• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.9
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• pp.5737-5742
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• 2015

Insert injection molding is a process in which molten plastic is injected into a mold that contains a pre-placed insert. During the injection stage, the insert can be deformed by the pressure applied by the polymer melts. The deformation of the insert changes the width of the flow path around the insert, which can cause several defects such as short shots or warpages of the parts. In order to reduce the deformation of the insert, it is important to achieve successful design of gating system, insert geometry, and molding conditions. In the present study, the insert deformations that occured during the injection molding of the BLDC motor stator were investigated by numerical analyses. The gate location and the insert shape were modified to reduce the insert deformation. Finally, the injection molding with the modified designs was carried out, and it was confirmed that the insert deformation was reduced.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.10 no.7
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• pp.1729-1734
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• 2009

About 40 million automotive vehicles all over the world and 0.55 million in Korea were retired from use annually. Every nation is desperate to decrease environmental pollution by ELVs(End of Life Vehicles) and try to tighten the regulations. Europe passed laws requiring OEMs to increase vehicles' recovery and reuse rate to 95% by 2015 from current 84%. The ferrous parts, 75% of total automobile weight, are almost recycled whereas the remaining 25% of the non-metal -predominantly plastics as well as form, glass and rubber- and the non-ferrous materials -copper, nickel and aluminium- end up in landfills. The recycling status of non-ferrous materials represented by copper and nickel is reviewed and how much the recycling rate will be improved is calculated.

• Polymer(Korea)
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• v.37 no.6
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• pp.722-729
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• 2013

In order to enhance the thermal conductivity of poly(dimethyl siloxane) (PDMS), boron nitride (BN) and carbon nanotubes (CNTs) were incorporated as the thermally conductive fillers. The amount of BN was increased from 0 to 100 phr (parts per hundred rubber) and the amount of CNTs was increased from 0 to 4 phr at a fixed amount of the boron nitride (100 phr). The thermal conductivity of the composites increased with an increasing concentration of BN, but the incorporation of CNTs had only a slight effect on the enhancement of thermal conductivity. Unexpectedly, the thermal degradation of the composites was accelerated by the addition of CNTs in 100 phr BN filled PDMS. Activation energy for thermal decomposition of the composites was calculated using the Horowitz-Metzger method. The curing behavior, electrical resistivity, and mechanical properties of PDMS filled with BN and CNTs were investigated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.287-290
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• 2005

Once hot forgings for automotive parts such as wheel bearing flange to which cyclic asymmetric bending stress is continuously applied are produced, it is necessary to control their microstructure to obtain superior mechanical properties. It is however hard to control the microstructure uniformly because the strength is reduced as coarsening of ferrite grains. To investigate the microstructural alteration according to process variables during hot working, the variation of the ferrite grain size was studied by utilizing of the computer aided servo-hydraulic Gleeble tester which is hot deformation behavior reproduction equipment. In addition, the effect of the ferrite grain size of raw material on the austenite grain behavior of hot forgings was also examined. The rolling contact fatigue resistance of the induction hardened SAE 1055 steel was compared with the occasion of the same condition of SAE52100 bearing steel. As a result, it was confirmed that the ferrite grain sizes of the forgings depend on the heating temperature and cooling start temperature during hot forging and cooling processes. The induction hardened SAE1055 steel showed a superior rolling contact fatigue resistance to the induction hardened SAE52100 steel. The reason is that SAE1055 steel is freer from the material defect such as segregation than the comparative steel.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.412-419
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• 2008

Using lightweight materials in vehicle manufacturing in order to reduce energy consumption is one of the most effective approach to decrease pollutant emissions. As a lightweight material, magnesium is increasingly employed in automotive parts. However, because of its hexagonal closed-packed(HCP) crystal structure, in which only the basal plane can move, the magnesium alloy sheets show low ductility and formability at room temperature. Thus the press forming of magnesium alloy sheets has been performed at elevated temperature within range of $200^{\circ}C{\sim}250^{\circ}C$. Here we try the possibility of sheet metal forming at room temperature by adopting incremental forming technique with rotating tool, which is so called as rotational-incremental sheet forming(RISF). In this rotational-incremental sheet forming the spindle tool rotates on the surface of the sheet metal and moves incrementally with small pitch to fit the sheet metal on the desired shape. There are various variables defining the formability of sheet metals in the incremental forming such as speed of spindle, pitch size, lubricants, etc. In this study, we clarified the effects of spindle speed and pitch size upon formability of magnesium alloy sheets at room temperature. In case of 0.2, 0.3 and 0.4mm of pitch size with hemispherical rotating tool of 6.0mm radius, the maximum temperature at contact area between rotating tool and sheet metal were $119.2^{\circ}C,\;130.8^{\circ}C,\;and\;177.3^{\circ}C$. Also in case of 300, 500, and 700rpm of spindle speed, the maximum temperature at the contact area were $109.7^{\circ}C,\;130.8^{\circ}C\;and\;189.8^{\circ}C$.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.5 s.170
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• pp.130-137
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• 2005

Recently, the importance of CAE research is growing with the advances of the automotive and computer industry. In addition, multi-body dynamics and powertrain analysis are the most important factors in improving the vehicle design. Since engine torque with curve-data was used for analyzing full car simulation in the multi-body dynamics system for many years, it is impossible to assess the concurrent analysis of the engine and powertrain element included in a real full car system. In powertrain, since vehicle are usually modeled as a simple mass and a inertia, they can not be seen as real cars. Moreover, it is hard to obtain additional dynamics data other than the longitudinal velocity value in movement. Because of the reason that was previously discussed, it is necessary to consolidate the two parts as one routine program for design and development through the coordinate system connectivity, and presented here is a program named O-DYN. Using an object-oriented language C++, this program has a good structure with the valuable characteristics of objectivity, inheritance, and reusability. The reliability of this multi-body dynamics program is examined by DADS, which is the general dynamics program, using DAE solver and PECE integral function with the common coordinator separation method. As a result, we can obtain a better solution and total dynamics data in either area through this process. This program will be useful for analyzing full car simulation with powertrain.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.589-592
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• 2005

Micro-forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). Micro-forming of $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk metallic glass(BMG) as a candidate material for this developing process are feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, micro-formability of a representative bulk metallic glass, $Zr_{62}Cu_{17}Ni_{13}Al_8$, was investigated for micro-forging of U-shape pattern. Micro-formability was estimated by comparing $R_f$ values $(=A_f/A_g)$, where Ag is cross-sectional area of U groove, and $A_f$ the filled area by material. Microforging process was simulated and analyzed by applying finite element method. FEM simulation results should reasonable agreement with the experimental results when the material properties and simulation conditions such as top die speed, remeshing criteria and boundary conditions tightly controlled. The micro-formability of $Zr_{62}Cu_{17}Ni_{13}Al_8$ was increased with increasing load and time in the temperature range of the supercooled liquid state. Also, FEM Simulation using DEFORM was confirmed to be applicable for the micro-forming process simulation.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.8
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• pp.3326-3333
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• 2012

In this paper, an educational simulator of automobile chassis electronic control system was developed. The developed system is composed of three parts, a driving condition control & monitoring system, a chassis electronic system monitoring & analysis system, and a virtual simulator & educational multimedia contents. The driving condition control & monitoring system has a commercial real car simulator, hydraulic equipments for representing driving conditions, and a remote control and monitoring system. In the chassis electronic system monitoring & analysis system, information of various sensors and actuators applied to the system can be monitored by Labview programs. Finally, the suggested virtual simulator and the multimedia with 2D Flash and 3D animations can be used effectively by means of teaching materials.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.5
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• pp.2628-2634
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• 2014

Vehicle washer heater system is more widely adopted to defrost a window or to clear the windshield glass in winter season. The washer heater system should be designed to heat up washer fluid rapidly to the target temperature for only a short time. A numerical analysis has been carried out to analyze the heat transfer characteristics with materials of inside parts in vehicle washer heater system with filler and flow path. ANSYS - FLUENT software is employed for the analysis. The axial symmetry model is three-dimensional and unsteady. It applies to the coupled method which is one of pressure based. Through this result, it was obtained to find the optimal material condition for the filler and flow path in washer system. For material of filler, the air with lower density was heated more rapidly rather than silicon carbide(SiC). For material of flow path, copper with the heat transfer coefficient of approximately four times greater than the nickel gives us higher efficiency. That is the reason why the heating time of methanol was reduced to make uniform temperature in washer heater system.

• Journal of the Korean Institute of Gas
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• v.25 no.5
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• pp.37-51
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• 2021

The pressure drop phenomenon that occurs when the same flow rate is supplied to the gas regulator was analyzed. The regulator moves the position of the piston through the interaction of the force acting on the upper and lower parts of the piston and the spring tension to release the pressure of a specific range in a specific environment as constant pressure, thereby maintaining the pressure. The flow characteristics and pressure control process of the regulator were investigated through a numerical analysis technique as the volume of the fluid inside the regulator changed. As the gap between the piston and the piston seat decreased, the pressure drop increased and the flow velocity increased. It was verified through numerical analysis that the piston was positioned at 0.12mm under the same conditions as the pressure-flow test (inlet pressure 3MPa, outlet pressure 0.8MPa, flow rate 70kg/h).