• Journal of Environmental Science International
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• v.16 no.10
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• pp.1169-1177
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• 2007

The main objective of this research was to evaluate the effects of process variables which were forming ability, flow displacement, effective stress, effective strain, fluid vector and products defects on manufactured artificial lightweight aggregate made of both incinerated sewage sludge ash and clay by means of the numerical analysis of a rigid-plastic finite element method. CATIA (3D CAD program) was used for an extrusion metal mold design that was widely used in designing aircraft, automobile and metallic molds. A metal forming analysis program (ATES Co.) had a function of a rigid-plastic finite element method was used to analyze the program. The result of extrusion forming analysis indicated clearly that a shape retention of the manufactured artificial light-weight aggregate could be maintained by increasing the extrusion ratio (increasing compressive strength inside of extrusion die) and decreasing the die angle. The stress concentration of metal mold was increased by increasing an extrusion ratio, and it was higher in a junction of punch and materials, friction parts between a bottom of the punch and inside of a container, a place of die angle and a place of die of metal mold. Therefore, a heat treatment as well as a rounding treatment for stress distribution in the higher stress concentration regions were necessary to extend a lifetime of the metallic mold. A deformity of the products could have made from several factors which were a surface crack, a lack of the shape retention and a crack of inside of the products. Specially, the surface crack in the products was the most notably affected by the extrusion ratio.

• Journal of Korea Foundry Society
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• v.32 no.4
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• pp.177-180
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• 2012

Ti-based bulk metallic glasses with high glass forming ability were developed through a systematic alloy design technique. The main alloy design strategy was the selection of alloying elements that may not be toxic in the human body. The $Ti_{45.0}Cu_{40.1}Zr_{12.7}Si_{2.2}$ alloy could be cast into an amorphous rod with the diameter of 3 mm by a suction casting technique using Cu mold. The compressive strength of the amorphous rod was measured as 1826 MPa. Since the Ti-based amorphous alloys consist of non-toxic elements, they can be widely used as bio-materials and eco-materials with unique and beneficial properties.

• Journal of Korea Foundry Society
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• v.23 no.3
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• pp.137-146
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• 2003

The main purpose of this study is to investigate the effects of process parameter on alpha-case formation of Ti and TiAl castings. The previous studies showed that the molten titanium is excessively reactive to the refractory oxide mold, resulting in alpha-caes of the titanium castings regardless of composition of titanium alloys. However, the behavior of the alpha-case formation of TiAl alloy is not consistent with conventional titanium alloy. In order to investigate the alpha-case formation of Ti and TiAl castings with process parameter, especially the associated factors of investment mold such as mold material, binder and mold preheating temperature. An attempt has been made to characterize the alpha-case of titanium casting by using optical microscope, EDS, XRD, EMPA and hardness profiles. The formation of the alpha-case on the surface of pure titanium during investment casting was rather by that of solid solution with metallic element from mold material. The required mold strength was obtained with $CaZrO_3$ because of the possibility of using water soluble binder. However, the separation phenomenon between facing and back-up mold materials should be considered. The interfacial reaction of TiAl alloy showed different behavior from that of pure titanium and $Al_2O_3$ was best mold materials. The effect of binder as well as mold material on the formation of alpha-case was significant.

• Laser Solutions
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• v.12 no.3
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• pp.1-6
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• 2009

This paper describes the method for the fabrication of micro dot array on a plastic mold steel using DPSS (diode pumped solid-states) UV laser and wet etching process. We suggest the process of the ablation of a photoresist (PR) coated on plastic mold steel and wet etching process using solutions of various concentrations of $FeCl_3$, $HNO_3$ in water as etchant. This method makes it possible to fabricate metallic roller mold because the microstructures are directly fabricated on the metal surface. In the range of operating conditions studied, $17\;{\mu}J$ laser pulse energy and 50 ms laser exposure time, an etchant containing 40wt% $FeCl_3$, 5wt% $HNO_3$ and etch time for 45 s gave the $10\;{\mu}m$ of micro dot pattern on plastic mold steel.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.487-488
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• 2006

Picosecond (ps) laser micro-machining has emerged as an attractive method of fabricating high-precision microstructures, especially in metals. In this paper, a metallic mold for diffraction gratings is fabricated with a mode-locked 12 Ps $Nd:YVO_4$ laser. Laser pulses with a wavelength of 355nm are irradiated on the surface of NOK 80, a mold material, to generate line patterns. In order to minimize the line width, laser power is set just above the ablation threshold of NOK 80. Results show that the spectrum from the fabricated mold is good enough for some industrial application.

• Laser Solutions
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• v.9 no.3
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• pp.1-5
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• 2006

Diffraction grating is the optical device which has periodic pattern. Decorative logotypes is the one of application of diffraction grating. In this paper diffraction grating for decorative logotype is fabricated by dot pattern in stead of line pattern. A metallic mold for diffraction gratings is fabricated with a mode-locked 12 ps Nd:YVO4 laser. Laser pulses with a wavelength of 355nm are irradiated on the surface of NOK 80, a mold material, to generate dot patterns. In order to minimize the dot diameter, laser power is set just above the ablation threshold of NOK 80. Results show that the spectrum from the fabricated mold is good enough for some industrial application

• Proceedings of the Korean Society of Laser Processing Conference
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• 2006.11a
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• pp.114-117
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• 2006

Diffraction grating is the optical device which has periodic pattern. Decorative logotypes is the one of application of diffraction grating. In this paper diffraction grating for decorative logotype is fabricated by dot pattern in stead of line pattern. A metallic mold for diffraction gratings is fabricated with a mode-locked 12 ps $Nd:YVO_4$ laser. Laser pulses with a wavelength of 355nm are irradiated on the surface of NOK 80, a mold material, to generate dot patterns. In order to minimize the dot diameter, laser power is set just above the ablation threshold of NOK 80. Results show that the spectrum from the fabricated mold is good enough for some industrial application.

• Journal of the Microelectronics and Packaging Society
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• v.28 no.4
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• pp.47-50
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• 2021

Nanoimprint lithography (NIL) has revolutionized the fabrications of electronics, photonics, optical and biological devices. Among all the NIL processes, roll-to-roll nanoimprinting is regarded best for having the attributes of low cost, continuous, simple, and energy-efficient process for nanoscale device fabrication. However, large-area printing is limited by the master mold deformation. In this study, a finite element model (FEM) has been constructed to assess the deformation of the roll mold adhesively wrapped on the carbon fiber reinforced material (CFRP) base roll. This study also optimizes the deformations in the metallic roll mold with respect to nip-forces applied in the printing process of nano-fabrication on large scale. The numerical simulations were also conducted to evaluate the deflection in roll mold assembly due to gravity. The results have shown decreasing trend of the deformation with decreasing nip-force. Also, pressure uniformity of about 40% has been optimized by using the current numerical model along with an acceptable deflection value in the vertical axis due to gravity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.405-408
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• 2003

Generally, the life of casting mold is limited by fatigue fracture or dimensional inaccuracy originated from wear in high temperature. Although recent research of metallic materials in high temperature fatigue have been much accomplished, many studies on brittle material as a die steel in high temperature fatigue does not have been reported. Especially, the study on the fatigue behavior over the transformation temperature is not studied sufficiently because of its difficult analysis and experiment. Therefore, reliable results of brittle material in high temperature fatigue behavior are needed. In this paper, stress-strain curves and stress-life curves in die STD61 steel are carefully examined between room temperature and 90$0^{\circ}C$, as the basic experimental data are used to predict from fatigue life of casting mold.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.282-285
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• 2009

Selective laser sintering (SLS) is a fast growing process of rapid production fur metallic based parts. To restore damaged mold surface using SLS, single layer experiments of $20{\mu}m$ Fe-Cr powder was performed under various heat input. Process window of $20{\mu}m$ Fe-Cr powder provided feasible process parameters for the smooth regular surface. To estimate coherence between melted powder and basematal, tendency of hardness distribution has been observed. Hardness of melted zone and remelted zone was diversified from 5GPa to 6.5GPa. It is over 2 times compared of hardness of basemetal. Average surface roughness of each direction on surface of melted powder was measured. Experimental results show that the mold restoring process using SLS can be successfully applied in the mold repair industry.