• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.10
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• pp.115-120
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• 2018

This study examined the cast quality of small-sized induction motor rotors during the die casting process. Numerical analyses with 3-dimensional half models were performed to investigate the filling patterns of aluminum molten metals into a mold after high-speed injections. The following were obtained from numerical analyses and experimental results. First, molten metals started to fill the lower end ring, then moved horizontally to fill the core slot and upper end ring, and finally stopped to fill the rotor core slot. Second, circulation of molten metals occurred at the lower end ring, resulting considerable porosity at the section of lower end ring from the experimental results. Third, further work for obtaining sound quality of rotor core cast is required to develop a new shape of the rotor core cast or improve the die casting conditions.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.12
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• pp.1647-1653
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• 2011

The cycle time in injection moulding greatly depends on the cooling time of the plastic part that is controlled by cooling channels. Cooling channels are required to facilitate the heat transfer rate from the die to the coolant without reducing the strength of the die. Employing layered manufacturing techniques (LMT), a die embedding conformal cooling channels can be fabricated directly while conventional cooling channels are usually made of straight drilled hole. Meanwhile, H13 tool steel is widely used as the die material because of its high thermal resistance and dimensional stability. However, H13 with a low thermal conductivity is not efficient for certain part geometries. In this context, the use of functionally graded materials (FGMs) between H13 and copper may circumvent a tradeoff between the strength and the heat transfer rate. This paper presents a method for modeling of conformal cooling channels made of FGMs.

• Journal of Korean Institute of Industrial Engineers
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• v.39 no.3
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• pp.149-155
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• 2013

Electric discharging machining (EDM) is commonly adopted to machine the precise and tiny part when it is difficult to meet the productivity and the tolerance by the conventional cutting method. The die-sinking EDM method works well to machine the micro-parts and the perpendicular wall of die and mould, whereas EDM drilling, called super drill, is excellent to machine the deep and narrow hole regardless the material hardness and the hole location. However, the electrode wear is rapid compared to the conventional cutting tool and makes it difficult to control the electrode feeding and to machine precisely. This paper presents an efficient method to estimate the electrode wear using hole pass-through experiment while the stochastic method is used to compensate for the estimation model. To validate the proposed method, the commercial EDM drill machine is used. The experiment result shows that the electrode wear amount can be predicted very precisely.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.2
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• pp.594-603
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• 1996

It has been known that the life time of cold forging dies is shorten by the cracks and wear produced during the operation. Thus it is required to mak the same new one too often, At this time of making new ont the cutting work and electical discharge machining were mormally used. But the precision of product is declined in every times of making the mew dies due to the diffefence in dimensional accuracy arised from the electical discharge machining. Especially it can't meet the delivery date because the production was delayed for making another die. Furthemore it has the problem of increasing the production cost. Therfore inthis study we tried to solve these problems using the hobbing method instead of electical discharge machining.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.2
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• pp.133-140
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• 2009

Presented in this paper is a method to generate round-endmill toolpaths for sculptured surfaces represented as a triangular mesh model. The proposed method is applicable in toolpath generation for ball-endmills and flat-endmills because the round-endmill is a generalized tool in three-axis NC (numerical control) milling. The method uses a wireframe model as the offset model that represents a cutter location surface. Since wireframe models are relatively simple and fast to calculate, the proposed method can process large models and keep high precision. Intersection points with the wireframe offset model and a tool guide plane are calculated, and intersection curves are constructed by tracing the intersection points. The final step of the method is extracting regular curves from the intersection curves including degenerate and self-intersected segments. The proposed method is implemented and tested, and a practical example is presented.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.4
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• pp.39-43
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• 2006

A computer-controlled micro tribotester has been developed to investigate the friction and wear characteristics of thin coatings, which can be applied to silicon-based materials. In the developed system, a step motor gives a reciprocating movement and an electromagnet applies a load between a ball and a plate specimen. Test results confirmed that the application of load in the range of $0.03{\sim}1.8N$ and with a sliding speed of $4.44{\sim}7.70mm/s$ was successfully accomplished. Advantages of the developed micro tribotester are: (1) realization of micro load and displacement applicable to micro electromechanical systems(MEMS) using DC motor and electromagnet (2) continuously variable load and reciprocating speed; and (3) high reliability, which allows for unattended use for long periods.

• Journal of Korea Foundry Society
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• v.18 no.4
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• pp.373-382
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• 1998

Particulate reinforced aluminum alloys produced by indirect squeeze casting are difficult to shape by cutting or milling. Therefore near net shape forming of complex shapes is of high economic and technical interest. The complex shape products of $SiC_p/6061$ Al composites are fabricated by the melt-stirring and indirect squeeze casting process. The mold temperatures are $200^{\circ}C$ and $300^{\circ}C$ and applied pressures are 70, 100, and 130 MPa. The volume fractions of the reinforcements are in the range of 5 vol% to 15 vol%. The reinforcement dispersion state are observed using on optical microscope. By employing observed results systematically a correlation is demonstrated among the microstructure, particles behavior, mechanical properties and processing parameters for an optimum melt-stirring(compocasting) and indirect squeeze casting process of MMCs. A procedure to establish the optimum squeeze casting of Al-MMCs is proposed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.956-959
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• 2001

In die and mould industry, major material such as cemented carbide is broadly used for increasing the life time and decreasing the cost. It is also required the development for the skills of wire-cut electrical discharge machining(WEDM), but the WEDMed surface was found to be worst due to the attached components of wire. Precision machining method like lapping is necessary for obtaining high quality surface. The lapping compound such as Al2O3 and SiC and cast iron lap can be used for lapping process. The components of Cu and Zn were found WEDMed surface of the specimen. As the result, the low quality of precision was obtained and the heat damage layer of the specimen was occurred. The value of surface hardness was deteriorated, and therefore finish process was required.

• Journal of the Korean Society for Heat Treatment
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• v.7 no.4
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• pp.233-243
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• 1994

Constitutive relation of thermoelasto-plastic material undergoing phase transformation during quenching process were developed on the basic of continuum thermodynamics. The metallic structure, temperature and residual stresses distributions were numerically calculated by the finite element technique. The metallic structure were defined by transformation from austenite to pearlite and characterized as a fuction of thermal history and mixture rule of phase. On the distribution of thermal stress along the radial direction, axial and tangential stresses are compressive in the surface, and tential in the inner part. Radial stress is tensile in the whole body. The reversion of residual stress takes plase at 11.5~15.5mm from the center.

• Journal of the Korean Society for Heat Treatment
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• v.8 no.3
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• pp.222-228
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• 1995

Mechanical alloying behaviour was investigated after adding 6, 8, 12wt% Fe powder into A1 matrix, respectively, in order to develop Al alloy. And the mechanical characteristics of the alloy which was produced by the above method were studied. The hardness and ultimata tensile strength of the material with different compositions were found to be increased with annealing temperatures and holding times. Intermetallic compound of $Al_3Fe$ and carbide of $Al_4C_3$ phases, which were generated from the different compositions during annealing, were found. It was suggested that enhancement of mechanical properties of Al-Fe alloy system was due to the presence of these preapitates that constrained grain growth and blocked dislocation movement in the alloy system.