• Proceedings of the KSME Conference
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• 2008.11a
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• pp.1825-1828
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• 2008

A simple method for the fabrication of porous nano-master for antireflective surface is presented. In conventional fabrication methods for antireflective surface, coating method with low refractive index has usually been used. However, it is required to have high cost and long times for mass production. In this paper, we suggested the fabrication method of antireflective surface by the hot embossing process using the porous nano patterned master on silicon wafer fabricated by low-temperature anodic aluminum oxidation. Through multi-AAO and etching processes, nano patterned master with high aspect ratio was fabricated at the large area. Pore diameter and inter-pore distance are about 150nm and from 150 to 200nm. In order to replicate anti-reflective structure, hot embossing process was performed by varying the processing parameters such as temperature, pressure and embossing time etc. Finally, antireflective surface can be successfully obtained after etching process to remove selectively silicon layer of AAO master.

• Transactions of Materials Processing
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• v.22 no.6
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• pp.317-322
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• 2013

A radio frequency(R/F) switch connector is widely used in wireless devices such as mobile phone and navigator to check defects of the circuit board of product. The R/F switch connector shell plays a role in protecting the switch connector. Previously, this part was machined using a turning, which is time-consuming and has poor material utilization. Furthermore, the workpiece material of brass containing lead that has excellent machinability has environmentally regulated during recent years. The purpose of the current study was to develop the connector shell by forming through progressive dies including embossing, burring and forging process in order to achieve higher productivity and dimensional accuracy without tool failure. To accomplish this objective, a strip layout was designed and finite element (FE) analysis was performed for each step in the process. Try-out for the connector shell was conducted using progressive die design based on FE-analysis results. Dimensional accuracy of developed part was investigated by scanning electron microscopy. The result of the investigation for the dimensions of the formed connector shell showed that the required dimensional accuracy was satisfied. Moreover, productivity using the progressive die increased four times compared to previous machining process.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.618-623
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• 2000

In order to increase the porductivity of electrical parts, manufacturing processes using progressive dies have been widely used in the industry. Motor cores have been fabricated using progressive stacking die with the lamination procedure for better electro-magnetic property. for the proper design of a process, a prediction of the process is required to obtain many design parameters. In this work, rigid-plastic finite element analysis is carried out in order to simulate the lamination this work, rigid-plastic finite element analysis is carried out in order to simulate the lamination process of the motor core. The effects of the embossing depth and the amount of deviation are investigated and compared with experiments. The forming process can then be predicted successfully from the results of analyses, which enables to design appropriately the die and the process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.10 no.5
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• pp.45-52
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• 2001

In order to increase the productivity of electrical parts, manufacturing processes using progressive dies have been widely used in the industry. Motor cores have been fabricated using progressive stacking die with the lamination procedure for better electro-magnetic property. For the proper design off process, a prediction of the process is required to obtain many design parameters. In this work, rigid-plastic finite element analysis is carried out in order to simulate the lamination process of the motor core. The effects of the embossing depth, the amount of deviation, and the number of stacked sheets are investigated and compared with experiments. The forming process can then be predicted successfully from the results of analyses, which enables an appropriate design to be made for the die and the process.

• Transactions of Materials Processing
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• v.15 no.1 s.82
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• pp.34-41
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• 2006

Microlens arrays were fabricated by a modified LIGA process composed of the exposure of a PMMA (Polymethylmethacrylate) sheet to deep x-rays and subsequent thermal treatment. A successful modeling and analyses for microlens formation were presented according to the experimental procedure. A nickel mold insert was fabricated by the nickel electroforming process on the PMMA microlens arrays fabricated by the modified LIGA process. For the replication of microlens arrays having various diameters with different foci on the same substrate, both hot embossing and microinjection molding processes have been successfully utilized with the fabricated mold insert. Replicated microlenses showed very good surface roughness with the order of 1 nm. The focal lengths of the injection molded microlenses were successfully estimated theoretically and also measured experimentally.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.4
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• pp.14-20
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• 2015

Molding technologies for plastic microstructures have been extensively investigated during the last two decades, and theoretical and numerical studies on the micro molding process have provided efficient tools for the development of such molding technologies. In this paper, we present a review of numerical simulation methods for the micro molding process. Basic models for a description of the material property, governing equations of the flow and heat transfer during the molding process, and numerical methods will be described. Particularly, numerical simulations for micro injection molding and hot embossing processes will be presented, and their main features noted and compared to those for conventional molding processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.23-28
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• 2005

Microlens arrays were fabricated using a modified LIGA process based on the exposure of a PMMA (Polymethylmethacrylate) sheet to deep x-rays and subsequent thermal treatment. A successful modeling and analyses for microlens formation were presented according to the experimental procedure. A nickel mold insert was fabricated by the nickel electroforming process on the PMMA microlens arrays fabricated by the modified LIGA process. For the replication of microlens arrays having various diameters with different foci on the same substrate, the hot embossing and the microinjection molding processes have been successfully utilized with the fabricated mold insert. Fabricated microlenses showed good surface roughness than the mold insert. The focal lengths of the injection molded microlenses were successfully measured experimentally and also estimated theoretically.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.6
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• pp.2458-2464
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• 2012

Recently, component materials for display are being developed into higher value-added industries which can strengthen national industrial competitiveness. However, a system for production of component materials for display is nearly depending on import, and its development level is inadequate. For this reason, localization of the embossing treatment system for production of the spacer tape and system improvement for increasing of productivity are needed. Therefore, in this paper, we propose rotary type embossing process system for spacer tape production for localization of system and increasing productivity. The system consists of unwinding, forming, cleaning, winding and testing parts. The mold of forming part is designed to rotary type. And we designed each part and made a prototype to test its performance. We measured embossing shapes, diameter and distance between each embossing and opposite embossing using three coordinate measuring machine. Also, we measured impurity level and the number of impurity particles of sample through the testing and cleaning part. Additionally, the productivity of spacer tape produced by the prototype is measured.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.616-624
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• 2009

In this work we demonstrate the hot-embossing process under different forming conditions such as forming temperature, load, and holding time in pressing, in order to determine the suitable conditions required for linear patterning on polymer plates (PC). Results showed that the replicated pattern depth increased in proportion to an increase in the forming temperature, load, and time. The reduction of the workpiece thickness increased according to the holding time in the pressing process. In the process of time, the reduction ratio of the workpiece thickness decreased due to the surface area increment of the workpiece, while the pressure on the workpiece declined. In order to reduce the bulging ratio we introduced a temperature difference between the upper and the lower punch.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1452-1455
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• 2004

Sandwich structures, which are composed of a thick core between two thin faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Depending on the application of a particular sandwich structure, various types of cores can be used. The production of sandwich sheets by a rolling process, which is a more efficient and economical approach compared to other types of processes, has become an increasingly important subject of study. In this paper, we have studied the embossing structure of sheet type and developed embossing roll mold with $\Phi$3 pattern and roll forming system.