• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.387-390
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• 2009

This study was designed to fabricate the micro-electro-mechanical systems (MEMS) parts such as micro spur gears using hot extrusion of gas atomized Al-78Zn powders. For this purpose, it is important to develop new methods to fabricate micro-dies and choose suitable extrusion conditions for a micro-forming. Micro-dies with Ni were fabricated by LIGA technology. LIGA technology was capable to produce micro-extrusion dies with close tolerances, thick bearing length and adequate surface quality. Superplastic Al-78Zn powders have the great advantage in achieving deformation under low stresses and exhibiting good micro formability with average strain rates ranging from $10^{-3}$ to $10^{-2}\;s^{-1}$ and constant temperatures ranging from 503 to 563K. Al-78Zn powders were compacted into a cylindrical shape (${\Phi}3{\times}h10$) under compressive force of 10kN and, subsequently, the compacted powders were extruded at 563k in a hot furnace. Micro-extrusion has succeeded in forming micro-gear shafts.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.101-104
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• 2000

Milli-structure components are classified as component group whose size is between macro and micro scale. that is, about less than 20mm and larger than 1mm. The forming of these components has a typical phenomenon of bulk deformation with thin sheets because of the forming size. In order to conventional metal forming, where numerical process simulation is already idly applied, the micro-forming process is characterized by some scale effects which have to be considered in an advanced process simulation. milli-structure rectangular cup drawing is analyzed and designed using the finite element method and experiment. The result of the finite element analysis is confirmed by a series of experiment.

• Transactions of Materials Processing
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• v.15 no.4 s.85
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• pp.326-332
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• 2006

Sandwich structures, which are composed of a thick core between two faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Depending on the 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 made a roll forming machine which progressive forming possible and force measurement for a roll forming of the sheet metal forming. And we designed a roll molding that arrayed of embossing size 3mm in diameter fabricate micro dimple inner structure plate. We carried out forming experiment such as array change and thickness to sts304 sheet. Ultimately, this research developed inner structure plate of high stiffness.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.30 no.7 s.250
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• pp.849-856
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• 2006

In this paper, fabric composite draping on hemisphere moulds were studied to find out the deformation behaviour of micro-tow structures of fabrics during draping and thermoforming. Aluminium and PVC foams were used to fabricate the hemisphere moulds for draping tests. In order to observe the local tow deformation pattern during the draping several specimens for microscopic observation were sectioned from the draped hemisphere structures. The effect of forming condition and mould properties on tow deformation was investigated by the microscopic observation of the tow parameters such as crimp angle. Normalization scheme was performed to compare tow parameter variations with different forming conditions. Stress-strain .elations of two different PVC foams (HT70 and HT110) were tested to investigate the effect of foam property on the micro-tow deformation during forming.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.439-442
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• 2003

This study presents a new computational model to analyze the grain deformation in a polycrystalline aggregate in a discrete manner and based directly in the underlying physical micro-mechanisms. As a result, specific characteristics have to be considered for the numerical analysis. The grains and grain boundary elements are introduced to model individual grains and grain boundary facets, respectively, to consider the size effects in the micro forming. The constitutive description of the grain elements accounts for the rigid-plastic and the grain boundary elements for elastic relationships. The capability of the proposed approach is demonstrated through application of grain element and grain boundary element in the micro forming.

• Transactions of Materials Processing
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• v.18 no.5
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• pp.422-427
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• 2009

Computed tomography(CT) has been applied to measure micro-defects in the aluminum knuckle parts manufactured by the thixoforming process. 6061 aluminum alloys were used to form knuckle samples in the semi-solid temperature after the SIMA processing of billets. Tensile specimens were cut from the different locations in a thixoformed knuckle. The size and the distribution of forming defects in tensile specimens were analyzed using CT scanning and image analysis technology before tensile tests. It has been qualitatively shown that the stress-strain curves were significantly affected by the size and the distribution of forming defects although the defect sizes lie in the range of micro-meters.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.7
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• pp.777-782
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• 2011

Micro features on the surface are well-known to have significant effects on optical or mechanical properties such as the optical interference, reflectance at the surface, contact angle, interfacial friction, etc. These surface micro features are increasingly employed to enhance the functionality of the applications in various application areas such as optical components for LCD or solar panel. Diverse surface features have been proposed and some of them are showing excellent efficiency or functionality, especially in optical applications. Most applications employing the micro features need manufacturing process for mass production and the injection molding and roll-to-roll forming, which are typical processes for mass production adopting polymeric materials, may be also preferred for micro patterned plastic product. Since the functionality or efficiency of the surface structures generally depends on the shape and the size of the structure itself or the array of the structures on the surface, it would be very important to replicate the features very precisely as being designed during the molding the micro pattern applications. In this paper, a series of research activities is introduced for roll-to-roll forming of micro patterned film including filling of patterns with UV curable resin, demolding of surface structures from the roll tool, control of surface energy and cure shrinkage of resin and dispose time and intensity of the UV light for curing of UV curable resin.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.3
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• pp.363-369
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• 2011

In this study, a direct pattern forming process on a plastic film using ultrasonic vibration energy is investigated. A tool horn containing micro-patterns is attached to an ultrasonic power supply, and is used to press a plastic film with ultrasonic vibration in order to replicate micro-patterns on the surface of the plastic film. To replicate micro-patterns with high accuracy, the tool horn should be designed to allow only the longitudinal vibration, not the transverse vibration. For this purpose, the design of a tool horn is investigated through finite element analysis, from which the resulting natural frequency of the tool horn can be adjusted in the range of the ultrasonic power supply. The analysis result is then reflected on the optimal design and fabrication of the tool horn. The validity of the developed tool horn is discussed through pattern-forming experiments using the ultrasonic vibration of the developed tool horn.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.245-249
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• 2001

This paper is concerned with numerical analyses for bulk forming of a single crystal milli-product, whose typical size ranges from a few hundreds ${\mu}m$ to a few mm. The numerical formulation invoked in this paper combines the crystal plasticity theory considering texture development and the ductile damage mechanics for growth of micro voids, since orientation development and growth of micro voids become the primary factors for bulk forming of milli-size products. As applications, milli-extrusion of a single crystal round bar and milli-rolling of a single crystal plate are simulated and the results are discussed in detail.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.596-600
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• 2009

Finite element simulation is an alternative method to practically find the forming limit diagram(FLD). In this paper, the novel fracture criterion is utilized to predict the FLD in conjunction with finite element analysis for sheet forming. The principal scheme of the fracture criterion in this paper is that growth of the micro voids leads up to fracture in the viewpoint of micro-mechanics. The numerical FLD is verified by results of the out-of plane stretching test using hemispherical punch. The verification is also conducted about two types of material. These results are in good accord with the experimental results. Especially, the proposed scheme is appropriate to predict FLDs for a restricted material with low ductility after the instability point or ultimate tensile strength.