• Transactions of the Korean Society of Mechanical Engineers B
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• v.39 no.4
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• pp.301-307
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• 2015

The diameter of a proton beam emanating from the MC-50 cyclotron is about 2-3 mm with Gaussian distribution. This widely irradiated proton beam is not suitable for semiconductor etching, precise positioning, and micromachining, which require a small spot. In this study, a beam cutting method using a microhole is proposed as an economical alternative. We produced a microhole with aspect ratio, average diameter, and thickness of 428, $21{\mu}m$, and 9 mm, respectively, for cutting the proton beam. By using this high-aspect-ratio microhole, we conducted machinability tests on microstructures with sizes of tens of ${\mu}m$. Additionally, the results of simulation using GEANT4 and those of the actual experiment were compared and analyzed. The outcome confirmed the possibility of implementing a micro process technology for the fabrication of three-dimensional microstructures of 20 micron units using the MC-50 cyclotron with the microhole.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.40 no.1
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• pp.65-71
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• 2016

In recent years, 3D printing has received increasing attention due to releases of low-cost 3D printers based on open-source platform. 3D printing is expected to reduce the barrier to entry in the traditional manufacturing processes by increasing flexibility and creating an advantage to manufacture customized products at low costs. In this study, a unique eyeglass frame was designed to have a snake shape, which has an asymmetric geometry unlike traditional frames. The eyeglass frame was designed in a customized manner by reflecting dimensional characteristics of a customer's face. Finite element analysis was performed to investigate the structural safety of the 3D printed frames during the assembly process. The analysis also considered the effect of anisotropic material properties as determined by tensile tests. The eyeglass frame was then printed using the customized sizes and the best building process. The eyeglass frame was successfully assembled with lenses and without structural failure during its assembly procedure.

• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.593-604
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• 2018

Laser-assisted machining (LAM) is known to be an effective and economical technique for improving the machinability of difficult-to-machine materials. In the LAM method, material is preheated using a laser heat source and then the preheated area is removed by following cutting tool. For laser-assisted turning (LAT), the configuration of the system is not complicated because laser irradiates from a fixed position. In contrast, laser-assisted milling (LAMill) system is not only complicated but also difficult to control because laser heat source must always move ahead of the cutting tool along a three dimensional (3D) tool path. LAMill is still early stage and cannot yet be used to machine finished products with 3D shapes. In this study, a laser-assisted fillet milling process was developed for machining 3D shapes. There are no prior studies combining fillet milling and LAMill. Laser-assisted fillet milling strategy was proposed, and effective depth of cut (EDOC) was obtained using thermal analysis. Experiments were designed using response surface method and cutting force prediction equations were developed using statistical analysis and regression analysis. The optimum machining conditions were also proposed, and energy efficiency of the LAMill was analyzed by comparing the specific cutting energy of conventional machining (CM) and LAMill.

• Journal of the Korean Society of Industry Convergence
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• v.26 no.4_1
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• pp.517-527
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• 2023

Many techniques have been proposed and investigated for microlens array manufacturing in three-dimensional (3D) structures. We present fabricating a microlens array using selective laser etching and a CO₂ laser. The femtosecond laser was employed to produce multiple micro-cracks that comprise the predesigned 3D structure. Subsequently, the wet etching process with a KOH solution was used to produce the primary microlens array structures. To polish the nonoptical surface to the optical surface, we performed reflow postprocessing using a CO₂ laser. We confirmed that the micro lens array can be manufactured in three primary shapes (cone, pyramid and hemisphere). Compared to our previous study, the processing time required for laser processing was reduced from approximately 1 hour to less than 30 seconds using the proposed processing method. Therefore, micro lens arrays can be manufactured using our processing method and can be applied to mass productionon large surface areas.

• Journal of Powder Materials
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• v.24 no.3
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• pp.202-209
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• 2017

A cold-work tool steel powder is used to fabricate 3-dimensional objects by selective laser melting using a high-pressure gas atomization process. The spherical powder particles form continuous carbide networks among the austenite matrix and its decomposition products. The carbides comprise Nb-rich MC and Mo-rich $M_2C$. In the SLM process, the process parameters such as the laser power (90 W), layer thickness ($25{\mu}m$), and hatch spacing ($80{\mu}m$) are kept fixed, while the scan speed is changed from 50 mm/s to 4000 mm/s. At a low scan speed of 50 mm/s, spherical cavities develop due to over melting, while they are substantially reduced on increasing the speed to 2000 mm/s. The carbide network spacing decreases with increasing speed. At an excessively high speed of 4000 mm/s, long and irregularly shaped cavities are developed due to incomplete melting. The influence of the scan pattern is examined, for which $1{\times}1 mm^2$ blocks constituting a processing layer are irradiated in a random sequence. This island-type pattern exhibits the same effect as that of a low scan speed. Post processing of an object using hot isostatic pressing leads to a great reduction in the porosity but causes coarsening of the microstructure.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.2
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• pp.610-619
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• 2016

Digital manufacturing (DM) technology helps engineers design products promptly and reliably at low production cost by simulating a manufacturing process and the material behavior of a product in use, based on three-dimensional digital modeling. The computing infrastructure for digital manufacturing, however, is usually expensive and, at present, the number of professional design engineers who can take advantage of this technology to a product design accurately is insufficient, particularly in small and medium manufacturing companies. Considering this, the Korea Institute of Science and Technology Information (KISTI) and H University is operating a DM track in the form of Industry-University-Research Institute collaboration to train high-performance-computing-based DM professionals. In this paper, a series of courses to train students to work directly into DM practice in industry after graduation is reported. The operating cases of the DM track for two years since 2013 are presented by focusing on the progress in establishment, lecture and practice contents, evaluation of students, and course quality improvement. Overall, the track management, curriculum management, learning achievement of students have been successful. By expediting more active participation of the students in the track and providing more internship and job offers in the participating companies in addition to collaborative capstone design projects, the track can be expanded by fostering a nationwide training network.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.3_1spc
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• pp.573-579
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• 2013

Once-through helically coiled steam generator tubes subjected to external pressure are of interest because of their application to advanced small- and medium-sized integral reactors, in which a primary coolant with a relatively higher pressure flows outside the tubes, while secondary water with a relatively lower pressure flows inside the tubes. Another notable point is that the values of the mean radius to thickness ratio of these steam generator tubes are very small, which means that a thick-walled cylinder is employed for these steam generator tubes. In the present paper, the maximum allowable pressure of helically coiled and thick-walled steam generator tubes with through-wall cracks under external pressure is investigated based on a detailed nonlinear three-dimensional finite element analysis. In terms of the crack orientation, either circumferential or axial through-wall cracks are considered. In particular, in order to quantify the effect of the crack location on the maximum external pressure, these cracks are assumed to be located in the intrados, extrados, and flank of helically coiled cylinders. Moreover, an evaluation is also made of how the maximum external pressure is affected by the ovality, which might be inherently induced during the tube coiling process used to fabricate the helically coiled steam generator tubes.

• Design & Manufacturing
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• v.6 no.1
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• pp.12-17
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• 2012

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, a full-3d simulation based on solid elements has been reported as a reliable approach. The present work covers three-dimensional injection molding simulation and relevant deformation analysis of an injection molded plastic lens based on 3d solid elements. Numerical analyses have been applied to the injection molding processes of three aspheric lenses for an image sensing module of a mobile phone. The reliability of the proposed approach has been verified in comparison with the experimental results.

• Journal of the Korea Institute of Military Science and Technology
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• v.15 no.3
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• pp.231-240
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• 2012

During the past two decades, Metal Injection Molding(MIM) has become a very competitive technology to fabricate small, precise and complex-shaped parts in large quantities. In this research, the applicability of MIM technology in the mass-production of the high precision fuze parts to save manufacturing cost was investigated. The water-atomized 17-4PH stainless steel powder, one of the best corrosion-resistant high strength materials, was injection-molded into real-shape fuze part and flat tensile specimens. The injection-molded parts were thermally debound in hydrogen gas flow without solvent extraction. Sintering of the debound parts was carried out in vacuum at temperatures ranging from $1150^{\circ}C$ to $1370^{\circ}C$. The sintering behavior, mechanical properties, dimensional precision, corrosion resistance of the MIMed 17-4PH stainless parts were investigated. It was found that almost all the properties of the MIMed parts were comparable to those of the mechanically machined parts. Also, actual military field tests using both MIMed and mechanically machined fuze parts were performed as well and were found to be very successful.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.143-148
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• 2008

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, a full-3d simulation based on solid elements has been reported as a reliable approach. The present work covers three-dimensional injection molding simulation and relevant deformation analysis of an injection molded plastic lens based on 3d solid elements. Numerical analyses have been applied to the injection molding processes of three aspheric lenses for an image sensing module of a mobile phone. The reliability of the proposed approach has been verified in comparison with the experimental results.