• 한국기계가공학회지
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• 제20권4호
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• pp.80-86
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• 2021

Plastics are widely used in mechanical and other fields due to their light weight, design flexibility, and molding processability. In processing plastics, defective products are mixed and reprocessed to improve production efficiency and reduce costs. In this study, an experiment was conducted to confirm the coefficient of thermal expansion of HDPE during this reprocessing. The coefficient of thermal expansion was measured at different measurement directions and heating rates. As a result, we observed that the coefficient of thermal expansion in the direction perpendicular to the injection direction is greater than that in the horizontal direction.

• 한국정밀공학회지
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• 제33권11호
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• pp.893-898
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• 2016

Plastic array lens are cheap to manufacture; however, plastic is not resistant to high temperatures and moisture. Optical glass represents a better solution but is a more-expensive alternative. Glass array lens can be produced using lithography or precision-molding techniques. The lithography process is commonly used, for instance, in the semiconductor industry; however, the manufacturing costs are high, the processing time is quite long, and spherical aberration is a problem. To obtain high-order aspherical shapes, mold-core manufacturing is conducted through ultra-precision grinding machining. In this paper, a $4{\times}1$ mold core was manufactured using an ultra-precision machine with a jig for the injection molding of an aspherical array lens. The machined mold core was measured using the Form TalySurf PGI 2+ contact-stylus profilometer. The measurement data of the mold core are suitable for the design criterion of below 0.5 um.

• 한국자기학회:학술대회 개요집
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• 한국자기학회 2013년도 자성 및 자성재료 국제학술대회
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• pp.95-95
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• 2013

The NdFeB magnet can be classified into the sintered magnet and bonded magnet. The former has superior magnet characteristics but the degree of freedom in shape is highly restricted, whereas the latter has a high degree of freedom, but its magnet characteristics are inferior to the former. When a NdFeB magnet is used at the elevated temperature, part of Nd must be replaced with a high priced Dy to increase its coercive force. For these reasons, a Dy free and high performance NdFeB bonded magnet is desired strongly. The author successfully developed a Dy free NdFeB anisotropic bonded magnet based on discovery of new phenomena called as d-HDDR reaction and its mass production process such as a thermally balanced hydrogen reaction furnace, micro capsuled powder, compression molding / injection molding under magnetic field, magnetic die and so on. Applied to DC brush seat motor for automotive use, the motor has become 50% small in size and weight. The commercialization of a half sized motor for automotive use has been realized up to the market share of 30%. At present, its commercialization is extending to various types of motors such as power tool, ABS motor, wiper motor, window motor, electric bike power motor, and compressor motor. It is expected that the applications will be increasingly enlarged to EV motor, wind generator, EPS motor, washing machine, and glass cutting machine. This innovative technology has realized Dy free high performance magnet and mudt make big contribution to not only rare element strategies but also energy conservation.

• 한국레이저가공학회:학술대회논문집
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• 한국레이저가공학회 2004년도 추계학술대회논문집
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• pp.22-28
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• 2004

Pit and rim formation on the Acrylonitrile Butadiene Styrene(ABS) plastic surface was evaluated after it was irradiated by $CO_2$ and Nd:YAG laser beams. Our results show that thermal effect floor was well observed at the outer wall of pit with $CO_2$ laser irradiated while it was not the case with Nd:YAG laser irradiated. Also the volume and depth of pit formation increase proportionally with the energy intensities of two laser irradiations, but there are significant differences in the slope, width, and FWHM of the Pit formation with two types of laser irradiations. This result shows that $CO_2$ laser irradiation leads to better cooling contraction effect while Nd:YAG laser irradiation induces better recoil pressure effect during the interaction between ABS plastic and laser beam irradiation. The shape of the laser marking could vary significantly depending on the traveling path of molten plastic during injection molding of ABS plastic. Therefore, the selection of material and molding process can have a great impact on the performance of optical storage media.

• Composites Research
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• 제32권6호
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• pp.360-367
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• 2019

자전거 프레임 및 산업 부품과 같은 다양한 산업 분야에 PETG 열가소성 복합 재료를 적용하려면 제조 된 복합 재료의 내충격성, 내구성, 기계적 특성 및 3D 분석을 안정성 검증이 필수적이다. 본 연구에서는 비정질 수지인 PETG 수지의 기계적 특성, 내구성 및 내충격성을 향상시키기 위해 다양한 질량분율의 POE(폴리올레핀 엘라스토머)를 보강하여 화합물 및 사출 성형 공정을 수행 하였다. POE질량분율에 따른 PETG 열가소성 복합재의 열적 및 기계적 특성 및 샤르피 충격 강도 등에 대한 분석을 수행 하였다. 열적 및 기계적 특성 분석 결과, POE 소재가 첨가 된 PETG 열가소성 복합재의 경우 열적 및 기계적 특성이 감소하는 경향이 있지만 내충격성이 우수한 경향을 나타내었고, POE첨가에 따른 3D 전산해석 결과, 파손여부 없이 우수한 안정성을 나타내었다.

• 한국분말재료학회지
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• 제4권3호
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• pp.170-178
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• 1997

An investigation was performed to apply the M3/2 grade high speed steel for metal injection molding using both prealloyed and elementally blended powders. The injected samples were subjected to a debinding step in $H_2/N_2$ gas atmosphere at a ratio that affected the carbon content of the material. The carbon content ranged from 1.4wt.% to 1.43wt%. with increasing $H_2$ content up to 80% $H_2$ in $H_2/N_2$ atmosphere for the prealloyed powders. The carbon contents of the elementally blended powders exhibited 1.44wt.% and 1.62wt.% at 10% $H_2/N_2$ and 20% $H_2/N_2$ gas, respectively. This level decreased to 0.17wt.% upon increasing the $H_2$ content. The sintered density of both powders increased rapidly as the temperature reached the liquid phase forming temperature. After forming the liquid phase, the density rapidly increased to the optimum sintering temperature for the prealloyed powders, whereas the density of mixed elemental powders goes up slowly to the optimum sintering temperature. The optimum sintering temperature and density are 126$0^{\circ}C$ and 97.3% for the prealloyed powders and 128$0^{\circ}C$ and 96.9% for the elementally blended powders, respectively. The microstructure of the specimen at the optimum sintering temperature consisted of fine grains with primary carbides of MC and $M_6C$ type for the prealloyed powders. The elementally blended powders exhibited coarse grains with eutectic carbides of MC, $M_2C$ and $M_6C$ type.

• International Journal of Precision Engineering and Manufacturing
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• 제8권2호
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• pp.38-43
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• 2007

This paper describes ultrasonically assisted grinding used to obtain a glossy surface quickly and precisely. High-quality surfaces are required for plastic injection molding dies used in the production of plastic parts such as dials for cellular phones. Traditionally, in order to finish the dies, manual polishing by a skilled worker has been required after the machining processes, such as electro discharge machining (EDM), which leaves an affected layer, and milling, which leaves tooling marks. However, manual polishing causes detrimental geometrical deviations of the die and consumes several days to finish a die surface. Therefore, a machining process for finishing dies without manual polishing to improve the surface roughness and form accuracy would be extremely valuable. In this study, a 3D positioning machine equipped with an ultrasonic spindle was used to conduct grinding experiments. An electroplated diamond tool was used for these experiments. Generally, diamond tools cannot grind steel because of excessive wear as a result of carbon atoms diffusing into bulk steel and chips. However, ultrasonically assisted grinding can achieve a fine surface (roughness Rz of $0.4{\mu}m$) on die steel without severe tool wear. The final aim of this study is to realize mirror surface grinding for injection molding dies without manual polishing. To do this, it is necessary to fabricate an electroplated diamond tool with high form accuracy and low run-out. This paper describes a tool-making method for high precision grinding and the grinding performance of a self-electroplated tool. The ground surface textures, tool performance and tool life were investigated A ground surface roughness Rz of 0.14 um was achieved Our results show that the spindle speed, feed rate and cross feed affected the surface texture. One tool could finish $5000mm^2$ of die steel surface without any deterioration of the ground surface roughness.

• 한국산학기술학회논문지
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• 제18권1호
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• pp.107-114
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• 2017

터보차저는 배기가스로 구동되는 엔진 과급기를 말하며, 배기에너지를 이용하여 배기통로에 연결된 터빈의 회전력을 변화시켜, 혼합 가스의 충전효율을 높여 출력과 연비를 향상 시키는 부품이다. 이러한 목적에 따라 과급을 조절해주는 것이 중요하며, 핵심 부품 중 노즐 슬라이드 조인트가 있다. 소재는 현재 오스테나이트 계 스테인리스강으로 높은 내열성과 내식성 등의 우수한 기계적 성질을 이용하고 있다. 그러나 절삭성이 나쁘기 때문에 절삭가공에 의해 복잡한 형상의 제품을 만드는데 어려운 점이 많다. 현재 노즐 슬라이드 조인트의 가공방법은 금속분말 사출성형후 치수정밀도를 위해 절삭가공을 행하고 있다. 따라서 본 연구에서는 Nitronic 60을 이용하여 터보차저 과급유량을 조절해주는 노즐 슬라이드 조인트의 제작 공정에서 절삭가공이 필요 없는 정형가공 공정을 제안하기 위하여, 기계적 특징에 영향과 연관이 있는 소결온도, 제품의 응력 및 변형률, 형상과 관련이 있는 모따기 펀치각도 및 펀치의 곡률반경을 설계변수로 선정하였다. 그에 따라 유한요소해석과 실험계획법인 다구찌법 및 SN비를 이용하여 가장 좋은 공정 조건을 제안하였다. 최종제품과 유한요소해석 결과의 상대밀도 및 정수압을 비교하여 경향이 일치함을 알 수 있었다. 따라서 다구찌법을 이용한 금속분말의 성형공정 설계에 유용하게 적용할 수 있을 것으로 판단된다.

• 대한기계학회논문집A
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• 제25권4호
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• pp.637-644
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• 2001

Polymer materials have a lot of merits including the low cost and the easiness of forming. For these reasons they are widely using at many manufacturing industries. Microcellular foaming process appeared at MIT in 1980s to save a quantity of material and increase mechanical properties. There are many process variables in appling microcellular foaming process to the conventional injection molding process. They can be solved by using Axiomatic Design Method which is very useful design method for designing a new product. Its main character is scientific and analytical. The information about the thickness of cavity plays an important role in making an effective foam. The goal of this research is to design mold system for advance of foaming magnitude with axiomatic design method. There is a relation between the change of cavitys thickness and foaming magnitude made after inserting a gas. R/t is a conception that indicate proportion between radius and thickness of cavity in mold system. By means of SEM observation of side surface of cavity sample, foaming magnitude of polymer in microcellular foaming process is decreasing gradually as the value of R/t is increasing. In this paper, an advanced mold system was presented by mapping the relation between functional requirements and design parameters.

• Design & Manufacturing
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• 제11권3호
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• pp.35-40
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• 2017

PCR(Polymerase chain reaction) is a technique to replicate and amplify a desired part of DNA. It is used in various aspects such as DNA fingerprint analysis and rare DNA amplification of an extinct animal. Especially in the medical diagnosis field, it provides various measurement methods at the molecular level such as genetic diagnosis, and is a basic tool for molecular diagnostics. The internal shape of the plastic vial tube for PCR analysis used in the DNA detection process, and the surface roughness and internal cleanliness can affect detection and discrimination results. The plastic vial tube demanded by the developer of the PCR analysis equipment should be changed to a structure that eliminates the residual washing solution in the washing process to ensure the internal cleanliness. Thus the internal structure and the internal surface design for improving the PCR amplification efficiency are key issues to develop the plastic vial tube for the DNA detection process.