• Journal of the Korean Society for Precision Engineering
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• v.20 no.5
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• pp.57-65
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• 2003

The formation of exit burr in drilling metals is analyzed by finite element method. The simplified burr formation model is suggested for the complex mechanism of burr formation in drilling on the basis of experimental data. Using the model the magnitude of burr is predicted and the effect of material properties of workpiece and cutting condition on burr formation is analyzed in the present study. The suggested model is verified by comparing simulation results and experimental ones. The predicted size and shape of burr are in good agreement with those observed by experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.213-216
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• 2001

A micro hole punching system was developed and micro holes of 100m in diameter were successfully made on brass sheets of loom in thickness. A micro punch made of tungsten carbide was designed to withstand the punch load, considering the buckling and the bending moment due to possible misalignment error. The punch was fabricated by the grinding process with diamond wheel. The die was designed considering the punch load and fabricated by micro electrodischarge machining process. In this system the stripper is designed to guide punch tip to minimize the possible misalignment. The punch was installed on a vertical stepper and the die was mounted on an X-Y translation unit. The precision motion controller controlled all motions of the micro hole punching system. In this study technical difficulties and solutions in the micro hole punching process were also discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.132-135
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• 2006

Injection molding is a flexible production technique for the manufacturing of polymer products, but introduces residual stresses. Residual stresses in a structural material or component are those stresses which exist in the object without other external loads. The layer removal and hole drilling method are used for the measurement of residual stress in injection molded polystyrene part. The hole drilling method is potentially more flexible for determining residual stress in complex geometries and can be used as an adoptable technique for the measurement of residual stress in polymeric materials. Results obtained by experiments agree with each other.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.9
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• pp.109-117
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• 2003

With development of high advanced technologies and skills, micro machining techniques also are being more functional and smaller. Some of the recently developed micro machining technologies are micro drilling, micro EDM, WEDG, LBM, micro milling, micro UVM etc. In these micro machining techniques, Micro -EDM is generally used for machining micro holes, pockets, and micro structures in difficult-cut-materials. For machining micro structures, first of all, tool electrode should be fabricated by WEDG process. In micro-EDM, parameters such as peak current, pulse width, duration time are very important to fabricate the tool electrode and micro structures. Developed experimental equipments are composed of RLC circuit with PWM. In this paper, using developed micro EDM machine, the characteristics of micro electro discharge machining are investigated at micro holes, slot, and pocket machining etc. Also the trends of tool wear are investigated in case of hole and slot machining.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.3
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• pp.134-140
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• 2008

Micro electrochemical machining (ECM) is conducted on stainless steel 304 using non-toxic electrolyte of citric acid. Electrochemical dissolution region is minimized by applying a few hundred second duration pulses between the tungsten SPM tip and the work material. ECM characteristics according to citric acid concentration, feeding velocity and electric conditions such as pulse amplitude, pulse frequency, and offset voltage are investigated through a series of experiments. Micro holes of $60{\mu}m$ in diameter with the depth of $50{\mu}m$ and $90{\mu}m$ in diameter with the depth of $100{\mu}m$ are perforated. Square and circular micro cavities are also manufactured by electrochemical milling. This research can contribute to the development of safe and environmentally friendly micro ECM process.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.2
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• pp.251-256
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• 2011

The radial overcut in micro electrochemical machining was investigated. The prediction of overcut is important not only for the machining accuracy but also for the shape control of micro structures. In micro ECM, machining gap or overcut depends on electrolyte, pulse voltage, pulse duration and dissolution time etc. Understanding of electrochemical dissolution rate is necessary for the overcut prediction. In this paper, the radial overcut of micro electrochemical machining according to pulse duration and dissolution time was simulated using electrochemical principles and also experimentally estimated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.260-265
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• 2002

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.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.10
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• pp.200-207
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• 2001

Burrs farmed in drilling are classified into three types, no burr, burrs with cap, teared burr. To control burr size in drilling, the second type burrs with cap are to be formed because it is small and uniform. It is necessary to understand the mechanism of cap formation to derive the burr formation into second type burr with cap. In several materials. second type burrs are formed in drilling by changing cutting conditions. It is observed that cap is formed as a result of the plastic deformation along the outside of exit hope. According to the tension behavior of the material in concentrated region between hole and drill outside edge, the geometry of burr with cap is determined. Simplified 2D FEM analysis shows good prediction for burr formation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.362-365
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• 2005

The hub hole is usually formed with a flanging process followed by a blanking process of a ]tole. Since the hole is made by blanking, the blanked surface is so rough that the formability in the region is rather poor. The emerging task is to identify the formability of the blanked region in the forming simulation and to relate the criterion to the real forming process by experiments. In this paper, hole expansion tests are carried out with respect to various hole conditions to verify the hole condition effect on the hole expansion ratio. The hole of specimens is made by machining or punching. In the case of punching, two different punching clearances are used for making the hole. From the results of test, fracture mechanism of the hole expansion is explained.

• Transactions of Materials Processing
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• v.16 no.3 s.93
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• pp.157-162
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• 2007

The hydropiercing process gives a lot of advantages to the tube hydroforming such as cost reduction and high productivity. However it has a drawback, the amount of deflection around the hole is bigger than that of conventional die piercing process. The deflection can cause the problem at the assembly process of stamped parts and hydroformed part. Therefore the reduction of deflection is one of the most important issues for hydropiercing process. In this study, the deflection around hydropierced hole was investigated by experiment. As a result of investigation, the amount of deflection is influenced by the internal pressure, the material thickness' and the size of hole. Especially the hole size is most influencing factor on the deflection around the hydropierced hole.