• Design & Manufacturing
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• v.8 no.2
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• pp.7-11
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• 2014

The Core-Shift is often generated on injection mold which have thin and long core. And Core-Shift brings out problems for thickness variation and product ejecting process. In this study, analysis of Core-Shift was performed according to change of materials of core(steel P-20, Be-Cu) and various polymers(PP, PC) by using MoldFolw MPI 6.1 which is commercial injection molding analysis program. As the results of analysis, the magnitude of Core-Shift was increased as being use polymer had lower fluidity and lower rigidity core. In the future, we will study the relationship between amount of Core-Shift and ejecting force.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.6
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• pp.708-714
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• 2016

In today's semiconductor industry, manufacturing technology is being developed for the purpose of processing large amounts of data and improving the speed of data processing. The packaging process in semiconductor manufacturing is utilized for the purpose of protecting the chips from the external environment and supplying electric power between the terminals. Nowadays, the WLP (Wafer-Level Packaging) process is mainly used in semiconductor manufacturing because of its high productivity. All of the silicon dies on the wafer are subjected to a high pressure and temperature during the molding process, so that die shift and warpage inevitably occur. This phenomenon deteriorates the positioning accuracy in the subsequent re-distribution layer (RDL) process. In this study, in order to minimize the die shift, a vision inspection system is developed to collect the die shift measurement data.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.8
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• pp.3358-3365
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• 2012

This paper presents a scheduling scheme for die casting processes considering power usage. The scheduling problem of a shift-based die casting process is represented by a linear programming (LP) model that maximizes the average efficiency of melting furnaces in regard of the usage of molten alloy, where the product quantities of each shift are used as primary variables. In this research, we propose a novel LP model that considers power usage of foundries. The developed LP model can derive product plans in which the expended power of a casting shift does not exceed a prescribed limit, while optimizing the efficiency of alloy usage. The simulation result of a case study demonstrates the superiority and applicability of the proposed scheme. This paper serves as a basic research on the role of foundries as an intelligent costumer in smart grid environment where the limit of power usage should be fulfilled.

• Design & Manufacturing
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• v.8 no.1
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• pp.5-9
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• 2014

This study is about 3D design for parts supporting copper pipes of wall-mounted air-conditioners manufactured by company "D" in Japan. Domestic press die manufacturers are obsessed with 2D die design and are afraid of taking risk with developing 3D die design and die manufacture. This hinders paradigm shift. In this study, the strip layout, which was already completed in the previous study, is altered by adding restriking. Based on the modified strip layout, the 3D die design is done in 15 processes.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.4
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• pp.1565-1574
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• 2011

Scheduling of die casting is a procedure of determining quantities of cast products so as to optimize a predetermined performance criterion. This paper presents a novel scheme of preventing product shortage raised by defective castings when die casting scheduling is applied to real casting operations. The previously developed linear programming (LP) model for die casting scheduling maximizes the average efficiency of melting furnaces in regard of the usage of molten alloy. However, the LP model is not able to cope with the problem of defective products occurring in the casting process. The proposed scheme is that whenever defective products are found in a shift, the foundryman produces additional cast products using the residue of molten alloy left at the end of the next shift. Neither the calculated amount of molten alloy nor the scheduling result of the LP model does not have to be altered for this method. The simulation result demonstrates the superiority and applicability of the newly proposed scheme.

• The Journal of Korean Academy of Prosthodontics
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• v.36 no.5
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• pp.738-747
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• 1998

The purpose of this study was to compare the positional stability of removable dies using several dowel pin systems. The removable dies were made by using five dowel pin systems: single dowel pin(Group I), single dowel pin and prepared groove on the die base(Group II), two-single dowel pin(Group III), two separate parallel dowel pins with plastic sleeves(Group IV), double straight dowel pins with metal sleeve(Group V). Special aluminum mold was made for specimens, and the dies of specimens removed and replaced thirty times with universal testing machine. Horizontal and vertical shift of dies was measured by Olympus monocular scanning tunneling microscope(STM5). The results were as follows: 1. The vertical shift was larger than the horizontal shift in all the other groups except Group I. 2. Single dowel pin system(Group I) was the most unstable of five dowel pin systems. 3. Double dowel pin systems with steeve(group IV, V) were the most stable of five dowel pin systems. 4. This study indicates that excellent horizontal positional stability is attainable with use of additional groove on the die base or double dowel pin. and excellent vertical positional stability is attainable with use of sleeve.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.28 no.1
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• pp.100-107
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• 2018

Objectives: This study examines exposure to hazardous substances in the working environment caused by exposure to toxic substances produced in the aluminum die casting process in the automobile manufacturing industry. Materials and Methods: The exposure concentration levels, detection rates and time-trend of 15 hazardous factors in the aluminum die casting process over 10 years(from 2006 to 2016) were used as a database. Results: The study found that hazardous factors in the aluminum die casting process were mostly metals. The rate for detected samples was 70.6%(405 samples), and that for not detected samples was 29.4%. The noise for an eight-hour work shift showed a 49.7% exceedance rate for TLV-TWA. Average noise exposure was 89.0 dB. The maximum exposure level was 105.1 dB. Conclusion: The high numbers of no-detection rates for hazardous substance exposure shows that there is no need to do a work environment measurement. Therefore, alternatives are necessary for improving the efficiency and reliability of the work environment measurement. Moreover, to prevent noise damage, reducing noise sources from automation, shielding, or sound absorbents are necessary.

• International Journal of Precision Engineering and Manufacturing
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• v.5 no.1
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• pp.36-41
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• 2004

The blanking of thin sheet metal using progressive dies is an important process on production of precision electronic machine parts such as IC leadframe. This paper summarizes the results of simulating the progressive blanking process by means of LS/DYNA. In order to verify the influence of blanking order on the final lead profile and deformed configuration, simulation technique has been proposed and analyzed using a commercial FEM code, LS/DYNA. The results of FE-simulations are in good agreement with the experimental result. After then, to construct rule base in progressive blanking process, FE-simulation has been performed using a simple model. Based on this result rule base is set up and then the blanking order of inner lead is rearranged. Consequently, from the results of FE-simulation using suggested method in this paper, it is possible to predict the shift of lead to manufacture high precision lead frame in progressive blanking process. The proposed method can give more systematic and economically feasible means for designing progressive blanking process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.169-172
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• 2000

In this paper, an OMM (On-the-Machine Measuring) system has been developed, which can perform measuring and inspection of sculptured surfaces of die and mold, by use of a scanning-type touch probe mounted into the spindle of a NC machine. The calibration procedures of a scanning prove (SP2-1, Renishaw) and an algorithm for measuring surface points by a ball-nosed stylus have been studied. The system has been developed based on commercial CAM software (Z-Master 2000), and tested through measuring a plastic injection molding-die. Also some experimental results of the calibration and measuring for given surface positions are analyzed to verify its accuracy and reliability.

• Design & Manufacturing
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• v.2 no.6
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• pp.23-27
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• 2008

It is well known that the family-mold has an advantage to reduce the cost for production and mold. However, defects are frequently occurred by over packing the smaller volume cavity during molding, especially when the family-mold has a volumetric difference between two cavities. In this study, the cavity-filling imbalance was confirmed by the temperature and the pressure sensors, and a variable-runner system was developed for balancing the cavity-filling. Experiments of balancing the cavity filling was carried out in the family-mold with the variable-runner system, and balancing the cavity-filling was confirmed by changing the cross-sectional area of a runner in the variable-runner system with the temperature and pressure sensors. The influence of the injection speed to the balancing-capability of the variable-runner system was also examined in the experiment.