• 한국금형공학회:학술대회논문집
• /
• 한국금형공학회 2008년도 하계 학술대회
• /
• pp.197-202
• /
• 2008

With the growth of electrical power needs, demand of the knife-type switches in the distribution boards is increasing. We have developed a knife-type switch which is not currently produced in Korea. The switch was desinged and a comprehensive tooling for it was also accomplished. A total of two sets of injection molds and three sets of press dies were designed and manufactured. The parts for knife switches were produced using the tools. Finally, the parts were assembled together and the switch is now under the test phase.

• Design & Manufacturing
• /
• 제14권2호
• /
• pp.49-55
• /
• 2020

Recently, when a new component of construction equipment is designed, a stamping process capable of producing parts having high appearance quality and precision has been gaining attention. However, in general, as it is developed based on existing parts made by welding metal sheets and tubes, frequent to die modification occurs, which increases the time and cost of developing new parts. Thus, it is necessary to reduce the cost by shortening the die development period. In this study, a stamping process was designed for the urea tank cover, which is a part for excavators, to reduce the die development period through sheet metal forming analysis. The stamping process was designed by determining the blank holding force after selecting the initial blank shape and size. The round value at the corner was modified such that formability is ensured. After selecting process parameters, the thickness reduction rate and spring-back effect were reviewed.

• Design & Manufacturing
• /
• 제8권1호
• /
• pp.27-30
• /
• 2014

Alloy tool steel such as SKD11 and SKD61 or high speed tool like SKH51 are used as materials for semiconductor dies. Cavities, curl blocks, pot blocks and housings are made from those materials. To make those parts from alloy tool steel or high speed tool, one utilizes discharge machining, and mechanical machining including machining center, milling, drilling, forming grinding and others. In the process of cutting machining and polishing, the die materials become unsuitable for machining owing to bubbles and foreign substances in them, which hinders production process. Therefore, this study focuses on die material selection criteria, and on analysis and comparison of material characteristics to help companies to solve their problems, make die manufacture less burdensome and extend die life.

• Design & Manufacturing
• /
• 제8권1호
• /
• pp.5-9
• /
• 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.

• Design & Manufacturing
• /
• 제14권3호
• /
• pp.37-43
• /
• 2020

Progressive drawing processing is one of the manufacturing processes used to mass-produce a variety of products on the industrial site. In this study, the goal is to achieve a uniform product thickness of at least 1.3mm by reducing the wall thickness of the coupler parts used in automotive air conditioning systems to within 15% using A5052-H32 materials. The progressive die was designed using Blank's law of volume invariance. Due to the characteristics of the drawing process, the material thickness in the punch R part decreases and the thickness in the die R part increases. When designing the progressive die of the coupler part, an ironing method, a push back method, and a stand-alone die pad method were applied to each process to design a mold in consideration of the drawing rate and to artificially adjust the thickness change. The suitability of the method used in die design was investigated by measuring the thickness change of forming parts for each process. In the final part, it was confirmed that the thickness measurement values of the five regions of a radial line were implemented as 1.34-1.36 mm.

• Journal of Computational Design and Engineering
• /
• 제2권2호
• /
• pp.96-104
• /
• 2015

Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD) data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

• Design & Manufacturing
• /
• 제7권1호
• /
• pp.7-10
• /
• 2013

Pencil-core dies are relatively new technology in Korea. It is not that no one had tried to make them but had failed due to lack of technologies. However, Posco TMC Co., Ltd, one of the leading die makers in the world, is capable of sophisticated dies including pencil-core dies. Spark plugs made by pencil-core dies have energy efficiency close to 100 percent, which compares to 46 percent of conventional spark plugs. Even though they are now mostly installed in LPG automobiles, more and more diesel and gasoline vehicles are adopting them. This study focuses on how to improve core shape precision using controling design and parts machining methods for pencil-core dies and productivity.

• Design & Manufacturing
• /
• 제13권4호
• /
• pp.34-39
• /
• 2019

In this paper, in order to improve the formability and quality of the injection molded parts in the molds for molding the motorcycle rear cowl injection molded parts with different volumes at the same time, the flow of the molded parts is changed through the injection molding CAE analysis by changing the gate position, runner size and position. It is to find the optimum gate position, the diameter of the runner and the position where the balance is equal. The molded article formed by the optimization resulted in the uniformity of the molten resin at the same time at the corner of the product, thereby maintaining the flow balance favorable for mass production at lower injection pressure.

• Design & Manufacturing
• /
• 제12권2호
• /
• pp.22-26
• /
• 2018

In the automotive industry these days, plastic parts have been developed and replaced with plastic parts by maintaining the same function of existing press parts for a variety of reasons. Injection molding plastic parts are subject to molding defects due to various factors, among which the sink marks usually occur in the areas where bosses and ribs are installed. In this study, we analyzed the influence of various factors on the occurrence of sink marks by using the flow analysis of the forming analysis program(Moldflow analysis) using the rib model with the T-shape. Tests have shown that the greatest influence on the sink mark of cosmetic products is the thickness and pressure of the ribs, and the thickness of the basic moulding thickness of the product increases. However, it was considered that the resin temperature and the mold temperature do not greatly affect the occurrence of the sink mark.

• Design & Manufacturing
• /
• 제9권3호
• /
• pp.34-40
• /
• 2015

In the study, Three-dimensional drawing parts for conformal cooling circuit cavity & core and their 3D Metal parts using DMLS(Direct MetalLaser Sintering) and NC integrated machining center were showned. For conformal cooling circuit cavity and core parts, I discussed its practicality to DMLS multiple machinins process introducing general manufacturing process and comparing with them.