diameter of the dot patterns by changing the input voltage of the solenoid actuator. Before machining, severe inhomogeneous plastic deformation around the machined dot patterns was also removed by annealing heat treatment. Therefore, it was verified that metal molds with dots patterns for optical products can be machined using a hybrid machining system and the hybrid process technology developed in this study.

• Structural Engineering and Mechanics
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• v.57 no.1
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• pp.141-159
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• 2016

Bearing joint dynamic parameter identification is crucial in modeling the high speed spindles for machining centers used to predict the stability and natural frequencies of high speed spindles. In this paper, a hybrid method is proposed to identify the dynamic stiffness of bearing joint for the high speed spindles. The hybrid method refers to the analytical approach and experimental method. The support stiffness of spindle shaft can be obtained by adopting receptance coupling substructure analysis method, which consists of series connected bearing and joint stiffness. The bearing stiffness is calculated based on the Hertz contact theory. According to the proposed series stiffness equation, the stiffness of bearing joint can be separated from the composite stiffness. Then, one can obtain the bearing joint stiffness fitting formulas and its variation law under different preload. An experimental set-up with variable preload spindle is developed and the experiment is provided for the validation of presented bearing joint stiffness identification method. The results show that the bearing joint significantly cuts down the support stiffness of the spindles, which can seriously affects the dynamic characteristic of the high speed spindles.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1243-1248
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• 2007

In recent, rapid manufacturing (RM) technology is widely used to develop an injection mould with a high performance. The objective of this paper is to develop the injection mould with a high productivity using a hybrid RM technology combining Laser-aided Direct Metal Tooling process with a machining process. The geometry decomposition has been utilized to improve the speed of the manufacturing for the mould. Mould with conformal cooling channels has been designed to improve cooling characteristics. Several experiments have been carried out to evaluate characteristics of the mould manufactured from the hybrid RM technology. In addition, injection molding tests have been performed to examine the performance of the manufactured mould. The results of the injection molding tests have been shown that a cooling time and the injection time of the designed mould are reduced to one-fifth and one-second that of the mould with convention cooling channels.

• Macromolecular Research
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• v.10 no.4
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• pp.194-203
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• 2002

In resin infusion process(RIP), the fiber and the resin are in contact with each other for an impregnation step and often results in flow-induced defects such as poor fiber wetting and void formation. Resin flow characteristics in transverse direction and process modeling for woven fabric were studied, and the process modeling was applied to the manufacturing of hybrid composite materials. This study also considered the compressibility of woven fabrics in a series of compression force, and it was fitted well to an elastic model equation. Void formation was varied with the processing conditions in the stage of manufacturing composites using RIP. It was concluded from this study that proper combination of pressure build-up and dynamic heating condition makes important factor for flow-induced composite processing.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.2
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• pp.214-218
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• 2011

In order to survive in turbulent and competitive markets, automotive part manufacturers try efforts to develop new manufacturing technologies for ultra-lightweight, high-intensity and environmentally-friendly parts. Most of front lower arm is manufactured by welding process between upper- and lower panel which are produced by press stamping process. Because lower arm mounted on the cross member parts is one of the important complementary parts. So, to improve safety and lightweight of these parts, hybrid technologies are used in this paper. As hybrid technologies are applied to be front sub-frame, rear cross member and other chassis parts as well as front lower arm, the 20% lightweight has been achieved compared with existing steel parts.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.3
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• pp.9-14
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• 2015

The Direct Metal Tooling (DMT) process is a kind of additive manufacturing processes, which is developed using various commercial steel powders, such as P20, P21, SUS420, and other non-ferrous metal powders. The DMT process is a versatile process that can be applied to various fields, such as the molding industry, the medical industry, and the defense industry. Among them, the application of the DMT process to the molding industry is one of its most attractive and practical applications, since the conformal cooling channel cores of injection molds can be fabricated at a slightly expensive cost by using the hybrid fabrication method of DMT technology compared with parts fabricated with machining technology. The main objectives of this study are to provide various characteristics of the parts made using the DMT process compared with the same parts machined from bulk materials and evaluate the performance of the injection mold equipped with a conformal cooling channel core fabricated using the hybrid method of the DMT process.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.1
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• pp.63-68
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• 2015

Micro/nano patterns for optical concentration and diffusion have been studied in the various fields such as displays, optics, and sensors. Conventional micro patterns were continuous and linear shapes due to using linear-type light sources, however, recently non-continuous patterns have been applied as point sources are used for dot-type light sources such as LEDs and OLEDs. In this study, a hybrid machining technology combining an indentation machining method and an AAO process was developed for manufacturing the non-continuous micro patterns having nano patterns. First, mirror-like surfaces ($R_a<20nm$) of pure Aluminum substrates were obtained by optimizing cutting conditions. Then, The letter of 'K' consisting of the arrays of the micro patterns was manufactured by the indentation machining method which has a similar principle to indentation hardness testing. Finally, nano patterns were machined by AAO process on the micro patterns. Conclusively, a specific letter having nano-micro hybrid patterns was manufactured in this study.

• Design & Manufacturing
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• v.14 no.4
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• pp.71-77
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• 2020

Various manufacturing technologies, including over-molding and insert-injection molding, are used to produce hybrid plastics and metals. However, there are disadvantages to these technologies, as they require several steps in manufacturing and are limited to what can be reasonably achieved within the complexities of part geometry. This study aims to determine a practical approach for producing metal/plastic hybrid components by combining plastic injection molding and metal die casting to create a new hybrid metal/plastic molding process. The integrated metal/plastic hybrid injection molding process developed in this study uses the proven method of multi-component technology as a basis to combine plastic injection molding with metal die casting into one integrated process. In this study, the electrical conductivity and ampacity were verified to qualify the new process for the production of parts used in electronic devices. The electrical conductivity was measured, contacting both sides of the test sample with constant pressure, and the resistivity was measured using a micro ohmmeter. Also, the specific conductivity was subsequently calculated from the resistivity and contact surface of the conductor path. The ampacity defines the maximum amount of current a conductive path can carry before sustaining immediate or progressive deterioration. The manufactured hybrid multi-components were loaded with increasing currents, while the temperature was recorded with an infrared camera. To compare the measured infrared images, an electro-thermal simulation was conducted using commercial CAE software to predict the maximum temperature of the power loaded parts. Overall, during the injection molding process, it was demonstrated that multifunctional parts can be produced for electric and electronic applications.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.2
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• pp.221-224
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• 2012

This paper presents the strength safety of a hybrid alarm valve by a finite element analysis. The stress and strain of a conventional hybrid alarm valve are calculated for the given maximum test pressure of 2MPa. Especially, the FEM computed maximum stress of a conventional hybrid valve is only 18.6% of yield strength, 370MPa. This means that the conventional valve is designed with a thick thickness of a valve structure. But, new hybrid alarm valve model, which is developed by optimized design method in this study, shows more low level of 43% in maximum stress and strain compared with that of a conventional hybrid valve. These results may recommend the reduction of a weight and a dimension for an optimized hybrid alarm valve.