• Journal of the Korean Society for Precision Engineering
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• v.16 no.2 s.95
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• pp.123-129
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• 1999

Ball-end milling process is widely used in the die and mold manufacturing because of suitable one for the machining of free-form surface. During the process, the pencil cutting operation can be adopted before finish cut to eliminate overload in uncut area caused by large diameter of ball-end mill. The ball-end mill cutter for the pencil cutting is easily deflected by cutting force due to the long and thin shape, and the tool deflection in pencil cutting is one of the main reason of the machining errors in a free-form surface. The purpose of this study is to find the characteristics of deflected cutter trajectory by constructing measurement system with eddy-current sensor. It was found that the severe reduction of corner radius produced the overcut during the plane cutting. Up cutting method induced the overcut both plane and slope cutting, but down cutting one induced the undercut. From the experiments, down cutting with upward cutting path can generate the small undercut surface.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1784-1788
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• 2003

For the improvement of geometrical accuracy in end milling, cutting method and cutting condition selection are investigated in this paper. As machining processes are composed of several steps such as roughing, semi-finishing. and finishing, cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting. The effects of tool teeth numbers, tool geometry, and cutting conditions on the form error are analyzed. Using the from error prediction method from tool deflection, cutting condition for geometrical accuracy improvement is discussed. The characteristics and the difference of generated surface shape in up and down milling are dealt with and over-cut free condition in up milling is presented. The form error reduction method by alternating up and down milling is also suggested. The effectiveness of the presented method is examined from a set of cutting tests under various cutting conditions. This research contributes to cutting process optimization for the geometrical accuracy improvement in die and mold manufacture.

• Journal of Korea Foundry Society
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• v.20 no.5
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• pp.330-335
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• 2000

Functional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported. But a system which can build directly 3D parts of high performance functional material as metal park would get long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we translated the wax patterns to numerous metal tool prototypes by new investment casting process combined conventional investment casting with rapid prototyping & rapid tooling process. With this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P pare to metal part.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2009.06a
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• pp.216-216
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• 2009

This paper describes a novel processing technique for the fabrication of polymer-derived SiCN (silicone carbonitride) microstructures for extreme microelectromechanical system (MEMS) applications. A polydimethylsiloxane (PDMS) mold was formed on an SU-8 pattern using a standard UV photolithographic process. Next, the liquid precursor, polysilazane, was injected into the PDMS mold to fabricate free-standing SiCN microstructures. Finally, the solid polymer SiCN microstructure was cross-linked using hot isostatic pressure at $400^{\circ}C$ and 205 bar. The optimal pyrolysis and annealing conditions to form a ceramic microstructure capable of withstanding temperatures over $1400^{\circ}C$ were determined. Using the optimal process conditions, the fabricated SiCN ceramic microstructure possessed excellent characteristics includingshear strength (15.2 N), insulation resistance ($2.163{\times}10^{14}\;{\Omega}$, and BDV (1.2 kV, minimum). Since the fabricated ceramic SiCN microstructure has improved electrical and physical characteristics compared to bulk Si wafers, it may be applied to harsh environments and high-power MEMS applications such as heat exchangers and combustion chambers.

• Design & Manufacturing
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• v.13 no.3
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• pp.12-18
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• 2019

Fluid jet polishing is a method of jetting a fluid to polish a concave or free-form surface. However, the fluid jet method is difficult to form a stable polishing spot because of the lack of concentration. In order to solve this problem, MR fluid jet polishing system using an abrasive mixed with an MR fluid whose viscosity changes according to the intensity of a magnetic field is under study. MR fluid jet polishing is not easy to formulate for precise optimal conditions and material removal due to numerous fluid compositions and process conditions. Therefore, in this paper, quantitative data on the factors that have significant influence on the machining conditions are presented using various simulations and the correlation studies are conducted. In order to verify applicability of the fabricated MR fluid jet polishing system by nozzle diameter, the flow pattern and velocity distribution of MR fluid and polishing slurry of MR fluid jet polishing were analyzed by flow analysis and shear stress due to magnetic field changes was analyzed. The MR fluid of the MR fluid jet polishing and the flow pattern and velocity distribution of the polishing slurry were analyzed according to the nozzle diameter and the effects of nozzle diameter on the polishing effect were discussed. The analysis showed that the maximum shear stress was 0.45 mm at the diameter of 0.5 mm, 0.73 mm at 1.0 mm, and 1.24 mm at 1.5 mm. The cross-sectional shape is symmetrical and smooth W-shape is generated, which is consistent with typical fluid spray polishing result. Therefore, it was confirmed that the high-quality surface polishing process can be stably performed using the developed system.

• Proceedings of the Korean Vacuum Society Conference
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• 2012.08a
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• pp.411-411
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• 2012

Over the recent years, surface enhanced Raman spectroscopy (SERS) has dramatically grown as a label-free detecting technique with the high level of selectivity and sensitivity. Conventional SERS-active nanostructured layers have been deposited or patterned on rigid substrates such as silicon wafers and glass slides. Such devices fabricated on a flexible platform may offer additional functionalities and potential applications. For example, flexible SERS-active substrates can be integrated into microfluidic diagnostic devices with round-shaped micro-channel, which has large surface area compared to the area of flat SERS-active substrates so that we may anticipate high sensitivity in a conformable device form. We demonstrate fabrication of flexible SERS-active nanostructured substrates based on soft-lithography for simple, low-cost processing. The SERS-active nanostructured substrates are fabricated using conventional Si fabrication process and inkjet printing methods. A Si mold is patterned by photolithography with an average height of 700 nm and an average pitch of 200 nm. Polydimethylsiloxane (PDMS), a mixture of Sylgard 184 elastomer and curing agnet (wt/wt = 10:1), is poured onto the mold that is coated with trichlorosilane for separating the PDMS easily from the mold. Then, the nano-pattern is transferred to the thin PDMS substrates. The soft lithographic methods enable the SERS-active nanostructured substrates to be repeatedly replicated. Silver layer is physically deposited on the PDMS. Then, gold nanoparticle (AuNP) inks are applied on the nanostructured PDMS using inkjet printer (Dimatix DMP 2831) to deposit AuNPs on the substrates. The characteristics of SERS-active substrates are measured; topology is provided by atomic force microscope (AFM, Park Systems XE-100) and Raman spectra are collected by Raman spectroscopy (Horiba LabRAM ARAMIS Spectrometer). We anticipate that the results may open up various possibilities of applying flexible platform to highly sensitive Raman detection.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.6
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• pp.52-57
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• 1999

Funtional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported by song etc. But a system which can build directly 3D parts of high performance functional material as metal part would need long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we tranlsated the wax patterns to numerous metal prototypes by new investment casting process combined conventional investment casting with rapid pototyping & rapid tooling process. with this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P part to metal part.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1999.05a
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• pp.240-244
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• 1999

This paper deals with the establishment of the cutting direction on inclined plane by using ball end mill. Ball-end milling is widely used for free form surface die and mold. In these machining, the cutting parts vary because the tool tip is hemisphere shaped. The cutting characteristics, such as cutting force, surface roughness and surface profile are varied according to the variation of cutting directions. The effective tool diameter was calculated on different tilt angles and tool-path. Tool life and cutting characteristics were estimated on variation of cutting directions in the same cutting speed. In this paper, the optimal cutting direction which can be applied 3-D sculpture surface cutting is suggested.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.12
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• pp.511-517
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• 2016

Current oil-type potential transformers for trains are filled with insulating oil, which could have problems like explosions due to rising inner pressure during train operation. Therefore, mold and dry-type potential transformers are being developed to prevent explosions. One problem in manufacturing mold-type transformers is preventing void formation around the coiled core inside the mold during epoxy filling, which could cause an electrical spark. Micro voids can remain in the resin after filling, and macro voids can occur due to the structure shape. A transformer that is being developed has a cavity at the junction of the core and the coil for better performance, and when highly viscous epoxy flows inside the cavity channel, macro voids can form inside it. Therefore, in this study, the free-surface flow of the mold filling procedure was analyzed numerically by applying the VOF method. The results were used to understand the phenomena of void formation inside the cavity and to modify the process conditions to reduce voids.

• Proceedings of the Korean Institute of Building Construction Conference
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• 2021.11a
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• pp.154-155
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• 2021

Appearance finish is important for amorphous buildings to maximize amorphousness, and GFRC, glass, and metal are mostly used as exterior materials for amorphous buildings currently applied. However, the existing exterior materials showed limitations in amorphous expression, texture, and color expression. In this study, a 3D stereoscopic panel mold was manufactured using the FDM method, one of the 3D printing technologies, and 3D stereoscopic panel production was reviewed using Ultra High Performance Concrete (UHPC), which has excellent physical and mechanical performance and expression. In order to overcome the limitations of unstructured expression, a UHPC 3D stereoscopic panel using the FDM method, one of the 3D printing technologies, was manufactured. Unlike steel molds, FRP molds, and EPS molds, the FDM method can be applied to various materials, and complex shapes are implemented. If it is used using recyclable materials as well as PLA filaments used in the FDM method, it will overcome the limitations of amorphous expression and activate the production of 3D stereoscopic panels that have secured eco-friendliness.