• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.6
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• pp.77-82
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• 2016

When drilling through Inconel 601 nickel-chromium-based alloys, a large amount of cutting oil is required to prevent tools from wear and fracturing due to heat buildup resulting from the high temperature resistance and toughness of this alloy. However, cutting oil supply has become a factor compromising the machining environment, and this has caused attention to shift to a more environmentally friendly cutting fluid supply system called minimum quantity lubrication (MQL). Our aim in this study was to find a more efficient drill processing method using MQL, and to verify its performance. To that end, we proposed a sealed cover, a step feed, and POSS-type cutting oil as measures to increase the effectiveness of MQL in view of the cutting force and tool wear, and established an improvement in efficiency using the proposed measures.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.5
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• pp.67-74
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• 2020

To predict the thermal deformation of an oven cabinet during the enamel process, we propose a simple finite element analysis method comprising two steps: heating and cooling. To this end, the basic mechanical and thermal properties such as thermal expansion of the enamel and steel plate were experimentally studied, and the mechanical properties of four different stainless steel (SUS) plates were evaluated to select the target material for the oven at high temperature conditions from 400 ℃ to 700 ℃. In the first analysis step of the enamel process, the SUS plate was heated to 850 ℃ and was then thermally expanded without considering the enamel coating. Next, assuming the perfect bonding of two materials (enamel coating and metal plate), the enamel plate was allowed to cool to room temperature till 22 ℃. From the results of comparing the experimental and analytical data, we can make a conclusion that the proposed method can be applied to evaluate the thermal deformation of enamel products. Especially, the thermal deformation of the oven can be predicted with different enamel coating conditions, such as uniform and nonuniform coating thickness.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.4
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• pp.71-78
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• 2020

The rotary feed axes of a 5-axis machine tool can increase the freedom of the tool posture, while reducing feed speed and rigidity. In addition, as a ball-end mill is inevitably used during machining by rotational feed, the step-over length is reduced compared to the flat-end mill, thereby reducing the material removal rate. Therefore, this study attempts to improve the material removal rate, feed speed, and machining stability using the corner radius flat-end mill and a fixed controlled machining method for the rotary feed axes during roughing. In addition, the tapered ball-end mill and simultaneously controlled machining method for the rotary feed axes were used for finishing to improve the propeller's 5-axis machining efficiency by enhancing the surface quality. In order to create the tool path effectively and easily, we propose a specific approach for using the propeller's geometric properties and evaluate the effectiveness of the proposed method by comparing it with the method of the dedicated module.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.5
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• pp.38-48
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• 2004

Recently the use of high-speed equipment in machine-tool industry has greatly increased, which requires the development of prognostics and prediction methods on the design stage. Conversion of the test/experiments stage from real to virtual reality will not only significantly reduce the design and manufacturing cost, but will also increase design quality. This paper shows how it is possible to develop the automated system for the design calculations of the air-bearing spindles. First, the general calculation method is introduced. It contains several steps, namely, geometry identification, pressure calculation, stiffiness calculation, dynamics characteristics calculation. For geometry identification reducing spindle shaft to rings was proposed, which helps to automate the calculation process. For pressure calculation the Peshti method was implemented. For stiffiness calculation the analysis was made, which shown the necessity of correct calculation step selection. Then the system of ordinary differential equations containing influence coefficients was evolved, which is used for trjectories calculation. The graphical representation of the calculation results shows the dynamic behavior of the spindle unit concerning various working conditions. Finally, this automated system is illustrated by an example of the air-bearing spindle calculation.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.2
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• pp.160-165
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• 2015

The 14k, 45k, and 70k Mw PCL have different crystallization temperatures and therefore have slightly different characteristics affecting the fiber diameter. To observe these behaviors, the fiber was produced at every step of $10^{\circ}C$ for each molecular weights and the diameter was measured. Moreover, the fiber was fabricated over the cooled ground plate to observe the change in fiber diameter in comparison to the normal ground plate. In case of molecular Mw 14k PCL, the diameter increased as the temperature increased. For Mw 45k PCL, the fiber diameter decreased as the temperature increased. As of Mw 70k PCL, the fiber diameter decreased with increasing temperature as well. When the experiment was conducted over the cooled collector plate, the data did not change significantly from the previous lexperiments.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.4
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• pp.337-344
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• 2014

While implicit integration methods such as Newton's method have excellent stability for the analysis of stiff and constrained mechanical systems, they have the drawback that the evaluation and LU-factorization of the system Jacobian matrix required at every time step are time-consuming. This paper proposes a Jacobian update-free Newton's method in order to overcome these defects. Because the motions of all bodies in a vehicle model are limited with respect to the chassis body, the equations are formulated with respect to the moving chassis-body reference frame instead of the fixed inertial reference frame. This makes the system Jacobian remain nearly constant, and thus allows the Newton's method to be free from the Jacobian update. Consequently, the proposed method significantly decreases the computational cost of the vehicle dynamic simulation. This paper provides detailed generalized formulation procedures for the equations of motion, constraint equations, and generalized forces of the proposed method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.1
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• pp.19-28
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• 2020

The spacer, which is located between the bucket and the arm of an excavator, has a role in preventing damage to the excavator arm during excavation work. When the durability of the spacer is increased, the lifetime of the arm can be extended and the processing costs can be reduced. To increase the durability of the spacer, tungsten carbide (WC) coating was applied on the surface of a spacer using the plasma transferred arc (PTA) process. The confirm the durability, a wear test using a pin-on disk type of wear testing machine was done under the given conditions and the wear amount on the surface of a tested specimen was measured using reflective digital holography. The results were compared with that of ALPHA-STEP.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.6
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• pp.847-851
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• 2010

It was attempted to develop an auto part by over molding injection mold that produces precision products in high productivity with use of an eco-friendly TPE substitute material for NBR. NBR is currently used in motor gear cover, one of the key parts in motor module for auto doors. Gear cover is composed of plastics and rubber mostly today, which requires a two (2) step process for production using two presses of different types. A hot press is used at this time for forming the rubber, which has drawback of requiring a rather long forming time of 400 seconds for one forming process. Even though this difficulty is overcome by reducing production time through employment of multi-cavity molds, time for forming process must be shortened for improvement of the productivity eventually, and the existing method of insert injection for products that have been formed with plastic material must be outgrown. In this point of view, over molding injection using TPE has a big advantage. Forming time is shortened to 54 seconds, and working the two (2) processes in series by one (1) press could solve the durability problem caused by deflection of the plastics, not to mention shortening the process time. Enhancement of productivity by almost 80% and improvement in the accuracy of the product could thus be achieved.

• Journal of the Korean Applied Science and Technology
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• v.24 no.4
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• pp.347-353
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• 2007

Fleshing scrap is a kind of wastes produced during leather making process and used in the test of manufacturing biodiesel. The early step of manufacturing biodiesel is fat recovery from fleshing scrap. Hence, we investigated the influence of the way of fat recovery on the fatty acid composition. We used three different recovery ways, that is chemical method by protein decomposition with acid/fat recovering, physical method by protein denaturalization with heat and vacuum/fat pressing, and biodiesel method by protein decomposition/fat recovering. The biological method yielded the best results in terms of appearance transparency. It was most effective to lower acid value. Also the recovered fat by biological method would be favorable methyl-ester reaction raw material for biodiesel because it contains more than 5% of oleic acid among unsaturated fatty acid.

• International Journal of Precision Engineering and Manufacturing
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• v.8 no.3
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• pp.14-19
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• 2007

Rapid prototyping (RP) technology can fabricate any 3D physical model regardless of geometric complexity using the layered manufacturing (LM) process. Stereolithography (SL) is the best-known example of RP technology. In general, the surface quality of a raw SL-generated part is unsatisfactory for industrial purposes due to the step artefact created by the LM process. Despite of the increased number of applications for SL parts, this side effect limits their uses. In order to improve their surface quality, additional post-machining finishing, such as traditional grinding, is required, but post-machining is time consuming and can reduce the geometric accuracy of a part. Therefore, this study proposes a post-machining technology combining coating and grinding processes to improve the surface quality of SL parts. Paraffin wax and pulp are used as the coating and grinding materials. By grinding the coating wax only up to the boundary of the part, the surface smoothness can be improved without damaging the surface. Finally, moulding and casting experiments were performed to confirm the suitability of the SL parts finished using the proposed process with rapid tooling (RT) techniques.