• Journal of the Korean Society of Industry Convergence
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• v.21 no.1
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• pp.1-8
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• 2018

The purpose of this study is to develop a high-strength, high-toughness, thin-walled aluminum shock absorber housing product by applying a high vacuum die casting method to improve internal gas defect and formability. The analysis program dedicated for the casting was used because it was too costly and time-consuming to adopt the gating system design. The final casting plan was designed based on the flow pattern of the material filled into the mold and the result of air pressure and air pocket after the material was completely filled in the mold. Gaty shape was designed as a split type. The runner was designed to have the same shape as the initial inlet curve of the cavity, and the flow of the molten metal was prevented from turbulent flow. The most favorable results were obtained when the injection speed was $V_2=4.0m/s$. Defects on pores were reduced by applying high vacuum level inside the mold.

• Design & Manufacturing
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• v.2 no.4
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• pp.24-31
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• 2008

The productive products are required diversification of product development and advanced for competitiveness. A lot of methods to fix architecture wrapping panels and stone materials are developed in domestic area very much. In this paper, it is very important that a fixing device of slate and molds were developed to reduce the production cost and improve safety. Therefore new model was suggested to reduce manufacturing cost and structure design and FEM analysis were performed to manufacture die press dies for mass production.

• Design & Manufacturing
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• v.2 no.4
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• pp.16-23
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• 2008

This paper describes $R_p,\;R_d,\;R_c,\;R_{cp},\;R_{cd}$ for design and manufacture of die by comparing the results. Results of this study could be reduced from three processes to two processes and drawing can be conducted using one die set by modifying structure of the punch head and die plate. Oil canning phenomenon can be prevented when circle blanking or ellipse blanking in blanking drawing. $R_c$, the important factor of drawing process was able to evaluate properly in designing of product.

• Design & Manufacturing
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• v.8 no.1
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• pp.40-44
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• 2014

As a rotating machine element, plastic gears are more and more widely used in such as industrial machine element, since plastic gear is lighter, higher wear-resistance, and higher vibration absorbing ability than metal gears. When operating plastic parts, tooth breakage and fatigue life shortened due to increasing number of applying load and tooth flank temperature rising, such that accuracy of plastic gears is divided from allowable range to cause vibration and noise. On this study, a internal plastic gears are developed which improved the filling balance molding process by a new injection mold structure. The new mold structure called HR3P(hot runner type 3plate mold). As the result from this studies, we obtained a very accurate roundness internal gears by using design of experiment.

• Design & Manufacturing
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• v.10 no.3
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• pp.39-45
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• 2016

The purpose of this study is to build effective cooling circuit design in injection mold to improve glass fiber reinforced laptop computer cover plastics' transcription and gloss. Moldflow Insight and Ansys CFD CAE program used to verify efficiency and the experiment mold is precision machined and brazing soldered to make three-dimension cooling channel. The temperature of mold in injection test are fixed to $80^{\circ}C$ and $160^{\circ}C$. The result of this experiment is the improved surface quality of plastics with 85% improvement of transcription in high temperature mold.

• Design & Manufacturing
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• v.9 no.3
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• pp.24-28
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• 2015

Speaking in general terms the form injection process can be described as a new process-variant of already known structural foam molding technology which roots go back to the early sixties. The most limiting factors of already know foaming processes are large cell size and the lack of uniformity of these cells as well and the inability to foam all kinds of plastic materials. In this paper, Process Study on weight change in injection rate during foaming. Experimental conditions were set as the injection speed 50,150,300 and 450 mm/s. The experiments PA, PA+GF, PP, was confirmed that the weight increase to PP+TA.

• Design & Manufacturing
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• v.13 no.2
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• pp.44-48
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• 2019

Motor core products are used as materials for electrical steel sheets and cold-rolled steel sheets according to the performance of motors. The cemented carbide material of the mold punch applied to the motor core material causes many troubles due to abrasion and burr problem. The selection of these materials has a great effect on the production life, mass production, product quality as well as mold life. The cemented carbide applied to the products of the motor core is recognized as a very important part. In this study, cold rolled steel sheet was applied to motor core SCP-1 steel 1.0mm, and The effects of abrasion and punching oil on the shear process were investigated for the selection of cemented carbide. Experiments were conducted to select and apply cemented carbide only for the motor core punch optimized for cold rolled steel. The results showed that the cemented carbide material of $CDK3^{***}$ produced the least wear and burrs.

• Design & Manufacturing
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• v.6 no.2
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• pp.90-95
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• 2012

The sheet metal forming proceccing is very important and indispensable in the automotive industry because the accuracy of prsee worked parts is directly related to the automotive quality. But when making mold it is difficult and expensive to modify mold. mold design technology is a critical technology in press plastic working. When design the mold there are lots of variables in press plastic working according to worked material, mold materials, conditions of heat treatment, clearance and so on. Abrasion of mold depends on these kind of conditions and sheared surface which is crucial for quality of product also depends on them. In this study, we conduct research on abrasion loss of mold according to 8, 10 and 12% of clearance for thickness of 1.0mm of worked material out of mold design variables of the products whose worked materials are high carbon steel and carbon tool steel by a practical experiment and perform a comparative evaluation of difference of abrasion loss mold with the alloy tool steel (STD11) and Tungsten Carbide (WC).

• Design & Manufacturing
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• v.15 no.2
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• pp.63-69
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• 2021

Springback is an essential task to be solved in order to make high-precision products in sheet metal forming. In this study, materials with four different elastic regions were used. For the forming analysis, the change of springback caused by the frictional force generated in the flange part during hat shape forming was considered by using the AutoForm analysis program. Factors affecting frictional force were blank holder force, friction coefficient, bead R and bead height. As a result of the forming analysis, the springback increases as the material with a larger elastic region increases. In addition, as the frictional force of the flange part increased, the tensile force in the forming direction increased and the springback decreased. In particular, the blank holder force and friction coefficient had a great effect on springback in mild materials (DC04, Al6016), and the bead effectively affects all materials. Through this study, it was considered that the springback decreased as the material with a smaller elastic region and the tensile force in the forming direction increased.

• Design & Manufacturing
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• v.13 no.4
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• pp.1-9
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• 2019

In-mold Coating is a method that can simultaneously perform injection molding and surface coating in injection mold. The material used for coating is two-component polyurethane which is composed of polyol and isocyanate. L-type mixing head can be used to mix polyol and isocyanate uniformly, and inject them inside the mold cavity. The surface quality of the injection molded products by using in-mold coating depends on the mixing uniformity between main agent and hardener. In this study, flow analysis was performed to design a mixing head for uniform mixing of two-component polyurethane. Especially the effects of design parameters of mixing head on mixing uniformity and nozzle pressure were investigated. The parameters of mixing head were mixing chamber diameter, cleaning cylinder diameter, nozzle alignment angle in the horizontal and vertical direction, and cleaning piston position. It was found that optimal design values were mixing chamber diameter of 3.5 mm, cleaning cylinder diameter of 5.0 mm, nozzle horizontal/vertical alignment angles of 140°/160°, and cleaning piston position of 1.8 mm. The optimal values would be used to develop a two-component mixing head achieving an uniform mixing for in-mold coating.