• Journal of Korea Foundry Society
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• v.19 no.6
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• pp.484-492
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• 1999

The microstructures and mechanical properties of high strength yellow brass, Al bronze and Sn bronze alloys fabricated by gravity die casting and squeeze casting were investigated. A rapid cooling of casting was enhanced by pressure applied during solidification of Cu alloys, the cooling rate of casting was more great for high strength yellow brass alloy than other Cu alloys. Grain size and phases of the squeeze cast products become refined to 1/2 level compared to gravity die castings. Squeeze cast Al bronze and high strength yellow brass has about 10-20% higher yield and tensile strength and slighter decreased or nearly same elongation, compared to gravity die cast ones. Sn bronze has nearly same strength and hardness, but shows increased in elongation, compared to gravity die cast ones.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.6
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• pp.33-38
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• 2019

Researchers have recently begun to study hot stamping processes to shorten the mold cooling time and improve productivity. These publications explain that the mold cooling time can be reduced by using a curved cooling channel, where the mold surface is processed to a uniform depth, instead of a straight cooling channel that uses the conventional gun drilling machine. This study investigates the characteristics of the front pillar of an automobile after using a mold with a curved cooling channel. To analyze the change in properties, we used a 1.6 mm boron steel blank and heated the prototype at $930^{\circ}C$ for 5 minutes. Next, we formed the prototype with a load of about 500 tons while varying the mold cooling time between 1 and 10 seconds. We subjected each prototype specimen to a tensile strength test, a hardness test, and a tissue surface observation.

• Design & Manufacturing
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• v.13 no.1
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• pp.61-67
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• 2019

The cooling unit of the industrial showcase consists of a compressor, a condenser and an evaporator. An axial fan is used to circulate the air to improve the efficiency of the heat exchanger. In the past, aluminum fans have been used, which have problems such as low performance, efficiency, high failure rate, and high noise. This study is to develop high performance, high efficiency plastic fan replacing aluminum fan. A major factor in determining the performance and noise of an axial fan is the angle and cross-sectional shape of the blade, which is suitable for raising the lift force, thereby controlling the vortex, which is the main cause of noise and performance degradation. In order to produce a high efficiency injection molded fan, it is necessary to develop a mold that minimizes the deformation of the injection process for the designed shape. In this study, we developed a high efficiency, low noise plastic injection fan with more than 11% performance improvement and noise reduction compared to conventional aluminum fan.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.367-370
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• 2009

Recently, ultra high strength products can be manufactured by the hot press forming process of Boron steel in automotive and electronics industries. In order to get high strength, the hot press forming should be accompanied by quenching process inducing phase transformation. In the study, the heat conductive die and the cooling channel were designed by the numerical simulation and the effect of three different parameters were determined to improve cooling characteristics.

• Design & Manufacturing
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• v.2 no.2
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• pp.6-9
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• 2008

Injection molding is representative process of plastic production. Most of numerical analyses for injection molding have been based on the Hele Shaw's approximation: two-dimensional flow analysis. The present work covers numerical analyses of injection molding using three-dimensional solid elements. The accuracy of the analysis results has been verified through some numerical examples in comparison with the various conditions. In this study, moldflow software was used to analyze the cooling analysis. The results of cooling analysis and testing catapult were compared for plastic products.

• Transactions of Materials Processing
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• v.15 no.2 s.83
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• pp.148-152
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• 2006

In this study, the experiments of warm deep drawing were done with heated die, and with heated die, and blankholder, and cooled punch in order to investigate the formability of AZ31 magnesium alloy sheet in warm deep drawing. For this, warm deep drawing experiments were executed under various temperatures and punch velocities. The results of warm deep drawing with heated die showed that fracture occurred around the punch part at punch velocity of 75mm/min and punch stroke of 10mm under temperature range of 373-523K, but did not occur under temperature range of 548-673K even punch stroke of 25mm. And fracture at the punch stroke of 25mm and the temperature of 523K did not occur under the punch velocity of 30mm/min, but occurred under punch velocity of 75 and 125mm/min. Also warm deep drawing with heated die and blankholder, and cooled punch showed that the temperature range happening maximum height under punch velocity of 10-100mm/min was around 498-523K. Finally, with heating and cooling technique necking of AZ31 magnesium alloy occurred at punch shoulder part under the temperature range of 293-423K, but at die wall part under the temperature range of 473-573K.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.199-200
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• 2006

PM recent developments focus on increasing this technology's competitiveness when compared to wrought materials. Warm compaction allows the replacement of a double press double sinter process with a single warm press and sintering step, thus allowing cost and time savings. Moreover there are added benefits to consider such as reducing work in process and lessening part's logistics cost. This paper presents a successful industrial trial to replace a double press-double sinter process with a warm die compaction and sintering process. The part chosen was a high performance gear containing 0,9% wt. carbon. Sintering was conducted in a belt furnace at $1120^{\circ}C$ in a nitrogen rich atmosphere with rapid cooling process in order to obtain a quasi fully martensitic structure with a minimum of 700HV0,1 and 450HV10 after annealing. The balance between properties and cost is favoured by the use of a singular lubricant developed in a Eureka frame project together with POMETON S.A. and die warm compaction. Warm compaction is only needed to be effective on the gear teeth, in order to achieve the required properties. Therefore only the die is actually heated. This simplified system avoids flow rate problems typically involved when using more elaborate warm compaction equipments.

• Transactions of Materials Processing
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• v.20 no.4
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• pp.316-323
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• 2011

The hot curvature-forming of large aluminum thick plate using a grid-typed hybrid die is a process for the production of a spherical LNG tank. Many variables such as the initial die surface quality, grid size, grid thickness, size of blank plate and cooling line design, control the success of the process. In addition, the plate used in this process is generally larger than $10{\times}10m$ in size. Thus, it is very difficult to predict the surface characteristics of the plate during forming and to measure the different parameters due to the high cost of the experiments. In order to optimize the process design for the grid-type die, the development of an analytical method to predict the surface characteristics of the final product in hot curvature-forming is needed. This paper described the development of the method and procedures for FE simulations of the hot curvature-forming process, including hot forming, air flow, cooling, and thermal deformation analyses. An experiment for a small scale model of the process was conducted to check the validity of the numerical method. The results showed that the curvature of the plate in the analysis agrees well with that of the experiment within 0.037 and 0.016% tolerance margins for its side and corner, respectively.

• IE interfaces
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• v.13 no.4
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• pp.717-724
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• 2000

In this paper, an integrated system of optimal design, performance evaluation, and die design and manufacturing of axial fans for cooling tower is presented. The design and performance evaluation are developed based on three dimensional flow analysis so as to ensure low noise and high efficiency. The methodologies are implemented on computer as a GUI system including 3-D surface modeling and 2-D drawing file output modules. The CAD/CAM system is engaged to design the die and generate NC tool path, but the processes are also automated and integrated into the system by means of a part program coded from the design data. It is shown that the newly developed fans have superior performance and shortened lead-time compared to the existing dead-copied fans.

• Transactions of Materials Processing
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• v.9 no.4
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• pp.413-420
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• 2000

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of front housing part of aircon compressor, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the filling and solidification stages for the sound casting products. Two cases of casting design that have different types of gating system are considered in the analysis. The potential sites where the casting defects may occur is examined by computer simulation and an improved design process is proposed. Also the effect of partial squeeze on the quality of casting products is considered and the optimal time lag after filling process is determined. For the die-stability, the effect of operational parameters such as die temperature, heat cycle and spot cooling on the die life has also been analyzed.