• Journal of the Korean Society for Precision Engineering
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• v.18 no.3
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• pp.40-46
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• 2001

An integrated analysis for the thermo-elastic deformation, fatigue, wear and brittle damage evolution of the shrink-fitted die with multi stress-ring of dissimilar materials is presented. A simple numerical algorithm for the moving elastic boundaries characterizing the contacts of the insert and multi stress-rings is presented. The initial stress distribution in the die due to shrink-fit is considered and the traction at the die surface contacting with the work piece is obtained by analyzing the elasto-plastic deformation of work piece. Elastic analysis of the separate-type die is performed and then the evolution of brittle damage, wear and fatigue life are predicted. This integrated analysis is applied to the extrusion die with two layers of stress-rings and the results are discussed in detail.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.26-30
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• 1996

This paper presents the performance of CBN tools in the machining of hardened die-materials, SKD11 and SKD61 steel with HRC 50, by high-speed face milling. Generally, grinding or EDM is being used in machining of hardened materials but the cost is very high. If those can be replaced by cutting, it will be a greatly economical advantage. CBN tool has been recognized as an effective tool in turning, but it has not been in milling. So wear and surface roughness mode of CBN tool for hardened SKD11 and SKD61 steel were investigated by high-speed face milling in this study Also the relation between cutting force and wear mode of CBN tools was investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.158-161
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• 2005

In this paper, the precision electric discharge machining technology, the powder electric discharge machining technology, is applied to making a cold forging die for making the helical type of clutch gear. Various working conditions are investigated with emphasis on reduction of the electrode wear and enhancement of the surface roughness. Through the research work, the key technology of making the helical gear forging dies is achieved.

• Design & Manufacturing
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• v.16 no.3
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• pp.28-33
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• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.05a
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• pp.252-252
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• 2004

새로운 공작기계나 절삭공구의 설계 및 개선을 위하여 절삭 공정 중 발생되는 절삭력 성분을 정확히 예측하는 것이 필요하다. 절삭 과정에서 절삭력 정보의 중요성은 그동안 공작기계 분야에서 익히 강조되어 왔다. 특히 주 절삭력 정보는 공구 파손을 예측하고 마모를 감지하여 그 밖의 다른 오동작을 검출해 내는 것에 있어서 매우 중요한 것으로 잘 알려져 있다. 최근 공작기계 강성 및 성능의 향상, 고속절삭용 공구의 발전, 금형 산업의 생산성과 정밀도 향상의 요구로 머시닝센터를 중심으로 고속가공에 관한 연구가 활발히 진행되고 있다. (중략)

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.19 no.4
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• pp.386-392
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• 2009

This paper reports on the research which investigates acoustic signals acquired in progressive compressing, hole blanking, shearing and burr compacting process. The work piece is the head pin of the electric connector, whose raw material is the preformed steel bar. An acoustic sensor was set on the bed of hydraulic press. Because the acquired signals include the dynamic characteristics generated for all the processes, it is required to investigate signal characteristics corresponding to unit process. The corresponding dynamic characteristics to the respective process were first studied by analyzing the signals respectively acquired from compressing, blanking and compacting process. The combined signals were then periodically analyzed from the grinding to the grinding in the sound frequency domain and in the ultrasonic wave. The frequency of around 9 kHz in the sound frequency domain was much correlated to the tool wear. The characteristic frequency in the acoustic emission domain between 100 kHz and 500 kHz was not only clearly observed right after tool grinding but its amplitude was also related to the wear. The frequency amplitudes of 160 kHz and 320 kHz were big enough to be classified by the noise. The noise amplitudes are getting bigger, and their energy was much bigger as coming to the next regrinding. The signal analysis was based on the real time data and its frequency spectrum by Fourier Transform. As a result, the acousto-ultrasonic signals were much related to the tool wear progression.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2014.11a
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• pp.29-29
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• 2014

최근 화석에너지 고갈 및 에너지 수요의 폭발적 팽창을 해결하기 위하여 경량화와 내마모 측면에서 고효율 시스템을 적용한 자동차 및 각종 성형 기기들이 개발되고 있다. 특히 장치의 고성능화라는 요구조건을 충족시키기 위해서는 금속가공산업에서 표면개질의 중요성이 부각되고 있다. 이러한 표면개질에는 일반적으로 표면의 성질을 개선하여 마모(abrasion) 및 국부 압력(local stress) 또는 피로(fatigue), 마식(wear and corrosion)에 견디게 하여 부품의 수명증대와 제품의 소형화에 기여하고 있다. 이러한 표면개질법에는 경질의 물질을 표면에 코팅시켜 재료표면의 특성을 향상시키는 방법과 금속의 표면에 다른 원소를 침투 및 확산시키는 방법으로 나눌 수 있다. 확산방법으로 침탄, 질화, 보로나이징, 크마이징 처리 방법 등이 있다. 상업적으로 가장 많이 사용되는 표면 개질법은 침탄기술로서, 고온에서 짧은 시간내에 물성 향상이 가능하지만, 강의 변태점 이상의 온도에서 진행됨으로서, 변형에 따른 문제가 발생되어 후처리를 필요로 하는 문제점을 가지고 있다. 반면, 질화법은 변태점 이하의 저온에서 철강 표면에 N을 침투시켜 강을 경화시키는 특징을 가진다. 변형이 적고 질소원자가 강내에 침투함으로 인해 내마모성, 내피로성, 내식성 등의 물리적 성질을 향상시키는 점에서 유리하여 각종 정밀 부품 및 자동차 부품, 금형 등에 많이 사용된다. 또한, 경도 향상 및 결정구조의 영향으로 코팅처리시 모재와 코팅 층의 밀착력 향상을 가져오면 이러한 이유로 코팅 층의 하지 층으로써 각광 받고 있다. 본 발표에서는 플라즈마 질화의 이해를 높이기 위해 관련 기술에 대한 전반적인 소개와 향후 플라즈마 질화 기술의 적용이 기대되는 침탄대체 적용 가능 부품, 침류질화 기술, PECVD 공정과의 접목 등 산업적은 응용 측면에서 응용 분야에 대한 소개를 진행하고자 한다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.9
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• pp.90-96
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• 2021

As real-time data of factories can be collected using various sensors, the adaptation of intelligent unmanned processing systems is spreading via the establishment of smart factories. In intelligent unmanned processing systems, data are collected in real time using sensors. The equipment is controlled by predicting future situations using the collected data. Particularly, a technology for the prediction of tool wear and for determining the exact timing of tool replacement is needed to prevent defected or unprocessed products due to tool breakage or tool wear. Directly measuring the tool wear in real time is difficult during the cutting process in milling. Therefore, tool wear should be predicted indirectly by analyzing the cutting load of the main spindle, current, vibration, noise, etc. In this study, data from the current and acceleration sensors; displacement data along the X, Y, and Z axes; tool wear value, and shape change data observed using Newroview were collected from the high-speed, two-edge, flat-end mill machining process of SKD11 steel. The support vector machine technique (machine learning technique) was applied to predict the amount of tool wear using the aforementioned data. Additionally, the prediction accuracies of all kernels were compared.

• Journal of the Korean institute of surface engineering
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• v.42 no.6
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• pp.272-275
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• 2009

The purpose of this study is to show the friction and wear characteristic behaviors of TiN and CrN coated SKD61 which is applied to Al 6xxx extrusion mold material. The friction and wear characteristic behaviors of both coating layers were investigated by the reciprocating friction wear tester under atmospheric pressure and un-lubricated state. The processing parameters in this study were temperature (50 and $120^{\circ}C$) and load (3, 5, and 11 kgf). This study was carried out while comparing the coefficient of friction and microstructure of TiN and CrN coating layers on SKD61. The coefficient of friction of CrN became lower than that of TiN at all conditions. Therefore, CrN was suggested to be more advantageous than TiN for extrusion mold.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.1
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• pp.31-37
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• 2011

Recently, the technology of surface treatment is being more important which affects the material cost reduction and substitution to the expensive material. The material used for the mechanical processing should have not only high intensity, but also strength toughness, wear resistance and corrosion resistance. In order to increase the durability and have better quality of the parts using such kind of tooling material, various kinds of research of the surface hardening through many kinds of heat resources is being done and practically applied. In this study, the characteristics of hardening surface zone for high strength of the press die material through laser beam irradiation are researched. In this study, it is experimentally observed by the status of the surface morphology, tensile strength, the hardness distribution of the base metal and wear condition by the surface hardness pattern by the laser beam based on the process parameters of $CO_2$ laser by using SM45C and STD11 used for press tool. Through this research, the characteristics of surface hardened zone for high strength of the thin metal by laser beam irradiation is done.