• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.5
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• pp.624-631
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• 2004

In this paper, new replication techniques fur a metal microcomponent having a real 3D shape were introduced. Helical gear was selected as one of a real 3D microcomponents for this study. The helical gear, which was made of photo-curable resin, was fabricated as a master pattern by microstereolithography technology. Then, a silicone rubber mold was fabricated from the master pattern. Lastly, a final bismuth alloy pattern was transferred from the silicone rubber mold by the microcasting process. In this paper, the replication technique is described in detail from the master pattern to the final pattern with some investigation on factors related to the technique.

• Journal of the Korean Society for Heat Treatment
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• v.34 no.6
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• pp.281-286
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• 2021

Arc ion plating (AIP), laser cladding, and nitriding are methods that can prevent mold damage or repair and create cracks and breakages on the die surface. The dissolution and soldering behavior of coated SKD61 by using arc ion plating, laser cladding, and nitriding was investigated. The structure of the coating was investigated as a function of deposition conditions by X-ray diffraction and the crystallographic orientation was determined using the texture factor. The TiAlN film deposited with AIP showed excellent corrosion resistance in the molten aluminum alloy at 680℃. In this paper, we have detailed the corrosion and mass loss phenomena associated with these steel-cast metal interactions.

• Design & Manufacturing
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• v.17 no.1
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• pp.27-32
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• 2023

In this paper, we intend to predict the mass of the spiral using CAE and machine learning. First, We generated 125 data for the experiment through a complete factor design of 3 factors and 5 levels. Next, the data were derived by performing a molding analysis through CAE, and the machine learning process was performed using a machine learning tool. To select the optimal model among the models learned using the learning data, accuracy was evaluated using RMSE. The evaluation results confirmed that the Support Vector Machine had a good predictive performance. To evaluate the predictive performance of the predictive model, We randomly generated 10 non-overlapping data within the existing injection molding condition level. We compared the CAE and support vector machine results by applying random data. As a result, good performance was confirmed with a MAPE value of 0.48%.

• Design & Manufacturing
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• v.17 no.3
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• pp.1-7
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• 2023

Blow molding is a manufacturing process in which thermoplastic preforms are preheated and then pneumatically expanded within a mold to produce hollow products of various shapes. The two-step process, a type of blow molding method, requires the output of multiple infrared lamps to be adjusted individually, so the process of finding initial conditions hinders productivity. In this study, digital twin technology was applied to solve this problem. A blow molding simulation technique was established and simulation-based metadata was generated. A response surface ROM (Reduced Order Model) was built using the generated metadata. Then, a dynamic ROM was constructed using the results of 3D heat transfer analysis. Through this, users can quickly check the product wall thickness uniformity according to changes in the control value of the heating lamp for products of various shapes, and at the same time, check the temperature distribution of the preform in real time.

• The Journal of Korean Academy of Prosthodontics
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• v.42 no.6
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• pp.654-663
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• 2004

Statement of problem. According to the fracture pattern in several reports, fractures most frequently occur in the interface between the ceromer and the substructure. Purpose. The aim of this in vitro study was to compare the macro shear bond strength and microshear bond strength of a ceromer bonded to a fiber reinforced composite (FRC) as well as metal alloys. Material and methods. Ten of the following substructures, type II gold alloy, Co-Cr alloy, Ni-Cr alloy, and FRC (Vectris) substructures with a 12 mm in diameter, were imbedded in acrylic resin and ground with 400, and 1, 000-grit sandpaper. The metal primer and wetting agent were applied to the sandblasted bonding area of the metal specimens and the FRC specimens, respectively. The ceromer was placed onto a 6 mm diameter and 3 mm height mold in the macro-shear test and 1 mm diameter and 2 mm height mold in the micro-shear test, and then polymerized. The macro- and micro-shear bond strength were measured using a universal testing machine and a micro-shear tester, respectively. The macro- and micro-shear strength were analyzed with ANOVA and a post-hoc Scheffe adjustment ($\alpha$ = .05). The fracture surfaces of the crowns were then examined by scanning electron microscopy to determine the mode of failure. Chi-square test was used to identify the differences in the failure mode. Results. The macro-shear strength and the micro-shear strength differed significantly with the types of substructure (P<.001). Although the ceromer/FRC group showed the highest macroand micro-shear strength, the micro-shear strength was not significantly different from that of the base metal alloy groups. The base metal alloy substructure groups showed the lowest mean macro-shear strength. However, the gold alloy substructure group exhibited the least micro-shear strength. The micro-shear strength was higher than the macro-shear strength excluding the gold alloy substructure group. Adhesive failure was most frequent type of fracture in the ceromer specimens bonded to the gold alloys. Cohesive failure at the ceromer layer was more common in the base metals and FRC substructures. Conclusion. The Vectris substructure had higher shear strength than the other substructures. Although the shear strength of the ceromer bonded to the base metals was lower than that of the gold alloy, the micro-shear strength of the base metals were superior to that of the gold alloy.

• Journal of Dental Rehabilitation and Applied Science
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• v.32 no.3
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• pp.246-254
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• 2016

Nowadays, 3 dimentional (3D) printing, especially Direct Metal Laser Sintering (DMLS) system is used in dentistry. DMLS system has recently been introduced for fabrication metal framework for metal ceramic crowns to overcome the disadvantages of the casting method and computer aided design/computer aided manufacturing (CAD/CAM) milling system. DMLS system uses a high-temperature laser beam to selectively heat a substructure metal powder based on the CAD data with the framework design. A thin layer of the beamed area becomes fused, and the metal framework is completed by laminating these thin layers. Utilizing DMLS system to fabricate fixed prostheses is expected to achieve free-from shaping without mold and limitations from cutting tools, fabricate prostheses with complex geometry, prevent distortion and fabrication defects that inherent to conventional fabrication methods. The purpose of this case report is to demonstrate various fixed prostheses such as long span fixed prostheses, post to achieve satisfactory results in functional and esthetic aspects.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.1
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• pp.21-26
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• 2014

When iodine container for dental mouth treatment is opened, thread for treatment is cut by the blade in cap of container. Due to the problem of corrosion in a short period time after the reaction of metal blade to iodine solution, it gives impact on patient hygiene. In order to solve the problem, alternative products such as ceramic blade are developed and produced recently. In case of ceramic blade, it is produced by handwork and machine work. In this study, for the quantity production of ceramic blade with powder injection molding, we proposed a delivery system to have uniform charge of 20 cavity. Using Moldflow, simulation on 20 Cavity flow was performed. And then the mold was obtained through mold production and modification.(based on simulation) After injection molding, debinder, sintering process was achieved for ceramic blade, and the cap product was completed via insert injection on ceramic blade. In this study, we verified possibility of quantity production of ceramic blade which showed effective performance for cutting.

• Design & Manufacturing
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• v.7 no.1
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• pp.45-49
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• 2013

Since the shell-molds are used to make casting the metal parts for the automobile industry, the quality may well be inconsistent with the lower productivity, increasing the cost of the end products. The primary elbow design shell molded steel castings being produced through extrusion process has $180^{\varnothing}$ O.D., $150^{\varnothing}$ I.D., 14mm thickness and 400mm length, while being processed onto the left side of the tubing. The primary cause for the poor processing is the uneven manual shell molding. If the manual shell molds should be produced to have even quality, they would not be processed for tube linking. The purpose of this study was to develop the flask-molds for manufacturing of the shell molds to ensure mass-production, consistent quality, ommission of processing and comfortable working environment. For this purpose, four flask-molds were produced and thereby, four shell molds were assembled. In particular, the shell molds for processing were formed of the fine coated sand to be blown. As a result, productivity increased about three times, while a consistent quality was ensured. Furthermore, the tubes could be linked with each other without being processed, while pallets could be stacked, stored, transported and managed more easily. In a nut-shell, the molding theory could be applied more effectively. However, it is conceived that this study should be followed up by future studies which will research into reliability and endurability of the end products.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.1
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• pp.35-40
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• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Design & Manufacturing
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• v.14 no.3
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• pp.17-22
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• 2020

As devices such as smartphones, tablet PC, and wearable devices have been miniaturized, the connectors that go into the devices are also designed to be very small. The connector combines the plug and the receptacle to transfer electricity. As devices are miniaturized, the contact shape is formed by partially thinning the thickness of the raw material of the terminal in order to lower the coupling height of the plug and receptacle. The product used in this study is a receptacle terminal used for 0.4mm pitch board to board connector among fine pitch connectors. When the material thickness is reduced by forging the receptacle terminal, the width change of the pin is checked. To reduce the thickness of the material by forging, pre-notching is applied in the first step, forging in the second step, and notching in the third step. After forming the width dimension of the pin to 0.28 mm in the pre-notching process, in the forging process, the material thickness 0.08 mm and 0.02 mm (25%) were forged and the thickness was changed to 0.06 mm and the width change amount of the pin was measured. The facility produced 10,000 pieces at 400 SPM using a Yamada Dobby (MXM-40L) press, and thirty pins were measured and the average value was shown. After forging by using C5210-H (HP) and NKT322-EH, which are frequently used in connectors, analyze the amount of change in each material. The effect of punching oil on forging is investigated by appling FM-200M, which is highly viscous, and FL-212, fast drying oil. This study aims to minimize mold modification by predicting the amount of material change after forging.