• Design & Manufacturing
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• v.9 no.3
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• pp.9-13
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• 2015

Plastic material has been applied to many automobile parts with the automotive lightweighting trend. In this study, a passenger air bag(PAB) housing which is produced by steel material in the present were molded using a plastics material. Before design and making of a mold for the PAB housing molding, it was carried out injection molding analysis. By analyzing the deformation results, the correction dimension for mold designing was determined. The design and manufacturing the mold applied the correction dimension were conducted. It was performed actual injection molding. The warpage value of the PAB housing was similar to the warpage of the injection molding analysis.

• Korean Journal of Computational Design and Engineering
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• v.13 no.5
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• pp.382-390
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• 2008

Five-axis machining has been applied to manufacture of turbine blades, impellers, marine propellers. Nowadays it extends to mold & die machining, where more productivity as well as added value is expected. The five-axis machining can be divided into positional and continuous, according to the variableness of tool orientation during material removal process. The positional five-axis machining is commonly applied to the regional machining on a whole part surface in mold manufacturing industry, where the tool orientation for each region (area) should be determined to be feasible, that is, avoiding any interference such as machine tool collision, etc. Therefore it is required for a CAM programmer to decide a feasible tool orientation in generating tool-paths on a designated area, because it is a very tedious job to obtain such information by utilizing a commercial CAM system. The developed system generates feasibility data on tool orientation and machining region, which facilitates the CAM programmer's decision on a feasible tool orientation.

• Design & Manufacturing
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• v.10 no.2
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• pp.29-33
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• 2016

Production machines have been more important, due to quality level of vehicle motor core is getting higher. That is why, to improve assembly fit of tooling and to be emphasized how much moving down caused of deterioration of high speed press, it is also getting more important parts as solution of problems. To analyze how much move based on condition of movement as tooling and high speed press, and to measure how much impact to embossing height caused of changing movement down. As the result of investigation, in case of material thickness 0.5mm, there is highest pull and force power when emboss height is 0.45mm. If emboss height is less than 0.45mm, pull and force power is getting lower, if emboss height is higher than 0.45mm, it is impossible to make it forming caused of changed press movement, also it has been piercing.

• Design & Manufacturing
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• v.8 no.1
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• pp.1-4
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• 2014

Large injection molds commonly have molding defects such as flashes and variation of product thickness. In this study, we conducted injection molding CAE analysis to find out the cavity pressure and structural analysis to find out mold deflection as input load conditions injection pressure obtained from injection molding analysis. As the results from CAE analysis, we found which element is the most effective on the mold deflection and we suggested a mold design to minimize the mold deflection.

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.23-26
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• 2008

In order to examine the deformation characteristics of Al circular pipe underthe biaxial compression, the horizontal biaxial compression die for the experiment was manufactured. From this, in the various compressive strain rate (1 mm/min. ${\sim}$ 400 mm/min.)conditions, the circular pipes, which were made by Al materials, were investigated based on the properties change of cross section area, punch load and deformation behavior. The tensile and compressive strains were evaluated from micro Vickers hardness tester. From these results, the punch load and deformation characteristic of Al circular pipes were highly changed in the compressive strain rate about 200 mm/min. The Al circular pipes had the tendency that the punch load decreased with increasing the compressive strain rate. In addition, following as the change of the shape and position of neutral axis due to the deformation proceeding of the circular pipe, the special point of the internal circular pipe at maximum load showed the maximum deformation strain and the maximum measured hardness value. The CAE (computer aided engineering) simulation using Deform-2D program was performed on the circular pipe in order to know and verify the exact compressive deformation behavior. From these results, the experimentally measured results were reasonably in good agreement with the simulation results.

• Design & Manufacturing
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• v.8 no.1
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• pp.19-22
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• 2014

Today, looking at the trend of product development, interests of injection technology to reduce weldline are growing because of increases of polymer composite materials that containing functional elements and demand of no-painted injection in accordance with environmental regulations. In this paper, surface temperatures of mold increased using high temperature gas for elimination of weldline and characteristics of weldline are analyzed according to mold temperature($60^{\circ}C{\sim}120^{\circ}C$).

• Design & Manufacturing
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• v.14 no.1
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• pp.22-29
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• 2020

The analysis was carried out using the press molding analysis program by applying six parameters such as material type change, material thickness, friction coefficient, r_p, r_d and blank holder pressure. As a result of CAE analysis of the soft material DC04 and the relatively hard material HX300LAD, the thickness of the punch R part of the soft material was significantly reduced. The flange portion is greatly increased in thickness in the hard material by the compression action. As a result of considering the deformation amount of 0.6mm, 1.0mm, 1.5mm according to the material thickness, the influence of the thickness is considered to be very small. In case of the material thickness of 0.6mm, the rate of change increases due to the deep drawing depth relative to the material thickness. The sizes of the punches R and die R have the greatest influence on the change in thickness of the material in drawing molding, the smaller the punch R, the thinner the edges of the product, The larger the R of the die, the greater the material thickness of the flange portion. As the coefficient of friction and the blank holder pressure increase, the frictional force of the flange portion increases, which increases the radial force in the drawing process and increases the thickness change of the flange portion.

• Korean Journal of Computational Design and Engineering
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• v.2 no.1
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• pp.35-43
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• 1997

Concurrent Engineering is one of the methods which are used for the rapid product development. One of the important features in Concurrent Egineering is that the development process is to be parallel and the organization should be cross-functional. In order that the process be parallel and that the organization be cross-functional, an integrated information system such as PDM (Product Data Management) is required. Although the integrated data base is constructed, it could be meaningless if the application softwares were not inter-operable. This study shows an example of intergrated information system from three-dimensional product design to mold design and tooling for the development of Deflection Yoke(DY) which is one of the important parts of Cathode Ray Tube(CRT). A three-dimensional product design software, which is based on a commercial code, has been developed by ourselves. Selective Laser Sintering(SLS), which is one of the rapid prototyping techniques, has been used in this study. Mold design has been done by the three-dimensional way. A newly developed method of mold tooling, which is called Quick Die Manufacturing(QDM), has been introduced.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.1
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• pp.35-40
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• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Design & Manufacturing
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• v.2 no.2
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• pp.1-5
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• 2008

Mechanical properties of the materials used for mold and industrial machinery under high strain rate loading conditions such as high impact loading are required to provide appropriate safety assessment to varying dynamically loaded mechanical structures. The Split Hopkinson Pressure Bar(SHPB) technique with a special experimental apparatus can be used to obtain the material behavior under high strain rate loading conditions. In this paper, the dynamic deformation behavior of a brass under high strain rate compressive loading conditions has been determined using the SHPB technique.