• Design & Manufacturing
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• v.16 no.1
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• pp.50-54
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• 2022

Coverglass of electronic equipments is thinner and slimmer, so the glass must have good bending strength. In these days, the polishing edge of glass is used by solid tool like grinding wheel. But solid tool leave micro crack or edge chipping in edge of glass. MR polishing is an optimal method by polishing edge of glass. MR polishing is used MR fluid that is a liquid tool. MR polishing doesn't leave tool path or residual stress, micro crack and edge chipping unlike grinding wheel polishing. In this paper, the results of grinding and MR polishing were compared and analyzed to improve bending strength by minimizing edge chipping of cover glass. It was derived that the depth and size of cracks have a significant influence on the bending strength of the glass edge. The edges of the glass using MR grinding were analyzed to have a better surface and higher bending strength than the glass using abrasive wheel grinding. It was confirmed that MR polishing had an effect on strength improvement by effectively removing cracks in the specimen.

• Design & Manufacturing
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• v.16 no.3
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• pp.16-21
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• 2022

In order to reduce the weight of parts and materials for the development of high-efficiency engines in accordance with the strengthening of automobile fuel efficiency regulations, the existing casting material is changed to a iron plate material, and plastic processing and turning operations are performed to lighten the weight and reduce the manufacturing cost. Among the pulley components applied to the damper pulley, the HUB product was manufactured by plastic machining instead of the existing casting process, and the inspection standardized for automating the inner diameter and parallelism measurement of the turning result of the new hub part with improved quality, and the inspection system for this Development of design and operation software to automate the inspection of the inner diameter and parallelism of the hub was described. The representative specifications of the development equipment are a hub inner diameter 22mm inspection system, a three-point inspection system with a parallelism of 0.15mm on the top.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.6_2
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• pp.1047-1053
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• 2022

The leaf spring for a truck absorbs shocks or vibrations from the road surface while driving with the elastic force of the material and prevents the shock from being transmitted to the vehicle body. It is subjected to cyclic stress, and fatigue fracture occurs frequently. This study analyzes fractured leaf spring from a 25 ton truck that has been operating for about a year. In the fractured portion, which is the origin of crack, inclusions were observed, and fatigue failure was caused by cyclic stress. In the stress calculation and FE analysis, the stress at the center of the leaf spring was obtained to be 54~65% of the yield strength of the base material and damaged material. It is most important to prevent the mixing of impurities in the steel manufacturing for leaf springs. The large stress portion of the leaf spring needs to introduce compressive residual stress by peening etc.

• Transactions of Materials Processing
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• v.31 no.4
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• pp.186-193
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• 2022

The application of UHSS sheet is being expanded up to 50% to reduce the weight of automobiles and improve safety. However, due to the high strength and low elongation of the ultra-high tensile strength steel sheet, product defects such as spring back and mold defects such as cracks and chippings also occur. In this study, Pin/Ring on Disc and Spiral wear tests were conducted to evaluate the durability of Ti/Cr-coated molds for forming 1.2GPa grade UHSS sheets. Component analysis and thickness were measured for each coating layer, and hardness and adhesion were investigated to determine mechanical properties. Combining the results of various wear tests, it was found that the TiAlN coating had the best wear and sticking resistance.

• Design & Manufacturing
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• v.17 no.1
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• pp.1-5
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• 2023

In multi-material injection molding, since two or more materials with different process conditions are used, it is essential to maximize process efficiency by operating the cooling or heating system to a minimum. In this study, Liquid silicone rubber (LSR) that can be cured at a low temperature suitable for the multi-material injection molding was selected and the cure behavior according to the process conditions was analyzed through differential scanning calorimetry (DSC). Dynamic measurement results of DSC with different heating rate were obtained, and through this, the total heat of reaction when the LSR was completely cured was calculated. Isothermal measurement results of DSC were derived for 60 minutes at each temperature from 80 ℃ to 110 ℃ at 10 ℃ intervals, and the final degree of cure at each temperature was calculated based on the total heat of reaction identified from the Dynamic DSC measurement results. As the result, it was found that when the temperature is lowered, the curing start time and the time required for the curing reaction increase, but at a temperature of 90 ℃ or higher, LSR can secure a degree of cure of 80% or more. However, at 80 ℃., it was found that not only had a relatively low degree of curing of about 60%, but also significantly increased the curing start time. In addition, in the case of 110 ℃, the parameters were derived from experimental result using the Kamal kinetic model.

• Design & Manufacturing
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• v.16 no.4
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• pp.7-16
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• 2022

A helmet is essential for safety when operating personal mobility. However, user's actual helmet wear rate is low due to the inconvenience of wearing and poor ventilation. In this study, a new helmet structure with improved ventilation for personal mobility devices was designed. To design a new structure with improved breathability compared to the existing helmet while satisfying the safety regulations for the helmet, a generative design method was applied to the shock-absorbing liner of the helmet. In addition, other materials were applied to create a structure with improved ventilation while maintaining safety. The generated design result was verified for shock absorption through simulation. As a result of the study, EPS, the current material was replaced with CFRP and Kevlar, and the structure was changed. This design was judged to satisfy safety regulations against impact. The new helmet structure is expected to improve the helmet usability for personal mobility and increase the helmet wear rate of users.

• Design & Manufacturing
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• v.17 no.2
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• pp.62-69
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• 2023

In this study, we conducted a study on the optimization of injection molding conditions to minimize deformation of plastic product. The charging management system housing of the vehicle was selected as the research subject. Melting temperature, cooling temperature, packing time, and packing pressure were selected as the main factors expected to affect the deformation of molded products. Each main factor was divided into 5 levels. Optimization of injection molding conditions to minimize deformation was performed using the Taguchi Method. We performed an analysis of variance (ANOVA) to identify significant factors affecting the deformation of plastic product. In order to select injection molding conditions that minimize deformation of plastic products, injection molding analysis was additionally performed for insignificant factors. We then compared the deformation of the molded part before and after optimization. As a result of comparing the injection analysis results of the basic conditions and the injection analysis results of the optimal conditions, it was confirmed that the amount of deformation after optimization was improved by about 10.9%.

• Design & Manufacturing
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• v.17 no.2
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• pp.1-8
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• 2023

This study aims to enhance the price and quality competitiveness of imported tiles by developing a robotic tile production automation line. The development process involved several steps, such as requirement analysis, derivation of technical specifications, conceptual design, engineering feasibility review, detailed design, and production. Emphasis was placed on the transfer process of the tiles' molds, and technological advancements were achieved through engineering interpretation, feasibility review, and performance evaluation. The developed automation system incorporates key specifications to ensure a transfer success rate of over 90%, thereby ensuring stable transportation of the tiles and minimizing defect rates during production. The maximum weight capacity for tile pick-up was set above 6 kg, allowing effective handling of tiles weighing 6 kg or less in automated tasks. Furthermore, the system enables safe and precise movement of the tiles to the desired location, with a transfer distance of at least 1.3 m and a transfer speed exceeding 0.2 m/sec, thereby increasing production efficiency.

• Design & Manufacturing
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• v.17 no.2
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• pp.15-21
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• 2023

In this study, a diamond turning machine and a laser-assisted machining module were utilized for the complex combined cutting of aspheric shapes and fine patterns on the surface of high-hardness brittle material, silicon. The analysis of material's form accuracy and corrective machining was conducted based on key factors such as laser output, rotational speed, feed rate, and cutting depth to achieve form accuracy below 1 ㎛ and surface roughness below 0.1 ㎛. The cutting condition and corrective machining methods were investigated to achieve the desired form accuracy and surface roughness. The rotational speed of the spindle and the linear feed rate of the diamond turning machine were varied in five stages for the cutting condition test. Surface roughness and form accuracy were measured using both a contact surface profilometer and a non-contact surface profilometer. The experimental results revealed a tendency of improved surface roughness with increased rotational speed of the workpiece, and the best surface roughness and form accuracy were observed at a feed rate of 5 mm/min. Furthermore, based on the cutting condition experiments, corrective machining was performed. The experimental results demonstrated an improvement in form accuracy from 0.94 ㎛ to 0.31 ㎛ and a significant reduction in the average value of the surface roughness curve from 0.234 ㎛ to 0.061 ㎛. This research serves as a foundation for future studies focusing on the machinability in relation to laser output parameters.

• Design & Manufacturing
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• v.17 no.2
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• pp.27-32
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• 2023

Liquid silicon rubber (LSR) has fine thermal compatibility and is widely used in various fields such as medical care and automobiles because it is easy to implement products with good fluidity. With the recent development of flexible sensors, the focus has been on manufacturing conductive elastomers, such as silicone as elastic materials, and carbon black, CNT, and graphene are mainly used as nanomaterials that impart conductive phases. In this study, mechanical behavior and curing behavior were measured and analyzed to manufacture a CB-LSR complex by adding Carbon Black to LSR and to identify properties. As a result of the compression test, the elastic modulus tended to increase as carbon black was added. When the swelling test and the compression set test were conducted, the swelling rate tended to decrease as the content of carbon black increased, and the compression set tended to increase. In addition, DSC measurements showed that the total amount of reaction heat increased slightly as the carbon black content increased. It is considered that carbon black was involved in the crosslinking of LSR to increase the crosslinking density and have a positive effect on oil resistance reinforcement.