• Journal of the Korean Society for Precision Engineering
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• v.14 no.5
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• pp.53-59
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• 1997

This study has been performed to inmvestigate MRR(metal removal rate), REW(relative electrode wear), surface roughness, heat transumutation layer and microhardness distribution in cross-section of the machined surface with various pulse-on duration and peak pulse current, using the copper and graphite electrode on the heat treated STD11 which is extensively used for metallic molding steel with the EDM. The results obtained are as follows; a) There exists critical pulse-on duration(If Ip equals 5A, .tau. on is 50 .mu. s) which shows the the maximum MRR in accordance with peak oulse current and the MRR decreases when the pulse-on duration exceeds the critical pulse-on during because of the abnormal electric discharge. b) Safe discharge is needed to make maximum of MRR and the metalic organization must be complicated for discharge induction. c) Graphite has much more benefits than copper electrode when rapid machining is done without electrode wear. d) The most external surface has the highest microhardness because of car- burizing from heat analysis of the dielectric fluid and the lower layar of the white covered layer has lower microhar dness than base matal because of softening.

• Proceedings of the KAIS Fall Conference
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• 2006.05a
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• pp.196-199
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• 2006

프레스금형의 부품 중에서 펀치와 다이플레이트를 제작하는데 주로 W-EDM을 이용한다. W-EDM전에는 기계가공으로 제작된 펀치와 다이플레이트로 제품을 생산하게 되면 생산량이 200만${\sim}$230만개를 생산하고 금형수명을 다하였다. 그러나 W-EDM으로 제작된 금형으로 제품을 생산하게 되면 생산수량이 70만${\sim}$80만개를 생산하고 금형수명이 다하였다. 이것은 W-EDM한 후에 발생되는 가공변질층에 기인하는 것으로 사료되므로 W-EDM전과 W-EDM후의 가공면에 대한 SEM촬영을 실시하여 가공변질층의 발생을 확인하고 이에 대한 제거방법을 연구하였다.

• Proceedings of the Korean Vacuum Society Conference
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• 2011.02a
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• pp.345-345
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• 2011

MgO는 암염구조를 가진 전형적인 이온 결합성 화합물로서 7.8eV의 띠틈을 갖고 흡습성이 강하다. 면 방전 구조 PDP에서 MgO 보호막은 면 방전으로 인한 유전층의 식각을 보호하고 2차 전자 방출을 통해 방전 전압을 낮추는 역할을 한다. 하지만 MgO 보호막은 증착시 흡수된 수분이 제거되어야 하고, 방전 특성 개선 및 방전 효율 향상을 위해 가공 처리에 관한 연구가 진행 되어야 한다. 본 연구는 MgO 보호막의 전자적 특성의 변화를 알아보기 위해 $O_2$ 분위기에서 전자빔 증착법을 이용해 MgO Powder를 사용하여 시료를 제작하였다. 표면에 흡착된 수분제거로 인한 특성 변화를 알아보기 위해 진공 챔버내에서 시료를 $500^{\circ}C{\sim}550^{\circ}C$의 열처리를 실시한 후 XPS(X-ray Photoelectron Spectroscopy), REELS(Reflection Electron Energy Loss Spectroscopy), UPS(Ultraviolet photoelectron Spectroscopy)를 이용하여 전자적 특성을 연구하였다. XPS 측정결과 시료의 열처리를 통해 C1s spectrum의 O-C=O(289eV) binding energy가 없어져 박막에 흡착된 불순물이 제거 되었으며 O1s spectrum에서 Hydroxides가 감소하고 530.0eV의 MgO 결합에너지쪽으로 커짐으로써 박막의 구조를 확인할 수 있었다. 그리고 $O^2$ 분위기에서 성장시킨 MgO 박막 기판을 열처리 후 REELS를 이용해 띠틈을 얻어보면 Ep=500eV에서 띠틈이 6.77eV, Ep=1500eV에서 띠틈이 7.33eV로 각각 측정되었다. Ep=500eV의 REELS 스펙트럼으로부터 산소 결함에 의한 표면 F Center는 4.22eV로 확인되었다.

• Composites Research
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• v.19 no.2
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• pp.13-19
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• 2006

In this paper, parametric study was carried out to design sandwich structures for EDM machines controlling stacking sequence, stacking thickness of composites and rib configuration. Sandwich structures which are dealt with in this paper are composed of fibre reinforced composite for skin material and foam or resin concrete for core materials. The sandwich column has cruciform rib to enhance bending stiffness of the structure and the bed has several vertical ribs to resist the normal forces and vibration. The design parameters such as rib thickness and stacking sequence were controlled to enhance the system robustness. Finite element analysis was also carried out to verify the variation of static and dynamic stiffness of the structures according to the variation of the parameters. Vibration tests were performed to verify the natural frequencies and damping ratios of the manufactured composite structures. The appropriate shape and configuration conditions for micro-EDM machine structures are proposed.

• Design & Manufacturing
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• v.1 no.1
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• pp.23-26
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• 2007

This paper has comparatively analyzed the characteristics of the machined surface of a specimen made by machining Die Steel STD11 and a specimen obtained by W-EDM steel. If a press die is manufactured through W-EDM, products of shapes that cannot easily be made through machining can be manufactured easily. However, the life of the press die is significantly reduced compared with the press die made through machining. This is believed to be caused by the deformed layer that has occurred on the surface of the press die that was made through W-EDM. The roughness of the 2 specimens was measured, and it was learned that the distribution of the roughness of the specimen made through the 1st W-EDM was rough.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.1
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• pp.21-26
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• 1993

A study on the fatigue fracture at electro discharge machined(E.D.M) surface has been made with special emphases on the microstructure variation and the residual stress distribution at the E.D.H heat affected zone. Results obtained are summarized as follows. (1) E.D.M brings about a variation of microstructure in heat affected zone, structures of molten, quenching, tempering are formed in order of formation from E.D.M surface. (2) Residual stress generated by E.D.M reduces the fatigue strength of the material through the influencing fatigue crack initiation and growth. (3) Magnitude of the residual stress existed in a microscopic area is approximately estimated by a COD measurement method which was originally suggested by authors.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.7 no.4
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• pp.545-549
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• 2006

W-EDM is generally used to manufacture punches and die plates from among press mold parts. Before W-EDM was used, however, punches and die plates manufactured via mechanical processing were used to manufacture products, with the die life of the mold expiring after 2,000,000~2,300,000 products have been manufactured. When the mold manufactured through W-EDM was used, however, its service life expired only after 700,000~800,000 products have been manufactured. Since this was attributed to the deformed layer formed after using W-EDM, the surfaces before and after W-EDM was used were scanned using SEM to verify the occurrence of such layer. This study sought to come up with a method of eliminating such phenomenon.

• Transactions of Materials Processing
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• v.22 no.1
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• pp.23-29
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• 2013

In this study, a micro/nano-random-pattern-structure surface was machined by electric discharge machining (EDM) followed by replicating the EDM surface with a silicone elastomer having low energy and greater hydrophobicity. The variation of hydrophobicity was of prime interest and was examined as a function of the surface roughness of the replicated silicone elastomer. The hydrophobicity was evaluated by the water contact angle (WCA) measured on the relevant surface. For the experiments, the original surfaces were machined by die sinking electric discharge machining (DS-EDM) and wire cutting electric discharge machining (WC-EDM). The ranges of surface roughness were Ra $0.8{\sim}19{\mu}m$ for the DS-EDM and Ra $0.5{\sim}4.7{\mu}m$ for the WC-EDM. In order to fabricate a hydrophobic surface, the EDM surfaces were directly replicated using a liquid-state silicone elastomer, which was thermally cured. The measured WCA on the replicated surfaces for DS-EDM was in the range of $115{\sim}130^{\circ}$ and for WC-EDM the WCA was in the range of $123{\sim}150^{\circ}$. Additionally, the dynamic hydrophobicity was evaluated by measuring an advancing and a receding WCA on the replicated silicone elastomer surfaces.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.1
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• pp.49-54
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• 2010

Rotor pole for AC(alternating current) generator is manufactured through transfer warm forging die. As soon as the material is heated at the warm manufacturing process, it is transferred to the first stage for upsetting work and then to the second stage for lateral extrusion work. The processes at the lateral extrusion work such as die block, die bushing, center punch, and side punch make severe condition and abrasion which leads to shorten the die life. This causes production decrease, long maintenance time, and low level of precision. Research on the die material selection, heat process cycle improvement, electric discharge machining trouble solution, and re-construction of main parts is expected to find a method to lengthen the die life up to 40 - 50%.