• Journal of the Korean Society for Precision Engineering
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• v.23 no.8 s.185
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• pp.171-177
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• 2006

This study was performed as a part of the research on the development of a maskless and electroless process for fabricating metal micro/nanostructures by using a nanoindenter and an electroless deposition technique. $2-{\mu}m$-deep indentation tests on Ni and Cu samples were performed. The elastic recovery of the Ni and Cu was 9.30% and 9.53% of the maximum penetration depth, respectively. The hardness and the elastic modulus were 1.56 GPa and 120 GPa for Ni and 1.51 GPa and 104 GPa for Cu. The effect of single-point diamond machining conditions such as the Berkovich tip orientation (0, 45, and $90^{\circ}$ ) and the normal load (0.1, 0.3, 0.5, 1, 3, and 5 mN), on both the deformation behavior and the morphology of cutting traces (such as width and depth) was investigated by constant-load scratch tests. The tip orientation had a significant influence on the coefficient of friction, which varied from 0.52-0.66 for Ni and from 0.46- 0.61 for Cu. The crisscross-pattern sample showed that the tip orientation strongly affects the surface quality of the machined are a during scratching. A selective deposition of Cu at the pit-like defect on a p-type Si(111) surface was also investigated. Preferential deposition of the Cu occurred at the surface defect sites of silicon wafers, indicating that those defect sites act as active sites for the deposition reaction. The shape of the Cu-deposited area was almost the same as that of the residual stress field.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.1
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• pp.95-101
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• 2022

This paper proposes a method to process the shape of an optical transmission road and attempts to determine the most suitable single processing method for an acrylic plate optical transmission road. In addition, by manufacturing an automatic pattern processing device to generate certain shapes on the acrylic plate at regular intervals, and measuring the illuminance of the patterned acrylic plate optical transmission road, the measured illuminance was confirmed to fall under the KS illuminance values presented in Table 1. In conclusion, when an incident light of approximately 20,000 lx is applied, the transmission illumination is approximately 200 lx, which represents a transmission rate of approximately 1% for incident light and corresponds to the KS illumination criterion F. Additionally, the right-angle triangular pyramid base size (A) processed at a temperature of 350 ℃ for one second was 2 mm, exhibiting the largest transmission illumination of 280 lx. When the transparent acrylic plate was set to a constant size of 1.6 mm at the bottom of the right-angle triangular pyramid, the fastest response occurred at a processing tip temperature of 350 ℃ (0.04 s). On the other hand, it took 10 s to process the size of the bottom of the right-angled triangular pyramid at a temperature of 200 ℃ to 1.6 mm, and it was confirmed that the optical transmission efficiency was significantly reduced because of the burr that occurred at this time.

• The Journal of Advanced Prosthodontics
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• v.10 no.4
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• pp.321-327
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• 2018

PURPOSE. The purpose of this study was to compare the cutting method and the lamination method to investigate whether the CAD data of the proposed inlay shape are machined correctly. MATERIALS AND METHODS. The Mesial-Occlusal shape of the inlay was modeled by changing the stereolithography (STL). Each group used SLS (metal powder) or SLA (photocurable resin) in the additive method, and wax or zirconia in the subtractive method (n=10 per group, total n=40). Three-dimensional (3D) analysis program (Geomagic Control X inspection software; 3D systems) was used for the alignment and analysis. The root mean square (RMS) in the 2D plane state was measured within $50{\mu}m$ radius of eight comparison measuring points (CMP). Differences were analyzed using one-way analysis of variance and post-hoc Tukey's test were used (${\alpha}=.05$). RESULTS. There was a significant difference in RMS only in SLA and SLS of 2D section (P<.05). In CMP mean, CMP 4 ($-5.3{\pm}46.7{\mu}m$) had a value closest to 0, while CMP 6 ($20.1{\pm}42.4{\mu}m$) and CMP 1 ($-89.2{\pm}61.4{\mu}m$) had the greatest positive value and the greatest negative value, respectively. CONCLUSION. Since the errors obtained from the study do not exceed the clinically acceptable values, the lamination method and the cutting method can be used clinically.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.3
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• pp.279-288
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• 2012

The material removal mechanism in machining is significantly affected by the cutting edge geometry. Its effect becomes even more substantial when the depth of cut is relatively small as compared to the characteristic length which represents the shape and size of the cutting edge. Conventionally, radius or focal length has been employed as the characteristic length with the assumption that the shape of cutting edge is round or parabolic. However, in reality, there could be various ways to determine the radius or focal length even for the same tool edge profile, depending on the region to be considered as cutting edge in the measured profile and the constraints to be set in constructing the best fitted circle or parabola. In this regard, the present study proposes various models to determine the characteristic length in terms of radius or focal length. Their physical compatibility are validated by carrying out 2D orthogonal cutting experiments using inserts with a wide range of characteristic length ($30{\sim}180\;{\mu}m$ in terms of radius) and then by investigating the correlation between the characteristic length and the cutting forces. Such validation is based on the common belief that the larger the characteristic length is, the blunter the cutting edge is and the higher the cutting forces are. Interestingly, the results showed that the correlation is higher for the radius or focal length obtained with a constraint that the center of best fitted circle or the focus of the best fitted parabola should be on the bisectional line of the wedge angle of tool.

• Journal of the Korean Society for Precision Engineering
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• v.33 no.12
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• pp.971-977
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• 2016

Recently, the problem of the accumulation of fine sludge from the cutting oil generated during machining processes has become a major threat to the environment. The fine sludge has adverse affects on the human body and the environment, and significantly contributes to marine pollution. However, a microfiltration technique that can process the sludge still needs to be studied and developed on a global scale. Therefore, it is necessary to develop eco-friendly equipment such as an ECO vacuum filter system and eco-friendly technologies for processing cutting oil. In this study, a structural analysis was carried out using a finite element method (FEM). Improved models of the suction chamber for the ECO vacuum filter system were proposed based on the analysis of the displacement and stress of the system. The model with the best result was then optimized using the commercial software, ANSYS. It was confirmed that, in the optimized model, displacement and stress were reduced in comparison with the initial model. Finally, the structural stability of the optimized model was verified through analysis.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.10
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• pp.19-26
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• 2021

In fine-particle injection processing, hard fine particles, such as silicon carbide or aluminum oxide, are injected - using high-pressure air, and a small amount of material is removed by applying an impact to the workpiece by spraying at high speeds. In this study, a two-axis stage device capable of sequence control was developed to spray various shapes, such as circles and squares, on the surface during the micro-particle jetting process to understand the surface-shape micro-particle-processing characteristics. In the experimental device, two stepper motors were used for the linear movement of the two degree-of-freedom mechanism. The signal output from the microcontroller is - converted into a signal with a current sufficient to drive the stepper motor. The stepper motor rotates precisely in synchronization with the pulse-signal input from the outside, eliminating the need for a separate rotation-angle sensor. The major factors of the processing conditions are fine particles (silicon carbide, aluminum oxide), injection pressure, nozzle diameter, feed rate, and number of injection cycles. They were identified using the ANOVA technique on the design of the experimental method. Based on this, the surface roughness of the spraying surface, surface depth of the spraying surface, and radius of the corner of the spraying surface were measured, and depending on the characteristics, the required spraying conditions were studied.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.6
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• pp.98-105
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• 2019

In order to improve the fuel economy and dynamic behavior of automobiles, the weight reduction tendency of automobile parts is obvious. Also, in order to maximize assembly and maintenance convenience, various parts are integrated and modularized. Multi-piece methods require many manufacturing processes and become a factor of lowering the strength of parts. It is advantageous to overcome the disadvantages by integrally manufacturing to reduce the processing steps and ensure the strength of the parts. However, when it is necessary to process in a narrow space inside the part, it is impossible to process with the existing spindle. The angle head spindle is only a component of a machine tool, but it is a core part that requires high technology and is highly utilizable in products requiring high precision machining. Therefore, various and continuous studies needs for angle head spindles in areas such as vibration absorption, operational safety, excellent dimensional stability, and strength. In this paper, we propose an optimal design for angle head spindle by performing structural analysis and shape optimization for angle head spindle gear and case.

• Design & Manufacturing
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• v.13 no.3
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• pp.12-18
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• 2019

Fluid jet polishing is a method of jetting a fluid to polish a concave or free-form surface. However, the fluid jet method is difficult to form a stable polishing spot because of the lack of concentration. In order to solve this problem, MR fluid jet polishing system using an abrasive mixed with an MR fluid whose viscosity changes according to the intensity of a magnetic field is under study. MR fluid jet polishing is not easy to formulate for precise optimal conditions and material removal due to numerous fluid compositions and process conditions. Therefore, in this paper, quantitative data on the factors that have significant influence on the machining conditions are presented using various simulations and the correlation studies are conducted. In order to verify applicability of the fabricated MR fluid jet polishing system by nozzle diameter, the flow pattern and velocity distribution of MR fluid and polishing slurry of MR fluid jet polishing were analyzed by flow analysis and shear stress due to magnetic field changes was analyzed. The MR fluid of the MR fluid jet polishing and the flow pattern and velocity distribution of the polishing slurry were analyzed according to the nozzle diameter and the effects of nozzle diameter on the polishing effect were discussed. The analysis showed that the maximum shear stress was 0.45 mm at the diameter of 0.5 mm, 0.73 mm at 1.0 mm, and 1.24 mm at 1.5 mm. The cross-sectional shape is symmetrical and smooth W-shape is generated, which is consistent with typical fluid spray polishing result. Therefore, it was confirmed that the high-quality surface polishing process can be stably performed using the developed system.

• The Bulletin of The Korean Astronomical Society
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• v.46 no.2
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• pp.76.3-77
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• 2021

GMT secondary mirror system consists of 7 segmented adaptive mirrors. Each segment consists of a thin shell mirror, actuators and a reference body. The thin shell has a few millimeters of thickness so that it can be easily bent by push and pull force of actuators to compensate the wavefront disturbance of light due to air turbulence. The one end of actuator is supported by the reference body and the other end is adapted to this thin shell. One of critical role of the reference body is to provide the reference surface for the thin shell actuators. Therefore, the reference body is one of key components to succeed in development of GMT ASM. Recently, Korea Research Institute of Standards and Science (KRISS) and University of Arizona (UA) has signed a contract that they will cooperate to develop the first set of off-axis reference body for GMT ASM. This project started August 2021 and will be finished in Dec. 2022. The reference body has total 675 holes to accommodate actuators and 144 pockets for lightweighting. The rear surface has a curved rib shape with radius of curvature of 4387 mm with offset of 128.32mm. Since this reference body is placed just above the thin shell so that the front surface shape needs to be close to that of thin shell. The front surface has a concave off-axis asphere, of which radius of curvature is 4165.99 mm and off-axis distance is about 1088 mm. The material is Zerodur CTE class 1 (CTE=0.05 ppm/oC) from SCHOTT. All the actuator holes and pockets are machined normal to the front surface. It is a very complex challenging optical elements that involves sophisticated machining process as well as accurate metrology. After finishing the fabrication of reference body in KRISS, it will be shipped to UA for final touches and finally sent to Adoptica in Italy, in early 2023. This paper presets the development plan for the GMT ASM Reference Body and relevant fabrication and metrology plans.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.3
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• pp.1645-1651
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• 2015

This paper describes the changes of shape accuracy in workpiece materials depending on the turning clearance angle. The experiments started from choosing three workpiece materials, SM45C(machine structural carbon steel), STS303(stainless steel) and SCM415 (chrome-molybdenum steel). The experiments showed specifically how features of selected materials changed when they were processed with diverse machining depths, 0.1 mm, 0.2 mm and 0.3 mm, with various negative angles, $0.0^{\circ}(-6.0^{\circ})$, $0.3^{\circ}(-6.3^{\circ})$ and $0.9^{\circ}(-6.9^{\circ})$, and called cutting edge inclination starting from a fixed rotational speed, 2,500 rpm, focusing on the feed rate, 0.07 mm/rev and 0.10 mm/rev. The results of the accuracy of processing, cylindricity, deviation from coaxiality, etc. were compared using the graph and table. The accuracy of cylindricity in the order of degree $0.0^{\circ}{\rightarrow}0.3^{\circ}{\rightarrow}0.9^{\circ}$ depending on the workpiece materials showed the best cylindricity when it was $0.9^{\circ}$. In conclusion, the accuracy improved in specific degrees irrespective of the quality of the materials when the bite negative angles increased. This means that workability improved in these experiments. In addition, the processing shape changed depending on depth of the cut and feed rate.