• Transactions of Materials Processing
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• v.12 no.4
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• pp.408-413
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• 2003

Dies may have to be replaced for a number of reasons, such as changes in dimensions due to die wear or plastic deformation, deterioration of the surface finish, break down of lubrication and cracking or breakage. In this paper, die cooling methods have been suggested to improve die service life considering die wear and plastic deformation in hot forging process. The yield strength of die decreases at higher temperatures and is dependent on hardness. Also, to evaluate die life due to wear, modified Archard's wear model has been proposed by considering the thermal softening of die expressed in terms of the main tempering curve. It was found that the use of die with cooling hole was more effective than that of direct cooling method to increase the die service life for spindle component.

• Korean Journal of Materials Research
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• v.34 no.3
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• pp.170-174
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• 2024

In this study, we report the microstructural evolution and shear strength of an Sn-Sb alloy, used for die attach process as a solder layer of backside metal (BSM). The Sb content in the binary system was less than 1 at%. A chip with the Sn-Sb BSM was attached to a Ag plated Cu lead frame. The microstructure evolution was investigated after die bonding at 330 ℃, die bonding and isothermal heat treatment at 330 ℃ for 5 min and wire bonding at 260 ℃, respectively. At the interface between the chip and lead frame, Ni₃Sn₄ and Ag₃Sn intermetallic compounds (IMCs) layers and pure Sn regions were confirmed after die bonding. When the isothermal heat treatment is conducted, pure Sn regions disappear at the interface because the Sn is consumed to form Ni₃Sn₄ and Ag₃Sn IMCs. After the wire bonding process, the interface is composed of Ni₃Sn₄, Ag₃Sn and (Ag,Cu)₃Sn IMCs. The Sn-Sb BSM had a high maximum shear strength of 78.2 MPa, which is higher than the required specification of 6.2 MPa. In addition, it showed good wetting flow.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.401-404
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• 2009

The purpose of this study is investigating the joint characteristics of advanced high strength steel DP780 and Al5052 alloy sheet in the clinching process. It is difficult to join the advanced high strength steel with light-weight materials like aluminum alloy, because of low formability of DP780. The defects of clinching joint such as necking of the upper sheet, cracks of the lower sheet and no interlocking were occurred by different ductility between advanced high strength steel and aluminum alloy. The clinching conditions should be optimized to interlock without any defects. In this study, the effect of process parameters of clinching process on joinability of advanced high strength steel with Al5052 alloy was investigated by using FE-analysis. From the result of FE-analysis, the clearance between clinching punch and die, die depth and the shape of die cavity mainly affected the joinability of advanced high strength steel with Al5052 alloy.

• Korean Journal of Materials Research
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• v.14 no.3
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• pp.168-174
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• 2004

The aim of this study is to investigate the effect of process conditions on the microstructual changes and mechanical properties of large 7175 aluminum die forgings. The cast billets of 370 and 720 mm in diameter were homogenized and die forged after direct chill casting. The size and volume fraction of second phase particles in 720 mm billet were larger than those of 370 mm billet. The interdendritic sites containing the second phase particles was considered to be a crack initiation region in the process of cold upsetting. The tensile and yield strength of die forged specimens of 720 mm billet in the direction of Land L T were higher than those of 370 mm billet. However, the tensile strength of these specimens were 5 to 10% lower than that of American military specification. The plane strain fracture toughness of die forged specimens of 370 mm cast billet showed almost the same level of 720 mm billet, which was die forged after free forging.

• Transactions of Materials Processing
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• v.31 no.5
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• pp.261-266
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• 2022

To reduce the weight of the vehicle, the application of the high strength steel sheets to chassis parts is increased. High forming load is induced during the shearing process of steel chassis parts made of high strength steel, and the possibility of an eccentric load is increased depending on the product seating condition on the die, which decreases the stability and lifespan of the die. In this paper, a three-dimensional finite element analysis with the continuum element was conducted using the damage theory for the cam-trimming process of the front lower arm. The structural analysis of the trimming die was performed with the forming load result obtained from the analysis, and the amount of deflection and the stress distribution of the die during the shearing process were evaluated for the confirmation of the tool stability. The shape of the weak region of the die was modified according to structural analysis and then the stability was confirmed with the finite element analysis. The analysis result showed that the possibility of tool failure during cam-trimming process was remarkably reduced, and the reliability of the proposed modified design was validated.

• 한국기계연구소 소보
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• s.17
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• pp.75-82
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• 1987

Shrink-rings (Stress-rings) are used in the fabrication of powder compaction dies to increase the allowable compaction pressures for a given die material. Optimum Procedures are used to insure that the stress distributions in the die and stress-rings ultilize fully the strength available in each of the die elements. Two criteria for the optimum die design are used: Maximum shear stress limit for one-piece dies and zero tensile stress limit for combined dies. Examples for each case are presented in this paper.

• The Journal of Korean Academy of Prosthodontics
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• v.38 no.5
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• pp.583-594
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• 2000

Dislodgement of a crown or extension bridge and the loosening of a retainer of a bridge is a serious clinical problem in fixed restoration. Generally these problems are considered to be associated with deformation of the restoration. During biting, the restoration is subjected to complex forces and deforms considerably within the limit of its elasticity. Deformation of the restoration under the occlusal force induces excessive stress in the cement film, which then leads to the cement fracture. Such a fracture may eventually cause loss of the restoration. Because most of the past retention tests for full veneer crown were done without fatigue loading, they were not exactly simulating intraoral environment. And the purpose of this study was to evaluate the effect of cyclic cantilever loading on the retentive strength of full veneer crowns depending on different type of cements and taper of prepared abutment. Steel dies with $8^{\circ}\;or\;16^{\circ}$ convergence angle were fabricated through milling and crowns with the same method. These dies and crowns were divided into 8 groups. Group 1 : $16^{\circ}$ taper die, cementation with zinc phosphate cement, without loading Group 2 : $16^{\circ}$ taper die, cementation with zinc phosphate cement, with loading Group 3 : $8^{\circ}$ taper die, cementation with zinc phosphate cement, without loading Group 4 : $8^{\circ}$ taper die, cementation with zinc phosphate cement, with loading Group 5 : $16^{\circ}$ taper die, cementation with Panavia 21, without loading Group 6 : $16^{\circ}$ taper die, cementation with Panavia 21, with loading Group 7 : $8^{\circ}$ taper die, cementation with Panavia 21 without loading Group 8 : $8^{\circ}$ taper die, cementation with Panavia 21, with loading After checking the fit of die and crown, the luting surface of dies and inner surface of crowns were air-abraded for 10 seconds. The crowns were cemented to the dies, with cements mixed according to the manufacturer's recommendations. A static load of 5kg was then applied for 10 minutes with static loading device. Twenty-four hours later, group 1, 3, 5, 7 were only thermocycled, group 2, 4, 6, 8 were subjected to cyclic loading after thermocycling. Retentive tests were performed on the Instron machine. From the finding of this study, the following conclusions were obtained 1. Panavia 21 showed significantly higher retentive strength than zinc phosphate cement for all groups (p<0.05). 2. There was a significant difference in the retentive strength between $8^{\circ}\;and\;16^{\circ}$ taper for zinc phosphate cement(p<0.05), but no significant difference for Panavia 21 (p>0.05). 3. Cyclic loading significantly decreased the retentive strength for all groups(p<0.05). 4. For zinc phosphate cement, there was 35% reduction of the retentive strength after loading in the $16^{\circ}$ taper die, 25% in the $8^{\circ}$ taper die, and for Panavia 21, 21% in the $16^{\circ}$ taper die, 18% in the $8^{\circ}$ taper die.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.1173-1174
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• 2006

Improvement of the strength is one of the most important subjects on soft magnetic composite (SMC) to increase the applica ble items. In this study, lubricants for inner lubricating SMC, which can be produced in lower cost than die wall-lubricatin g SMC, varied to investigate their effect on the strength. The newly developed SMC with self-lubricating resin shows high st rength equivalent to that of SMC obtained by die wall lubrication.

• Korean Journal of Materials Research
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• v.13 no.12
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• pp.812-818
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• 2003

The aim of this study is to investigate the fabrication processes on the microstructual changes and mechanical properties of large 7175 aluminum die forgings. The billets range from 370 to 720 mm in diameter were homogenized and hot forged after direct chill casting. The strength and elongation of the homogenized cast billets were revealed nearly same level independent of the billet diameter. However, these properties of ø370 mm cast billet were superior to those of $\Pie720$ mm billet under$ T_{6}$ / condition. The tensile strength of die forged specimens under $T_{6}$ condition increased up to 20% than that of solution treatment, however, the elongation was reduced to 50%. The fracture toughness of die forged specimens under $T_{6}$ condition was 35.6∼39.0 MPa$.$$m^{1}$2 irrespective of the billet size and free forging processes, but this property increased up to 10% by$V_{74}$ treatment. The fracture toughness of die forged specimen manufactured with ø370 mm cast billet showed nearly same level of ø720 mm billet which was processed using MF or Cog free forging followed by die forging.

• Journal of Sensor Science and Technology
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• v.32 no.3
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• pp.159-163
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• 2023

Salt cores have attracted considerable attention for their application to the casting process of electric vehicle parts as a solution to ecological issues. However, the salt core still has low mechanical strength for use in high-pressure die casting. In this study, we investigated the improvements in the bending strength of KCl-based salt cores resulting from the use of reinforcing materials. KCl and Na₂CO₃ powders were used as matrix materials, and glass fiber and carbon fiber were used as reinforcing materials. The effects of carbon fiber and glass fiber contents on the bending strength properties were investigated. Here, we obtained a new fiber-reinforced salt core composition with improved bending strength for high-pressure die casting by adding a relatively small amount of glass fiber (0.3 wt%). The reinforced salt core indicates the improved properties, including a bending strength of 49.3 Mpa, linear shrinkage of 1.5%, water solubility rate of 16.25 g/min·m² in distilled water, and hygroscopic rate of 0.058%.