• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.19 no.10
• /
• pp.44-51
• /
• 2020

We studied the heating characteristics of a whirling spindle. This spindle is an important component of a whirling machine for turning a ball screw shaft. In the manufacturing process for a conventional ball screw shaft, a single tool is used to form a spiral in a lathe machine tool. Thereafter, a high-frequency heat treatment process is performed. Recently, a whirling-type cutting method has emerged. This method can perform hard turning in the rotating direction of the spiral portion of the ball screw shaft by rotating and mounting multiple tools. The whirling method can be applied to the heat-treated material. In this study, an experimental apparatus was constructed to analyze the whirling spindle. The experiment proceeded in four steps. The rotating speed of the whirling spindle was set to ISO random and sequential rising conditions. Cooling and non-cooling modes in the cooling jacket were tested. As a result of the above experiment, the heating characteristics of the whirling spindle were derived.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.10a
• /
• pp.493-497
• /
• 2002

In the part industry, pipe has required high accuracy in surface roughness and size. Especially, when producing the high frequency welding pipe, cutting process is very important as the finishing process that remove the hot welding bead. The objective of this paper is to investigate the hot machining high frequency welded pipe by simulation and experimental tests. To test the cutting process as hot machining, all cutting environment is reproduced in turning with heating system, and the test is accomplished by comparing with room temperature machining and hot machining in consideration of cutting force, tool wear and cutting temperature.

• Korean Journal of Metals and Materials
• /
• v.47 no.10
• /
• pp.667-674
• /
• 2009

High temperature wear of STD 61 tool steels sliding against the Al-9%Si coated steels used for hot press forming has been studied in comparison with that of the tool steels sliding against the uncoated steels. Wear tests have been performed using a pin-on-disc configuration under an applied normal load of 50N for 20 min with heating the coated and uncoated steels up to 800$^{\circ}C$. It was found on the worn surface of the STD 61 tool steels sliding against the Al-9%Si coated steels that the formation of the glazed layers containing Al transferred from the coated tribopair may contribute to a reduction of the coefficient of friction, and detachment in part occur due to delamination wear, resulting in higher specific wear rate. On the other hand the Fe-oxide wear debris entrapped on the softer surface of the uncoated steels can act as a tribosurface, leading to decreased adhesive wear of the STD 61 tool steels, resulting in a lower specific wear rate.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.3
• /
• pp.130-134
• /
• 2016

Due to the need for advanced technologies in the automotive industry, the demand for lighter and safer vehicles has increased. Even though various nonferrous metals, like Aluminum, Magnesium and also Carbon Fiber Reinforced Plastic (CFRP), have been implemented in the automotive industry, a lot of technical research and development is still focused on ferrous metals. In particular, the market volume of High Strength Steel (HSS) parts and Ultra High Strength Steel (UHSS) by hot press forming parts has expanded significantly in all countries' automotive industries. A new tool steel, High Thermal-Conductivity Tool Steel (HTCS), for stamping punches and dies has been developed and introduced by Rovalma Company (Spain), and it is able to support better productivity and quality during hot press forming. The HTCS punches and dies could help to reduce cycle time due to their high thermal conductivity, one of the major factors in hot press forming operation. In this study, test dies were manufactured in order to verify the high thermal conductivity of HTCS material compared to SKD6. In addition, thermal deformation was inspected after the heating and cooling process of hot press forming. After heating and cooling, the test dies were measured by a 3D scanner and compared with the original geometry. The results showed that the thermal deformation and distortion were very small even though the cooling time was reduced by 2 seconds.

• Journal of computational fluids engineering
• /
• v.21 no.2
• /
• pp.90-98
• /
• 2016

A numerical study is conducted on thermal performance of a large-area hot plate specially designed as a heating and cooling tool for thermal nanoimprint lithography process. The hot plate has a dimension of $240mm{\times}240mm{\times}20mm$, in which a series of cartridge heaters and cooling holes are installed. The material is stainless steel selected for enduring the high molding pressure. A numerical model based on the ANSYS Fluent is employed to predict the thermal behavior of the hot plate both in heating and cooling phases. The PID thermal control of the device is modeled by adding user defined functions. The results of numerical computation demonstrate that the use of cartridge heaters provides sufficient heat-up performance and the active liquid cooling in the cooling holes provides the required cool-down performance. However, a crucial technical issue is raised that the proposed design poses a large temperature non-uniformity in the steady heating phase and in the transient cooling phase. As a remedy, a new hot plate in which heat pipes are installed in the cooling holes is considered. The numerical results show that the installation of heat pipes could enhance the temperature uniformity both in the heating and cooling phases.

• Transactions of Materials Processing
• /
• v.19 no.1
• /
• pp.50-58
• /
• 2010

In order to successfully implement hot die forging process for the large-size titanium alloy products, it is necessary to devise a customized heating method for the billets and the die tools, as well as the die tool design. This study aims at establishing a hot die forging process of the large-size titanium alloy container products by applying the warm die, semi-hot die and hot die forging process step-wise. To accomplish this purpose, forging mechanism and the die tools were designed considering the strength of die materials at the given die heating temperature. The movable heating devices for the billet and the die tools were also introduced to prevent overcooling of billet and die tools. To verify the applicability of the designed forging process, real-size forging tests were carried out and the quality of forged products, including dimension, surface condition, microstructure and the mechanical properties was evaluated.

• Nuclear Engineering and Technology
• /
• v.33 no.5
• /
• pp.468-482
• /
• 2001

As a process of Direct Containment Heating (DCH) issue resolution for Korean Standard Nuclear Power Plants (KSNPs), a containment load/strength assessment with two different approaches, the probabilistic and the deterministic, was performed with all plant-specific and phenomena-specific data. In case of the probabilistic approach, the framework developed to support the Zion DCH study, Two-Cell Equilibrium (TCE) coupled with Latin Hypercubic Sampling (LHS), provided a very efficient tool to resolve DCH issue. In case of the deterministic approach, the evaluation methodology using the sophisticated mechanistic computer code, CONTAIN 2.0 was developed, based on findings from DCH-related experiments or analyses. For three bounding scenarios designated as Scenarios V, Va, and VI, the calculation results of TCE/LHS and CONTAIN 2.0 with the conservatism or typical estimation for uncertain parameters, showed that the containment failure resulted from DCH loads was not likely to occur. To verify that these two approaches might be conservative , the containment loads resulting from typical high-pressure accident scenarios (SBO and SBLOCA) for KSNPs were also predicted. The CONTAIN 2.0 calculations with boundary and initial conditions from the MAAP4 predictions, including the sensitivity calculations for DCH phenomenological parameters, have confirmed that the predicted containment pressure and temperature were much below those from these two approaches, and, therefore, DCH issue for KSNPS might be not a problem.

• Journal of Electrical Engineering and Technology
• /
• v.10 no.3
• /
• pp.1383-1388
• /
• 2015

Proportional integral derivative (PID) control is one of the conventional control strategies. Industrial PID control has many options, tools, and parameters for dealing with the wide spectrum of difficulties and opportunities in manufacturing plants. It has a simple control structure that is easy to understand and relatively easy to tune. Injection mold is warming up to the idea of cycling the tool surface temperature during the molding cycle rather than keeping it constant. This “heating and cooling” process has rapidly gained popularity abroad. However, it has discovered that raising the mold wall temperature above the resin’s glass-transition or crystalline melting temperature during the filling stage is followed by rapid cooling and improved product performance in applications from automotive to packaging to optics. In previous studies, optimization methods were mainly selected on the basis of the subjective experience. Appropriate techniques are necessary to optimize the cooling channels for the injection mold. In this study, a digital signal processor (DSP)-based PID control system is applied to injection molding machines. The main aim of this study is to optimize the control of the proposed structure, including a digital PID control method with a DSP chip in the injection molding machine.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
• /
• v.20 no.10
• /
• pp.645-653
• /
• 2008

Spiral-jacketed thermal storage tanks can greatly simplify solar heating systems while maintaining the thermal performance at a similar level as conventional systems with an external heat exchanger. Proper design of the spiral-jacket flow path is essential to make the most of solar energy, and thus to maximize the thermal performance. In the present work, computational fluid dynamics (CFD) analysis was carried out for a spiral-jacketed storage tank installed in a solar heating demonstration system. The results of the CFD analysis showed a good agreement with experimentally determined thermal performance indices such as the acquired heat, collector efficiency, and mixed temperature in the storage tank. This verified CFD modelling approach can be a useful design tool in optimizing the shape of spiral-jacket flow path and the flow rate of circulating fluid for better performance.

• Transactions of Materials Processing
• /
• v.11 no.1
• /
• pp.61-68
• /
• 2002

The thermal shock and thermal fatigue test has been carried out to analyze the thermal characteristics of tool steels for hot forging and the effects of mechanical properties on this study have been investigated. The resistance to thermal shock is first of all a matter of good toughness and ductility. Therefore, a proper hot-work tool steel should be characterized by high fracture strength and high temperature toughness. Based on these results, some critical temperature($T_{fracture}$) at which fracture occur can be measured to characterize the thermal resistance of the materials. During thermal fatigue tests, the thermal fatigue cracks occur because of the repetitive heating and cooling of the die surface and the thermal fatigue damage was evaluated by analyzing different number of cycles to failure. The results showed that the resistance to thermal shock and thermal fatigue were found to be favoured by high hot tensile strength and high hot hardness, and thermal resistance of SKD61 was superior to that of ESC, SKT4 and this was caused by higher mechanical properties of SKD61.