• Transactions of Materials Processing
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• v.23 no.2
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• pp.88-94
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• 2014

The under-drive brake piston is an essential part in the automatic transmissions of automobiles. This component is manufactured by forging after blanking from S55C plate with a thickness of 6mm. It is difficult to design the plate forging process using a thick plate approach since there will be limited material flow as well as large press loads. Furthermore, the under-drive brake piston has a complex shape with a right angle step, which often results in die unfill and abrupt increase in press load. To overcome these obstacles, a separate die for filling material sufficiently to the corner of the right angle step is proposed. However, this approach induces an uncontrolled workpiece surface between the dies, resulting in flash. This excess flash degrades the tool life in the final machining after cold forging as well as increases the cycle time to obtain the net-shape of the part. In the current study, we propose an optimum process design using a conventional die shaped with the benefit of finite element analysis. This approach enhanced the process efficiency without sacrificing the dimensional accuracy in the forged part. As the result, the optimum plate forging process was done with a two stage die, which reduces weight of by 6% compared with previous process for the under-drive brake piston.

• The Journal of the Korean dental association
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• v.52 no.6
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• pp.332-345
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• 2014

In recent years, precision machining of the dental prosthesis by computer assisted system is becoming pervasive in clinical dentistry. Prosthesis fabricating system that is designed by computer software and made by computer devices is called as a CAD/CAM (Computer-Aided Design/Computer-Aided Manufacturing) system. By the use of dental CAD/CAM system, the improvement of marginal compatibility and mechanical properties in prosthesis can be obtained more effectively, an aesthetic quality by using new materials such as zirconia can be increased. Also, the restoration process can be simple and efficient, the production time can be shortened, the process of manufacture can be standardized, and the mass production is possible. What is clear is that these benefits are theoretically possible, but the dentist or dental technician must understand the CAD/CAM basic principles and limitations for obtaining the maximum advantages of CAD/CAM system. For this reason, this article will be presented about the basic principles of CAD/CAM system and the factors of error that might occur in the CAD/CAM process based on my empirical study.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.5
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• pp.1074-1083
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• 1993

NC simulation has been used to replace the test cutting of NC machining. Although it can reduce the NC part programming effort, it still has a problem. If any error is found during the simulation, then the part has to be reprogrammed and it is time consumming. This paper presents a method for verifying and editing the NC code after the post-processing without going back to the part programming stage. A data structure and an algorithm to verify and edit the NC code interactively with the aid of graphics is introduced. Z-map method is used for the shaded image display and cross-sectional view display of the macined parts. The method was implemented in a IBM/PC-386 with MS-Windows software, and the multi-window function of the of the MS-Windows is used for the simultaneous editing and verification.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.1
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• pp.57-64
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• 2010

Metal Injection Molding (MIM) is attractive because it produces consistent, complex-geometry components for high-volume, high-strength, and high-performance applications. Also MIM using in optical communication field, display field, and semi-conductor field is a cost-effective alternative to metal machining or investment casting parts. It offers tremendous single-step parts consolidation potential and design flexibility. The objective of this paper is to study the suitability of design, flow analysis, debinding and sinterin processes, and capability analysis. The suitable injection conditions were 0.5~1.5 second filling time, 11.0~12.5 MPa injection pressure derived from flow analysis. The gravity of the product is measured after debinding an sintering. The maximum and minimum gravity levels are 7.5939 and 7.5097. the average and standard deviation are 7.5579 and 0.0122; when converted into density, the figure stands at 98.154%. According to an analysis of overall capacity, PPM total, which refers to defect per million opportunities(DPMO), stands at 166,066.3 Z.Bench-the sum of defect rates exceeding the actual lowest and highest limits-is 0.97, which translates into the good quality rate of around 88.4% and the sigma level of 2.47.

• Journal of the Society of Naval Architects of Korea
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• v.44 no.2 s.152
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• pp.198-209
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• 2007

In this paper, we present the gouging and collision-free tool-path generation for manufacturing model propellers using the 5-axis NC machine. Because it takes much time to generate tool-paths when we use general purpose CAD/CAM systems, a specific system would be necessary for marine propellers. Overall manufacturing process is composed of two steps: roughcut and finishcut steps. The roughcut is conducted using only 3-axis for efficient machining and the finishcut is done using 5-axis for avoiding collision. The tool-path that might happen to gouging is searched and the tool position is also decided for avoiding interference between the tool and the propeller blades. The present algorithm is applied extensively to the surface piercing propellers. Some results are demonstrated for its validation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.11
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• pp.2336-2341
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• 2002

When WC and group IV elements are added to Ti(C,N)-Ni cermet, microstructures of the cermet is changed. The change effects directly on the property of the material. In this study, the amount of WC and group IV elements of Ti(C,N) cermet tool was investigated. The composition of WC was changed from 5 to 20wt% to determine the effect of WC on the cutting performance of cermet tool. The more WC was added, the longer the tool life of the cermet tool was. The cermet with lwt% ZrC and l4wt% WC showed the best cutting performance among the investigated cermet tools. The cutting performance of cermet cutting tools suggests the possibility in interrupted cutting for reliability test experimentation was performed repeatedly with $Ti(C_{0.7},N_{0.3})- l4WC-1ZrC-20Ni$ cermet tool machining SCM440. The flank wear of cermet cutting tool at given time condition is suitable for Normal distribution and Log normal distribution by Chi squared test.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.6 s.165
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• pp.979-987
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• 1999

In a high precision vertical machining center, the estimation of cutting forces is important for many reasons such as prediction of chatter vibration, surface roughness and so on, and cutting forces are difficult to predict because they are very complex and time variant. In order to predict the cutting forces of end-milling process for various cutting conditions, a mathematical model is important and this model is based on chip load, cutting geometry, and the relationship between cutting forces and chip loads. Specific cutting force coefficients of the model have been obtained as interpolation function types by averaging farces of cutting tests. In this paper, the coefficients are obtained by neural network and the results of the conventional method and those of the proposed method are compared. The results show that the neural network method gives more correct values than the function type and that in teaming stage as the omitted numbers of experimental data increases the average errors increase.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.79-88
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• 2002

High speed machining system have been used in industrial because it is effective to a material manufacturing with various shape. Recently the end-milling processing is needed the high-precise technique with good surface roughness and rapid time in aircraft, automobile part and molding industry. Therefore this study proposed to decide best manufacturing cutting condition for surface roughness and rapid manufacturing tune by using computer Image processing system and 3D modelling. Until the 16,000 rpm, the surface roughness is decreased rapidly, but it is not over that. The 22,000 rpm is the spindle speed with the optimum surface in the high speed end-milling. In the case of the feed rate with 2,000 mm/mm and 8,000 mm/mm, the surface roughness is better than 4,000 mm/min and 6,000 mm/min. By using the 3D modelling, it is effectively represented shape characteristics of working surface m high speed end-milling.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.9
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• pp.15-23
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• 2020

Spline is a machine component using transmits rotating energy with grooves on internal of boss and external periphery of shaft. Internal spline is generally produced by machining process. However, to reduce manufacturing cost and save time, plastic deformation process such as backward extrusion is gradually adapted for spline production. In plastic deformation process, forming load, stress on tools and flow flaws should be taken into account to have sound products. For this purpose, kinematically admissible velocity fields for Upper Bound Method in backward extrusion of internal spline has been suggested, then forming load and relative pressure have been calculated. Internal spline forming experiments have been con-ucted under hydraulic press and the calculated forming load well predicts the load of experiment.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.3
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• pp.261-269
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• 2009

Micro end-milling process is applied to fabricate precision mechanical parts cost-effectively. It is a complex and time-consuming job to select optimal process conditions with high productivity and quality. To improve the productivity and quality of precision mechanical parts, micro end-mill wear and cutting force characteristics should be studied carefully. In this paper, high speed machining experiments are studied to construct the optimum process design as well as the mathematical modeling of tool wear and cutting force related to cutting parameters in micro ball end-milling processes. Cutting force and wear characteristics under various cutting conditions are investigated through the condition monitoring system and the design of experiment. In order to construct the cutting database, mathematical models for the flank wear and cutting force gradient are derived from the response surface method. Optimal milling conditions are extracted from the developed experimental models.