• Journal of the Korean Society for Precision Engineering
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• v.15 no.12
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• pp.212-219
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• 1998

During machining of dies and molds with sculptured surfaces. the cutter contact area changes continuously and results in cutting force variation. In order to implement cutting force prediction model into a CAM system, an effective and fast method is necessary. In this paper. a new method is proposed to predict mean cutting force. The cutter contact area in the spherical part of the cutter is obtained using Z-map, and expressed by the grids on the cutter plane orthogonal to the cutter axis. New empirical cutting parameters were defined to describe the cutting force in the spherical part of cutter. Before the mean cutting force calculation, the cutting force density in each grid is calculated and saved to force map on the cutter plane. The mean cutting force in an arbitrary cutter contact area can be easily calculated by summing up the cutting force density of the engaged grid of the force map. The proposed method was verifed through the slotting and slanted surface machining with various inclination angles. It was shown that the mean force can be calculated fast and effectively through the proposed method for any geometry including sculptured surfaces with cusp marks and holes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.177-180
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• 2009

Tube hydroforming provides a number of advantages over the conventional stamping process, including fewer secondary operations, weight reduction, assembly simplification, adaptability to forming of complex structural components and improved structural strength and stiffness. A hydroformed vehicle body component has an attachment flange or the like-formed as an integral part of the hydroforming process. For a given flange shape, a parting plane for the dies is established relative to which the various surfaces of the flange shape, in cross section, have no significant reverse curvature. This study shows analysis results that form the flanged tubular parts in the hydroforming. The thickness variations and defects during the hydroforming for flange forming could be analyzed by FE analysis. FE analysis was performed by LS-DYNA/Dynaform 5.5.

• Transactions of Materials Processing
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• v.19 no.1
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• pp.32-37
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• 2010

Hydroforming has attracted a great deal of attention in the manufacturing industries for vehicles and transportation systems. Hydroforming technology contributes to weight reduction, increased strength, improved quality and reduced tooling cost. Hydroformed automotive parts used as structure components in vehichle body frame often have to be structurally joined at some point. Therefore it is useful if the hydroformed automotive parts can be given a localized attachment flange. For a given flange shape, a parting plane for the dies is established relative to which the various surfaces of the flange shape, in cross section, have no significant reverse curvature. In this study, hydroforming process for flange forming was proposed. FE analysis to form flanged circular shape and flanged rectangular shape was preformed with Dynaform 5.5. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as tool geometry and hydraulic pressure has been performed and optimized. The results show that flanged automotive parts can be successfully produced with tube hydroforming.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.5
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• pp.1182-1191
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• 1994

This paper presents an enhanced method of slit beam projection intended for the rapid measurement of 3-dimensional surface profiles of dies and molds. Special emphasis is given to optimizing the design of optical system so that the measuring accuracy can be maximized by adopting two-plane camera calibration together with sub-pixel image processing techniques. Finally, several measurement examples are discussed to demonstrate that an actual measuring accuracy of $\pm$ 0.2 mm can be achieved over the measuring range of 500 mm{\times}300mm{\times}200mm$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.115-119
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• 2001

This paper presents development of a Finite Element Analysis program. The program was developed on the based of second-dimensional plane strain rigid plasticity finite element analysis and an implicit program is coded. The program was tested by being applied to the axisymetric hydrostatic bulge forming processes using the circle dies. By the Finite Element Analysis at the fluid in chamber and at the blank material, we could know that the hydrostatic bulge forming processes can be influenced of material, the diameter of product and the forming velocity The developed Finite Element Analysis program was approved by the analysis results about forming variables.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.3
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• pp.80-93
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• 1996

A 2-dimensional FEM/GEM program was developed under the plane strain assumption using linear line elements for analyzing stretch/draw forming operations of an arbitrarily shaped draw-die. FEM formulation adopted a new algorithm for solving force equilibrium as well as non-penetration condition simultaneously. Also, a rigid-viscoplastic material model with Hill's normal anisotropic yield condition and rate-sensitive hardening law is assumed, along with the Coulomb friction law in the contact regions. For the case of numerical divergence at nearly final forming stages, geometric force equilibrium method(GEM) is also introduced. The developed program was tested by simulating the forming processes of cylindrical punch/open die, and the drawing processes of automotive oilpan and hood inner panel in order to verify the usefulness and validity of FEM/GEM formulation. The numerical simulation verified the validity and robustness of developed program.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.1 s.173
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• pp.173-181
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• 2000

Depending upon the method of the surface generation and the quality of the boundary curves provided, the resulting surfaces may have global or local irregularities in many cases. Thus it would be necessary for the designer to evaluate the surface quality and to modify the surface. This capability is very important because the defect of the surface requires the rework of the dies that causes a big loss in cost and delivery time. To simulate the reflection line test in the actual production line, a faster generation algorithm is presented. Among., various surface interrogation methods using reflection lines, Blinn-Newell type of reflection mapping is applied to generate reflection lines on the trimmed NURBS surface. The generation of reflection lines is formulated as a surface-plane intersection problem, and solved by surface-contouring techniques. In addition, a modified reflection map is proposed to eliminate the discontinuity of reflection lines due to the configuration of the reflection map. A fast reflection line algorithm is developed utilizing an efficient traced contouring technique, and proved to be well suited for real-time quality-assessment task.

• Journal of Mechanical Science and Technology
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• v.15 no.2
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• pp.160-171
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• 2001

Depending upon the method of the surface generation and the quality of the designed boundary curves, the resulting surfaces may have global or local irregularities in many cases. Thus, it would be necessary for the designer to evaluate the surface quality and to modify the surface. This is very important because the defect of the surface causes the rework of the dies, increasing cost and delivery time significantly. To simulate the reflection line test in the actual production line, a faster algorithm for generating reflection lines is presented. In this paper, among various surface interrogation methods using reflection lines, Blinn-Newell type of reflection mapping is applied to generate the reflection lines on the trimmed NURBS surfaces. The derivation of reflection lines is formulated as a surface-plane intersection problem (Jung 1994) and is solved by surface-contouring techniques. Also, for eliminating the discontinuity of reflection lines due to the configuration of reflection map, a modified reflection map is proposed. An efficient traced contouring technique is utilized for the computational efficiency and proves to be well suited for the real-time quality-assessment task.

• Laser Solutions
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• v.14 no.2
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• pp.24-29
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• 2011

The design of a telecentric f-${\theta}$ lens with a field of view (FOV) $30^{\circ}$ and an effective focal length of 1000mm is presented. The optical stop is placed at the front plane and the design is based on a geometric ray tracing technique, and the designed system consists of a series of convex and concave lenses. The designed f-${\theta}$ lens showed a considerable reduction in weight with a simplified structure and resulted in a good performance in the designated FOV. Detail analysis of rays is also presented. 653nm (red laser), 586nm (green laser), and 468nm (blue laser) were simulated as a light source and image illuminating source. The developed optical design requires 7 pieces of lenses made of SF1, N-FK56, N-LAK33, and BK7 glass materials. With optimal parametric design, the effective focal length was calculated to be 974.839mm which is very close to the initial design target. For the manufacturing purpose, the dimensions of lens curvature and thickness were truncated with error ranging 0.1% to 3.2%. As a result, the overall error was calculated to be 3.2% which can be still tolerable for display, laser material, and machining processing.

• The Journal of Korean Academy of Prosthodontics
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• v.54 no.3
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• pp.226-233
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• 2016

Purpose: The purpose of this study was to evaluate the adaptation of lithium disilicate crowns fabricated by CAD-CAM (computer aided design-computer aided manufacturing) and heat-press technique to compare two different measurement methods in assessing fit of the ceramic crowns: micro CT and cross-section technique. Materials and methods: A prepared typodont mandibular molar for ceramic crown was duplicated and ten dies were produced by milling the PMMA (polymethylmethacrylate) resin. Ten vinyl polysiloxane impressions were made and stone casts were produced. Five dies were used for IPS e.max Press crowns with heat-press technique. The other five dies were used for IPS e.max CAD crowns with CAD-CAM technique. Ten lithium disilicate crowns were cemented on the resin dies using zinc phosphate cement with finger pressure. The marginal and internal fits in central buccolingual plane were evaluated using a micro CT. Then the specimens were embedded and cross-sectioned and the marginal and internal fits were measured using scanning electronic microscope. The two measurement methods and two manufacturing methods were compared using Mann-Whitney U test (SPSS 22.0). Results: The marginal and internal fit values using micro CT and cross-section technique were similar, showing no significant differences. There were no significant differences in adaptation between lithium disilicate crowns fabricated with CAD-CAM and heat-press technique. Conclusion: Both micro CT and cross-section technique were acceptable methods in the evaluation of marginal and internal fit of lithium disilicate crown. There was no difference in adaptation between lithium disilicate crowns fabricated with CAD-CAM and heat-press technique except occlusal fit.