• Journal of the Korean Society for Precision Engineering
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• v.12 no.2
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• pp.154-161
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• 1995

In order to analysis of the stress distribution around flaws and the interaction effects between fatigue cracks, stress around micro hole was analyzed by Finite Element Method(F.E.M.) and micro hole specimens were tested using rotary bending fatigue machine and twisting fatigue machine to identify stress effects for fatigue cracks initiating from micro holes and interaction effects between micro holes. The results are as follows : Interaction effects of .sigma. $_{y}$for the micro hole side is larger than the large micro hole side when the interval between micro holes is near. Stress concentration factor increase as the diameter of micro hole becomes smaller. But, stress field of micro hole is smaller than that of large micro hole at h .leq. r (h:depth of micro hole, r:radius of micro hole) and that of large hole is larger than that of small micro hole at h >r expect the small range from micro hole.e.

• Journal of Ocean Engineering and Technology
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• v.1 no.2
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• pp.74-82
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• 1987

This study has been made to investigate into the behavior of fatigue limit, of fatigue crack initiation, and of fatigue crack propagation under the condition of rotating bending stress; specifically on the independency of stress field as well as the crack behavior of surface micro hole defect, which is made artificially through the specimen. The results obtained can be summarized as followa; 1) For the single micro hole defect, initiation of fatigue crack is occurred at both tips of microhole defect simultaneosly along the slip which are produced in the range of maximum principal stress arround micro hole defect independent of the size of micro hole defect. 2) For the neighbored deuble micro hole defects with equal size, in the range ($\frac{L}{r}$)ratio $\gtrsim$ 3 defined as the size of micro hole defect(2r) to the distance between the centers of micro hole defects (2L), the crack behavior of the micro hole defects is same as single one. However, for the range of $\frac{L}{r}$<3, the interference effect becomes significant as the ratio approaches to 1.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.4
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• pp.52-59
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• 2005

When a micro hole is machined by EDM with a cylindrical electrode, the hole diameter is different at the inlet and the outlet of the micro hole. The taper shape of the micro hole is caused by not only wear of the electrode but the eroded particles. The eroded particles cause secondary discharge during machining the micro hole. As a result, the diameter of the inlet becomes larger than that of the outlet. In this paper, a new method is proposed to reduce the difference in diameter between the inlet and the outlet of the hole. Observed was that the feed depth and machining time affect the formation of taper shape On this experimental basis, ultrasonic vibration was applied to reduce machining time, and capacitance was changed during machining to use the difference in discharging energy of different capacitances. Using the proposed method, a straight micro-hole was fabricated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.239-244
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• 2002

In this study, we developed the manufacturing technology of micro-hole and micro-shaft for micro punching system using micro electrical discharge machining and micro electro chemical machining. Micro punching dies of tungsten carbide with $55\;{\mu}m\;and\;110\;{\mu}m$ diameter and $250\;{\mu}m$ depth were made by micro electrical discharge machining. The form accuracy and surface roughness of die hole were pretty good and it was shown that the punched hole quality was fine. WC micro-shaft with $30\;{\mu}m$ diameter was made by the multistep micro electro chemical machining. The developed technologies can be effectively used in precision manufacturing of micro punching die and mass production of micro-shaft.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.260-265
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• 2002

In micro hole punching process, it is very difficult to align punch with die hole. Misalignment can cause a falling-on in hole quality and breakage of punch and die. Micro punching using soft die plate without a die hole has a big advantage because it is not necessary to align punch with die hole and to consider die clearance. Soft die plates are made by polymers or hard rubbers which are softer than metals. In this study, several micro punching experiments are conducted. Micro punching test with some materials shows that micro hole punching is feasible with some soft die plates. Through the section shape obtained by mounting and polishing, the punched hole quality is measured and the shapes of burr and dome we studied.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.5
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• pp.1259-1268
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• 1995

The stress distribution around micro holes and the behavior of stress interaction between micro holes are considerd in the study. Several conclusions are extracted as follows : (1) The stress interaction varies with the distance e between micro holes. When the two micro holes are spaced in such a manner that theri two closest points are separated by a distance of micro hole radius (e=1), stress distribution is affected by a opposite micro hole in all the closest region. In addition, if two closest points are seperated by twice the distance of a micro hole radius (e=2), stress distribution is affected by a opposite micro hole in the region of -0.8.leq.x/r.leq.0.8 and the interaction effect can be neglected for e=4. (2)If the depth becomes larger than the radius, or the radius varies, the shape and magnitude of stress distribution around micro holes varies. (3) Hoop stress around a micro hole for the two dimensional configuration is larger than that of the three dimensional micro hole located on the surface of material for .theta. < 60.deg., but it is reversed for .theta > 60.deg.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.7
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• pp.737-744
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• 2012

EDM is the manufacturing process that uses the thermal energy to machine electrically conductive part. Despite a lot of research has been conducted for decades, the best aspect ratio of the micro hole using micro-EDM has not been over 30, yet. In the present study, new fabrication scheme was introduced to increase the aspect ratio of micro hole dramatically. Micro holes with less than 10 aspect ratio were aligned and welded together to manufacture a micro hole with extreme aspect ratio. Alignment of the micro hole with over 380 aspect ratio was conducted by the home-made apparatus installed with microscope and laser beam. The micro hole with extreme aspect ratio was used to shape pencil beam from proton beam generated from MC-50 cyclotron. The pencil beam was utilized to machine test specimen whose result was compared with GEANT4 computer simulation. It was shown that the experimental and simulation result were closer as the aspect ratio of the micro hole was bigger.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.11
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• pp.1053-1058
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• 2007

Micro-EDM technology (or the manufacture of miniature parts is used to make a micro hole. Two electrode shaping methods, mechanical electrode grinding and WEDG technique, have been studied. In this study, an electrode shaping method by using previously machined hole is introduced in order to obtain an optimal hole-making condition. Key factors such as applied voltage, capacitance, feedrate, and hole-dimension have an influence on the fabricating error of electrode shaping, which are taper ratio of a hole, electrode form accuracy, and electrode surface. Therefore, we try to investigate the optimal fabricating of electrode shaping from various experiments. Results from experiments, it was able to minimize the electrode fabricating error as voltage increases, and also applied feedrate and capacitance decreases.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.2
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• pp.150-157
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• 1985

In terms of behavior of fatigue cracks propagated after build-up around the artificial drilled miro-hole, this study has been made of the build-up process of slips and micro cracks, behavior of micro-crack propagation and the definition of fatigue limit under the rotating bending stress with low carbon steel. The results of this study are as follows: (1) The fatigue limit is the repropagating critical stress for the nonpropagating cracks which have grown to some limit around the micro-hole in regard of the magnitude of micro-hole. (2) Behavior of the slips and micro-cracks initiation are occurring simultaneously in front and in rear of micro-hole tips in the view of the rotational direction, regardless of the magnitude of micro-hole. (3) Behavior of fatigue crack propagation is different from magnitude of micro-hole, its behavior is propagation of single crack about respectively large hole, but about respectively small hole, fatigue crack propagated joining phenomena of micro-cracks. (4) The behavior of fatigue fracture is affected by the factor of its defects in the view of magnitude of micro-hole when the diameter of the micro-holes are smaller than 50.mu.m, and this is also affected with the size effect of micro-hole diameter.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.179-188
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• 2003

The objective of our study is to investigate the micro fabric ability by conventional metal forming processes. In the present investigation, micro hole punching was studied. We tried to control punching process at the micro level and scaled down the standard blanking condition for $25{\mu}m$ hole fabrication. To accommodate this, tungsten carbide tooling sets and micro punching press were carefully designed and assembled meeting accuracy requirements for $25{\mu}m$ hole punching. With our developments, 100, 50, and $25{\mu}m$ holes were successfully made on metal foils such as brass and stainless steel of 100, 50, and $25{\mu}m$ in thickness, respectively, and hole sizes and shapes were measured and analyzed to investigate fabrication accuracy. Shear behavior during micro punching was also discussed. Our study showed that the conventional punching process could produce high quality holes down to $25{\mu}m$.