In this study on machine measuring system based on solid feature was developed. This system was applied with injection mold using 3 dimensional solid modeler for verification. Developed program include pre-processor, main processor, and post processor. In pre-processor there are functions which check intersection, simulate motion of probe and calculate measuring time. Main processor generates measuring path and output NC code in Unigraphics. In post-processor functions that include evaluation of undercut or overcut and display of measuring procedure are offered. In addition analysis module for quality control of measured data on manufactured product was developed with geometric and dimensional tolerance concept. As the result developed program could get stability of system, precision of product, rapidity and cost down of manufacturing process compared with before measuring process.

The STD11 and KP4 are important steels and applied to the manufacturing of the die and mold. The purpose of this study is to investigate the machinability of tool steels of STD11(HRC60) and KP4(HRC32) when machining them by using ball end milling tools coated with TiAlN. Cutting forces by using a Kistler piezo-cell type tool dynamometer, surface roughness and tool wear by using tool microscope are used in the tests. The results from the cutting tests of KP4 specimens show that 85m/min. of cutting speed and 0.32mm/rev. of feed per revolution are optimum conditions for the higher productivity and 0.26mm/rev. with the same cutting speed are optimum conditions for better surface finishing. The results from machining STD11 workpiece at 30m/min. of cutting speed and 0.17m/rev. of feed per revolution show recommended for the higher productivity. The KP4 shows relatively smaller cutting forces than STD11 and STD11 shows the better surface finish than KP4.

Profile machining using cutter diameter compensation is widely used in die and mould manufacturing. Especially automotive die makers try to use 3D-profile machining for trimming or flange dies. But the technological requirements and implementation issues haven't been defined. In this paper we summarized the requirements and issues of 3D-profile machining. Approximation of input profiles into sequences of line and helical arc is the first major issue. The second major issue is removing cutter interference from the approximated curves holding z-values when the maximum cutter diameter is given. Keeping constant machining width, local machining, path linking problems and several detail technological requirements are also discussed.

Die Factory follows typical order adaptive manufacturing, and delaying delivery affects directly product development of customer, Manufacturing Management System is tried to comply with the appointed date of delivery. It acquires running signal from NC milling, calculates manufacturing results, and offers the basic data to manage the operation ratio. Thus it offers Production data necessary to accomplish the objective of progress improvement for Unmanned Manufacturing. Manufacturing Management System runs on Web Environment, and is composed of electronic work order, operation ratio data acquisition and totaling module.

Recently, the development of aerospace and automobile industries brought new technological challenges, related to the growing complexity of products and new geometry models. High speed machining using 5-Axis milling machine is widely used for 3D sculptured surface parts. 5-axis milling of turbine blade generates the vibration, deflection and twisting caused from thin and cantilever shape. So, the surface roughness and the waviness of workpiece are not good. In this paper, The effects of cutter orientation and lead/tilt angle in 5-Axis high speed ball end-milling of turbine blade were investigated to improve the geometric accuracy and surface integrity. The experiments were performed at lead/tilt angle $15^{\circ}$ of workpiece with four cutter directions such as horizontal outward, horizontal inward, vertical outward, and vertical inward. Workpiece deflection, surface roughness and machined surface were measured with various cutter orientations such as cutting direction, and lead/tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle. The results show that when 5-axis machining of turbine blade, the best cutting strategy is horizontal inward direction with tilt angle.

The present work is investigated optimal design for the injection molding process of a hand brake cover. The viscoelastic flow through a hand brake cover shape in the mold were calculated and compared with the experimental data. Numerical analysis reasonably predicted the general performance i.e hold pressure, cooling time and hold pressure time. In order to determine optimal process parameters, Numerical analysis and experiments have been performed for various process conditions. In this study, we obtained to increase in the productivity by $160\%$ by optimal process conditions.

Most of numerical analyses for injection molding have been based on the Hele Shaw's approximation: two-dimensional flow analysis. In some cases, that approximation causes significant errors due to loss of geometrical information as well as simplification of the flow characteristics along the thickness direction. The present work covers numerical analyses of injection molding using three-dimensional solid elements. The accuracy of the analysis results has been verified through some numerical examples in comparison with the classical shell-based approach. The proposed approach are then applied to predict product defects and to improve flow characteristics for a precision electronics part. In addition, design of experiment has been utilized in order to find the optimal process conditions for better product quality.

The injection molding of the plastic optics is basically same as the conventional molding except it requires very intricate control of all the molding processing parameters. In the plastic optics, the problem of injection molding is the shrinkage. The shrinkage must be removed and predicted. This shrinkage is becoming more important than any other problems in precision molding because it can affect the focal length of a lens or the total performance of the optical system. This study focused on avoiding the shrinkage that the mold design allows for the optics. In making mold, the surface accuracy(P-V) of the lower and lower mold are $0.201{\mu}m\;and\;0.434{\mu}m$ respectively. A surface roughness(Ra) is below $0.02{\mu}m$ due to selecting the appropriate tools and using the injection molding machine in high degree. In injection molding of the plastic lens, mold temperature, resine temperature and injecting pressure are important process parameters. Injection molding process is carried out according to varying mold temperature and injecting pressure. As a result P-V(peak to valley) of spheric lens is $3.478{\mu}m$ and that of aspheric lens is $1.786{\mu}m$.

With recent trends leaning towards product miniaturization, the advent of new material and speedy delivery times, old style conventional trial-and-error methods have been only serving to weaken corporate competitiveness. Reliant on tiny increments of time-consuming experience, this antiquated approach begets a delayed delivery of product development, cost loss and quality depreciation. To solve such problems, the Dedicated Injection Molding CAPA (Computer Aided Plastics Application) performs a preliminary examination on problems rising from every stage of creation - from appropriate material selection and mold design to mass production - through a computer system. Thus, it determines the optimum design variables and process conditions while diagnosing and solving defective molds.

The gas injection molding technique(GIT) is a special injection molding process and has been an established and acknowledged process technique for many years. GIT has proved successful in cases where warpage has to be minimized, sink marks avoided and material input reduced. The classic field of application for GIT, however, is the production of thick-walled, rod shaped parts or hollow articles. Through this application, the handle part for automobile is molded and this part is consequently used as a insert for the additional injection molding process encapsulated with PVC.

Surface defects in injection molded parts are due to the unsteady flow of polymer melt which are related to the geometries of cavity and gate, the operational conditions of injection and the rheological properties of polymer. In this study we have examined jetting phenomena in injection molding process for three kinds of PCs which have different molecular weight and structure, PBT and PC/ABS alloy with several injection speeds. We have used various cavity shapes that are tensile, flexural and impact test specimens with various gate and cavity thicknesses. Through this study we have observed that the formation of surface defect associated with jetting during filling stage in injection molding is strongly related to die swell. This means that the jetting is strongly affected by the elastic property rather than the viscous property in viscoelastic characteristics of molten polymer. Large die swell would eliminate jetting however, the retardation of die swell would stimulate jetting. In the point of mold design, reducing the thickness ratio of cavity to gate can reduce or eliminate jetting and associated surface defects regardless of magnitude of elastic property. It also enlarges process window that can produce steady flow of polymer melt in injection molding.

Warm draw die technique which is one of the new forming technologies to improve formability of sheet metal is applied to the cylindrical and square cup drawing of stainless-aluminum clad sheets. In experiments the temperature of die and blank holder is varied from room temperature to $180^{\circ}C$, while the punch is cooled by circulation of coolant to increase the fracture strength of workpiece on the punch comer area. Test materials chosen for experiments are STS304-A1050-STS304 clad sheets. Teflon film as a lubricant is used on both sides of a workpiece. The limit drawing ratio and relative drawing depth as well as quality of drawn cups(distribution of thickness)are investigated and validity of warm drawing process is also discussed. No separation between each laminated material after drawing occurred through inspection by microscope as well as application of penetrant remover and bond strength test. Therefore, warm forming technique was confirmed to give better results in deep drawing of stainless clad sheet metal.

In this study, springback analysis of side rear member is carried out. Side rear member is one of the parts which shows severe springback problems. Forming, trimming, flanging and springback stages can be analyzed successively. From forming analysis, we identified the possible spots in which tearing may occur and can prevent failure. In springback analysis we used the boundary conditions same as applied to the blank on the checker so that the computational result can be compared with experimental one. Form .the comparison, springback analysis can yield relatively good results in a qualitative sense. However, in order to get good deformation result quantitatively, there still remains unsettled tasks in the forming analysis with very small die radius. It is found that we have to develop the element with better bending characteristics and precise contact treatment.

Spring back is the typical deformation of pressing process. This phenomenon much affects productivity and especially Incurs the unexpected result of assembling process. We have been searching for the various of the spring back to minimize spring back effect, because it is inevitable.

The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce Al, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared as the die-castings and the thin walls of the plaster mold cavity may not be completely fillet Because of lower mechanical properties induced by the large grain structure and incomplete Idling, the conventional plaster casting process is not suitable for the trial die-casting Process. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have runner system, are made using these patterns. Imparted pressurized vibration to molten metal has made grain structure of castings much finer and improved fluidity of the molten metal enough to obtain complete filling at thin walls which can not be filled in the conventional plaster casting process.

This paper describes the experimental results on direct selective laser sintering of WC-Co mixture for rapid tooling. The experiments were carried out within an air, argon and nitrogen atmosphere. Coupons of single layer were sintered at various laser powers, scanning speeds and scan spacings. As the energy density (energy per unit scanned area) is increased, the thickness of coupons is increased. The main problem took place during sintering within an air atmosphere was severe oxidation of WC-Co mixture. As the laser power is increased and/or scanning speed is decreased, more severe oxidation occurred. Within an argon and nitrogen atmosphere the oxidation is reduced significantly. Experiments on multi-layer sintering were also carried out.

As in most metal forming processes, die and lubrication are of vital importance in hydrostatic extrusion. An efficient die design and lubrication system selection reduce the pressure required for a given reduction ratio by lowering friction at the billet-die interface. In contrast to the conventional macroscopic extrusion, fine-wire fabrication requires higher extrusion pressure and effect of friction is much more significant. Forming fine Au, Ag, and Cu wire with hydrostatic extrusion process in cold condition, the effect of extrusion die angle, lubrication and billet's initial diameter was studied.

미세 절삭에 의한 마이크로 형상가공 및 이를 이용한 미세금형 가공기술개발을 위하여 절삭 공구를 이용한 기계적 미세 가공법에 대한 고찰과 더불어 shaping, end-milling, drilling 등의 가공이 가능한 기계적 미세 가공시스템을 구성하고 이를 이용한 미세 치형 그루브와 미세 격벽 등 미세 형상 구조의 금형 개발을 위한 가공실험을 수행하였다. 본 실험에서는 먼저 shaping 방식으로 세 종류의 다이아몬드 바이트를 사용하여 알루미늄, PMMA, Nickel, 황동 등의 소재에 pitch $150{\mu}m$, 높이 $8{\mu}m$ 내외의 미세 치형의 금형 코어를 가공하였고, 다음으로 Z축에 air spindle을 설치하여 $\phi0.2mm$의 end-mill(WC)을 사용하여 황동 소재에 깊이 $200{\mu}m$, 폭 $200{\mu}m,\;100{\mu}m,\;50{\mu}m,\;30{\mu}m$의 두께 변화를 주어 미세 격벽에 대한 가공실험을 하였다. 미세 구멍가공실험으로는 drilling 전용장비를 구성하여 $\phi0.6\~0.15mm$의 drill공구로 SM45C와 세라믹$(Si_3N_4-BN)$ 소재에 스텝이송방식에 의한 미세 구멍 가공 실험을 실시하였다.

In this study, we developed the manufacturing technology of micro-hole and micro-shaft for micro punching system using micro electrical discharge machining and micro electro chemical machining. Micro punching dies of tungsten carbide with $55\;{\mu}m\;and\;110\;{\mu}m$ diameter and $250\;{\mu}m$ depth were made by micro electrical discharge machining. The form accuracy and surface roughness of die hole were pretty good and it was shown that the punched hole quality was fine. WC micro-shaft with $30\;{\mu}m$ diameter was made by the multistep micro electro chemical machining. The developed technologies can be effectively used in precision manufacturing of micro punching die and mass production of micro-shaft.

Ultrasonic machining technology has been developed over recent years for the manufacture of cost-effective and quality-assured precision parts for several industrial application such as optics, semiconductors, aerospace, and automobile. Ultrasonic machining process is an efficient and economical means of precision machining of ceramic materials. The process is non-thermal, non-chemical and non-electric md hardly creates changes to the mechanical properties of the brittle materials machined. This paper describes the characteristics of the micro-hole of $Al_2O_3$ by ultrasonic machining with tungsten carbide tool. The effects of various parameters of ultrasonic machining, including abrasives, machining force and pressure, on the material removal rate, hole quality, and tool wear presented and discussed. The ultrasonic Machining of micro-holes in ceramics has been under taken and the machining mechanism in the ultrasonic machining of ceramics based on the fracture-mechanics concept has been analyzed.

Micro cell structures with high aspect ratio were fabricated by injection molding method. The mold inserts had dimension $1.9cm\times8.3cm$ composed of a lot of micro posts and were fabricated by LIGA process. The size of the micro posts was $157{\mu}m\times157{\mu}m\times500{\mu}m$ and the gaps between two adjacent posts were $50{\mu}m$. Using Polymethylmethacrylate (PMMA) injection molding was performed. The key experimental variables were temperature, pressure, and time. By controlling these, good shaped mim cell structures with $50{\mu}m$ in wall thickness and $500{\mu}m$ in depth were obtained. In order to understand micro molding mechanism, shape changes of molded PMMA were studied with experimental variables. And the durability of mold insert was investigated, too. The results show that the most important factor in molding processes was the mold temperature that is closely related to the filling of the melt into the micro cavity. And the holding time before cooling showed a great effect on the quality of molded PMMA.

In micro hole punching process, it is very difficult to align punch with die hole. Misalignment can cause a falling-on in hole quality and breakage of punch and die. Micro punching using soft die plate without a die hole has a big advantage because it is not necessary to align punch with die hole and to consider die clearance. Soft die plates are made by polymers or hard rubbers which are softer than metals. In this study, several micro punching experiments are conducted. Micro punching test with some materials shows that micro hole punching is feasible with some soft die plates. Through the section shape obtained by mounting and polishing, the punched hole quality is measured and the shapes of burr and dome we studied.

Milli-structure components are classified as a component group whose size is between macro and micro scales, that is, about less than 20mm and larger than 1mm. The bending of these components of thin sheets has a typical phenomenon of bulk deformation because of the forming size. The recent trend towards miniaturization causes an increased demand for parts with very small dimensions. The conceptual miniature bending process enables the production of such parts with high productivity and accuracy. The stress values of the flow curve decrease with miniaturization, which means that coarse grained materials show a higher resistance against deformation, when the grain size is in the range of the sheet thickness. In this paper, a new numerical approach is proposed to simulate intergranular milli-structure in forming by the finite element method. The grain element and grain boundary element are introduced to simulate the milli-structure of strip in the bending. The grain element is used to analyze the deformation of individual grain while the grain boundary element is for the investigation on the movement of the grain boundary. Also, the result of the finite element analysis is confirmed by a series of milli-sized forming experiments.

Deep drawing process for rectangular drawn section is different with that for axisymmetric circular one. Therefore deep drawing process for rectangular drawn section requires several intermediate steps to generate the final configuration without any significant defect. In this study, finite element analysis for multi-stage deep drawing process for high precision rectangular cases is carried out especially for an extreme aspect ratio. The analysis is performed using rigid-plastic finite element method with an explicit time integration scheme of the commercial program, LS-DYNA3D. The sheet blank is modeled using eight-node continuum brick elements. The results of analysis show that the irregular contact condition between blank and die affects the occurrence of failure, and the difference of aspect ratio in the drawn section leads to non-uniform metal flow, which may cause failure. A series of experiments for multi-stage deep drawing process for the rectangular cases are conducted, and the deformation configuration and the thickness distribution of the drawn rectangular cases are investigated by comparing with the results of the numerical analysis. The numerical analysis with an explicit time integration scheme shows good agreement with the experimental observation.

The shearing process for the sheet metal is normally used in the precision elements such as a frame of TFT-LCD or lead frame of If chips. In these precision elements, the burr formation prevents the system assembly and needs the additional burr removing process. In this paper, we developed the small size NC punching system which has an aligning kinematics between the rectangular shaped punch and die. The punch is driven by an ai cylinder and the sheet metal is moving on the X-Y table system which is driven by two stewing motors. The microprocessor control the whole system and communicate with the monitoring PC by RS232C serial communication protocol. The graphic user interface program in PC monitors nil control the punching system. The cross shaped joint hinge supports the punching die and positioned by two differential screws, whose are installed in perpendicular directions. The aligning between the punch and die is performed using the sheets of half thickness(0.1mm Brass) of the real process for the frame of the TFT-LCD. Using half thickness Brass, the burr formation is magnified and we can decide the aligning direction more easily then using the real thickness(0.2mm) Aluminum. In this paper, the aligning results are measured manually using the SEM photographs and we hope to make the automated aligning procedures using some kinds of image processing techniques.

In recent automotive industries, fine blanking technology widely used in production of components with relatively thick gauges in brake systems, seat recliner, door locks, and auto transmission systems. Due to its advantages to obtain almost final product quality using fine blanking forming process without additional finish machining processes, consequently saving the production costs. In this paper we intended to develope the small sized module gear toothed dual seat recliner sector gear(0.5mm module) for car seats using fine blanking process which needed semi piercing with computer simulation and a lot of try and errors to achieve required accuracy and geometric quality. However through the some corrections of tool geometries with tryout test, we could get successful results.