• Journal of the Korean Society for Precision Engineering
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• v.15 no.7
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• pp.85-90
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• 1998

The business of manufacturing is increasingly becoming time-compressing, precise and long-life oriented, owing to various needs from the consumers and harsh global competition. With the emergence of the layer laminate manufacturing method, it is possible to produce prototypes directly from 3D CAD and additive process, the production time and cost have shortened dramatically. However there are some problems like surface-step, dimensional deviation and warp. A newly developed powder casting is suitable for rapid-manufacturing metallic tools. Powder casting can serve as a promising rapid tooling method because of high density characteristics and low dimensional shrinkage below 0.1％ during sintering and infiltration. By this process, we have realized significant time savings bypassing the wait for prototype tooling and cost savings eliminating the expense of conventional prototype tooling process.

• Design & Manufacturing
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• v.13 no.1
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• pp.5-12
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• 2019

In this paper, we studied the micro tool deflection, micro cutting with low temperature, and deformation of micro ribs caused by cutting forces. First, we performed an integrated machining error compensation method based on captured images of tool deflection shapes in micro cutting process. In micro cutting process, micro tool deflection generates very serious problems in contrast to macro tool deflection. To get the real images of micro tool deflection, it is possible to estimate tool deflection in cutting conditions modeled and to compensate for machining errors using an iterative algorithm correcting tool path. Second, in macro cutting fields, the cryogenic cutting process has been applied to cut the refractory metal but, the serious problem may be generated in micro cutting fields by the cryogenic environment. However, if the proper low temperature is applied to micro cutting area, the cooling effect of cutting heat is expected. Such effect can make the reduction of tool wear and burr formation. For verifying this passibility, the micro cutting experiment at low temperature was performed and SEM images were analyzed. Third, the micro pattern was deformed by the cutting forces and the shape error occurred in the sidewall multi-step cutting process were minimized. As the results, the relationship between the cutting conditions and the deformation of micro-structure during micro cutting process was investigated.

• Design & Manufacturing
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• v.12 no.3
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• pp.36-41
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• 2018

Metal 3D printing is very useful for making the injection molds containing complex conformal cooling channels. The most important issue of the 3D printed molds is cost and life cycle. However, powder bed fusion (PBF) methods are vulnerable to fatigue loading because of the presence of pores and rough surfaces. In the present study, the fatigue test was performed to obtain fatigue analysis input data for predicting the durability of a 3D printed injection mold core. The metal 3D printer used to manufacture the specimen was OPM250L from Sodick, and the metal powder material was maraging steel. The ultrasonic fatigue testing method was adopted for the fatigue test. A key advantage of the ultrasonic fatigue method is that $10^8{\sim}10^9$ long cycle test data or more could be obtained within a relatively short period. Based on the results of the experiment, the effect of heat treatment was negligible. However, there was an apparent difference in durability depending on the presence or absence of the surface treatment.

• Transactions of Materials Processing
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• v.26 no.4
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• pp.240-245
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• 2017

Mixed-model production technology is a method of producing multiple products with one production process and production line in order to reduce wasted manpower and adjust to market trends. In other words, mixed-model production is a flexible production system that changes production volume by model according to market demand. This study has developed a progressive laminated stamping die technology to enable flexible production of a motor core consisting of attaching and detaching the Cam on the back of the punch so that two kinds of stator and two kinds of rotor could be produced in one progressive die.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.186-190
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• 1996

The technology of LASER lamination joining of sillicon steel sheets has been studied in this paper. Conventional sheets lamination process does not meet the requirments for the improvement electric parts performance. In response to this, a new LASER spot joining method has been developed. This study performs the SASER spot lamination joining while synchronizing the sillicon steel sheets in the dies with the press movement. Several conclusions have been drawn in this paper. Effects of beam focus, power, atmosphere gas and press oil etc.

• Proceedings of the CALSEC Conference
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• 2001.08a
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• pp.105-109
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• 2001

성형의 종류 ◈금속 성형 ㆍ 스탬핑(Stamping) ㆍ 정밀 블랭킹(Fine Blanking) ㆍ 딥 드로잉(Deep Drawing) ㆍ 다이캐스팅(Die Casting) ㆍ 인베스트먼트 주조(Investment Casting) ㆍ 분말 야금(Power Metallurgy) ㆍ 인발(Wire Drawing) ㆍ 압출(Extrusion) ㆍ 단조(Forging) ㆍ ㆍ코이닝(Coining) ㆍ... ◈비금속 성형 ㆍ 사출(Injection) ㆍ 압축(Compression) ㆍ 블로우 성형(Blow Molding) ㆍ 진공 성형(Vacuum Molding) ㆍ 발포 성형(Foam Molding) ㆍ 피복(Encapsulation) ㆍ 회전식(Rotational) ㆍ 주조(Casting) ㆍ 적층(Laminating) ㆍ 압출(Extrusion) ㆍ...(중략)

• Korean Journal of Metals and Materials
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• v.50 no.2
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• pp.107-115
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• 2012

Direct laser melting (DLM) is a powder-based additive manufacturing process to produce parts by layer-by-layer laser melting. As the properties of the manufactured parts depend strongly on the deposited laser-melted bead, deposited layers obtained by the DLM process were characterized in this study. This investigation used a 200 W fiber laser to produce single-line beads under a variety of different energy distributions. In order to obtain a feasible range for the two main process parameters (i.e. laser power and scan rate), bead shapes of single track deposition were intensively investigated. The effects of the processing parameters, such as powder layer thickness and scan spacing, on geometries of the deposited layers have also been analyzed. As a result, minimum energy criteria that can achieve a complete melting have been suggested at the given powder layer thickness. The surface roughnesses of the deposited beads were strongly dependent on the overlap ratio of adjacent beads and on the energy distributions of laser power. Through microstructural analysis and hardness measurement, the morphological and mechanical properties of the deposited layers at various overlapped beads have also been characterized.

• Design & Manufacturing
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• v.16 no.2
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• pp.1-6
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• 2022

As environmental regulations are strengthened, automobile manufacturers continuously research lightweight structures based on carbon fiber reinforced plastic (CFRP). However, it is difficult to see the effect of strength reinforcement when using a single CFRP material. To improve this, a hybrid laminate in which CFRP is mixed with the existing body structural steel was proposed. In this paper, CFRP patch reinforcement is applied to each compression/tensile action surface of a 22MnB5 metal sheet, and it was evaluated through a 3-point bending experiment. Progressive failure was observed in similar deflection on bending deformation to each one-sided reinforced specimen. After progressive failure, the tensile reinforced specimen was confirmed to separate the damaged CFRP patch and 22MnB5 sheet from the center of the flexure. The compression reinforced specimen didn't separate that CFRP patch and 22MnB5, and the strength reinforcement behavior was confirmed. In the compression reinforced specimen, damaged CFRP patches were observed at the center of flexure during bending deformation. As a result of checking the specimen of the compression reinforcement specimen with an optical microscope, It is confirmed that the damaged CFRP patch and the reinforced CFRP patch overlapped, resulting in a concentrated load. Through the experimental results, the 22MnB5 strength reinforcement characteristics according to the reinforcement position of the CFRP patch were confirmed.

• Proceedings of the Korean Society of Dyers and Finishers Conference
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• 2012.03a
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• pp.74-74
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• 2012

섬유 프리프레그(Prepreg)는 강화섬유를 수지에 함침하여 B-stage로 만든 복합재료의 중간성형재료이다. 최종적으로 프리프레그를 금형에 적층하여 가열 가압하여 수지를 경화함으로써 최종제품이 완성된다. 본 연구에서는 직물형 프리프레그를 사용하였는데, 사용되는 직물형태로는 복합재료 성형공정에서 형태안정성이 우수한 평직물과 능직물이 주로 사용된다. 직물형 프리프레그를 사용한 복합재료는 작업성과 형태안정성이 우수하면서 내충격특성이 우수하여 오토바이용 헬멧, 방탄용 헬멧 등에 주로 사용된다. 프리프레그에 요구되는 주요 특성중 하나는 Tack성으로서, 성형 과정에서 프리프레그를 여러 장 적층할 때 적층된 층 간에 미끄러지지 않으면서 잘 고정되어 적층 작업을 원활하게 하는 역할을 한다. Tack성은 수지의 B-stage 경화 후의 점성 거동에 따라 변화될 수 있는 것으로 표면의 끈끈함의 정도로서 알 수 있다. Tack성은 온도에 민감하여 측정 시에 일정한 온도의 유지가 중요하다. 이러한 온도에 대한 민감성 때문에 프리프레그의 저장시 저온에서 저장하는 것이 원칙인데, 상온에 있을 경우 시간경과에 따른 Tack성 변화가 크게 나타나게 된다. 따라서 본 연구에서는 아라미드 섬유와 열경화성수지를 이용하여 프리프레그를 제조하고 이를 상온상태에서 보관 시 일정시간 경과에 따른 Tack성 변화를 알아보고자 하였다.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.12
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• pp.1093-1100
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• 2014

The goal of this paper is to investigate preliminary the applicability of 3D printing technologies for the development of the hot bulk forming process and die. 3D printing technology based on the plastic material was applied to the preform design of the hot forging process. Plastic hot forging dies were fabricated by Polyjet process for the physical simulation of the workpiece deformation. The feasibility of application of Laser-aided Direct Metal Rapid Tooling (DMT) process to the fabrication of the hot bulk metal forming die was investigated. The SKD61 hot-working tool steel was deposited on the heat treated SKD61 using the DMT process. Fundamental characteristics of SKD 61 hot-working tool steel deposited specimen were examined via hardness and wear experiments as well as the observation of the morphology. Using the results of the examination of fundamental characteristics, the applicability of the DMT process to manufacture hot bulk forming die was discussed.