• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.269-272
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• 2004

The present study used a diagrammatic analysis of 6 sigma quality control and Taguchi method for injection molding process of monitor back-cover, evaluated the influence on the cycle time with part design, mold design, molding process and standardization activity involving design & molding, adopted analysis of sensitivity and effective factors of the part design and molding process conditions for productivity, identified main design molding factors, as critical ones influencing on the quality and productivity, of which is summarized as design guidance. The main contribution factors for cycle time can be sequentially enumerated as follows; hot spot, part thickness, coolant inlet temperature, melt temperature cooling line layout, etc.. As a first step critical factors of the design process of current monitor housing were investigated. And the optimal and better critical factors found in the first step were applied to a new product proving our process was correct. Moldflow software was used for injection molding simulation, and Minitab software for the statistical analysis. Finally, the productivity was increased by about 33 percents for our specific case.

• 한국결정성장학회지
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• 제13권2호
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• pp.68-72
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• 2003

본 논문에서는 3차원 마이크로구조물을 위한 새로운 UV-LIGA 공정을 개발하였다. 일반적으로 photoresist는 얇은 두께로 코팅이 되지만, SU-8은 수십 $\mu\textrm{m}$ 이상의 두께를 가질 수 있으며, 높은 형상비를 갖는다. SU-8과 같은 Thick photoresist는 기존의 baking 공정과 같이 급격한 cool down을 할 경우 stress에 의한 crack이 발생한다. 이와 같은 경우 도금을 위한 마이크로구조물이 구현이 되지 않는다. SU-8의 코팅, bake에서의 시간 조절, 그리고 PEB의 시간 조절 및 cool down조절을 통하여 stress에 의한 crack이 발생하지 않도록 3차원 마이크로구조물을 제작 할 수 있도록 하였다.

• 대한기계학회논문집A
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• 제26권9호
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• pp.1923-1930
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• 2002

In this paper, we present modeling and simulation of microlens formation by means of a deep X-ray lithography followed by a thermal treatment of a PMMA (Polymethylmethacrylate) sheet. According to this modeling, X-ray irradiation causes the decrease of molecular weight of PMMA, which in turn decreases the glass transition temperature and consequently causes a net volume increase during the thermal cycle resulting in a swollen microlens. In this modeling, the free volume theory including the relaxation process during the cooling process was considered. The simulation results indicate that the modeling in this study is able to predict the fabricated microlens shapes and the variation pattern of the maximum heights of microlens which depends on the conditions of the thermal treatment. The prediction model could be applied to optimization of microlens fabrication process and to designing a micro mold insert for micromolding processes.

• 한국정밀공학회지
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• 제28권3호
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• pp.370-376
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• 2011

Recently, the application range of plastic gears is widely expanding by the development of engineering plastics with good mechanical properties. Plastic gears have excellent performances such as light weight, water resistance and vibration absorbing ability for metallic gears. In this study, the optimization of injection molding process was done for the large disk type plastic gears of auto phoropter. Design Of Experiment (Taguchi method) was adopted to find a tendency of molding conditions that influence the flatness of disk type gear. Four main factors for molding conditions were selected based on injection temperature, filling time, packing pressure and mold temperature. Also, Filling, packing and cooling analyses were carried out to evaluate Z directional deflection of large disk type gear by using the simulation software (Moldflow) based on the DOE. From the results, it was found that the injection temperature and packing pressure are the most sensitive parameters for the Z directional deflection of large disk type gears.

• 한국주조공학회지
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• 제24권2호
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• pp.94-100
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• 2004

Gas porosity which is a common defect in aluminum alloy casting, is also thought to be severer in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring. Fundamental experiments were carried out to evaluate the effect of process variables such as the melt treatment, the cooling rate and pouring temperature on the density and mechanical properties in A356.2 castings with simple bar shape. The density of grain refined specimen was slightly lower than that of degassed one, but was higher than that of no treated one and that of shot ball packed specimen was higher than the other specimens. The tensile strength and elongation were in the ranges of $200{\sim}230MPa$ and $0.5{\sim}1.5%$ respectively. The density and hardness of lost foam cast specimens decreased with increase in pouring temperature.

• 소성∙가공
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• 제29권4호
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• pp.218-228
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• 2020

The prediction of final mass and optimized process conditions of injection molded products using Artificial Neural Network (ANN) were demonstrated. The ANN was modeled with 10 input parameters and one output parameter (mass). The input parameters, i.e.; melt temperature, mold temperature, injection speed, packing pressure, packing time, cooling time, back pressure, plastification speed, V/P switchover, and suck back were selected. To generate training data for the ANN model, 77 experiments based on the combination of orthogonal sampling and random sampling were performed. The collected training data were normalized to eliminate scale differences between factors to improve the prediction performance of the ANN model. Grid search and random search method were used to find the optimized hyper-parameter of the ANN model. After the training of ANN model, optimized process conditions that satisfied the target mass of 41.14 g were predicted. The predicted process conditions were verified through actual injection molding experiments. Through the verification, it was found that the average deviation in the optimized conditions was 0.15±0.07 g. This value confirms that our proposed procedure can successfully predict the optimized process conditions for the target mass of injection molded products.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.225-226
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• 2006

As the technique of high-speed end-milling is widely adopted to machining field. The investigation for microscopic precision of workpiece is necessary for machinability evolution. The environmental pollution has become a big problem in industry and many researcher have investigated in order to preserve the environment. The environmentally conscious machining and technology have more important position in machining process. In the milling process, the cutting fluid has greatly bad influence on the environment. The damaged layer affect mold life and machine parts in machining. In this study, the cutting force, the surface roughness, micro hardness and residual stress is evaluated according to machining environment. Finally, it is obtained that the characteristics of damaged layer in environmentally conscious machining is better than that in conventional machining using cutting fluid.

• 한국기계가공학회지
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• 제12권6호
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• pp.30-36
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• 2013

An FFD(flexible fine die) is an embossed mold that consists of a thin plate ranging from 0.6 to 3 mm in thickness. FFDs are primarily used for cutting LCD films and F-PCB sheets. In the high-speed micro-milling process of flexible fine dies, the lubrication and cooling of the cutting edges is very important from the aspect of eco machining and cutting performance. In this paper, a comparative study of tool wear and surface roughness between cutting fluid and hybrid lubrication for eco-machining of FFD was conducted for processes of high-speed machining of highly hardened material (STC5, HRC52). Especially, the incorporated fluid method for eco machining, in which the cutting performances can be simultaneously measured, was introduced. The machining results show that hybrid lubrication, instead of conventional cutting fluid, leads to excellent tool wear and surface roughness and represents the proper conditions for eco micro-machining of flexible fine dies.

• 한국태양에너지학회 논문집
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• 제35권1호
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• pp.89-96
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• 2015

n-octadecnae based shape stabilized phase change material (SSPCM) was prepared by using vacuum impregnation method. And an exfoliated graphite nanoplate (xGnP) which has high thermal conductivity properties is used as a PCM container. And then we made heat storage concretes which contains SSPCM for reducing heating and cooling load in buildings. In the prepararion process, the SSPCM was mixed to a concrete as 10, 20 and 30wt% of cement weight. The thermal properties and chemical properties of heat storage concrete were analyzed from Scanning electron microscope (SEM), Fourier transformation infrared spectrophotometer (FT-IR), Deferential scanning calorimeter (DSC), Thermogravimetric analysis (TGA) and TCi thermal conductivity analyzer. And we conducted surface temperature analysis of SSPCM and xGnP by using heat plate and insulation mold.

• 한국기계가공학회지
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• 제17권6호
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• pp.98-104
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• 2018

Deflected 4-way panels of ceiling air conditioners produced by injection molding process have caused dew condensation at the edge of products. In order to prevent this drawback with reducing weight and deformation, this study proposed renovated process adopting microcellular foaming. According to results from 2-sample t-test and analysis of variance(ANOVA), the critical factors affecting weight were melt temperature and injection speed. In addition, the vital effects on deformation were structure at the edge, mold temperature and cooling time. Optimal conditions of these parameters were derived by regressive analysis with CAE and response surface method(RSM), and then applied to an actual design and process stage to analyze performance. As a results, it clearly showed that new process improved process capability as well as reduced both weight and deformation by 18.8% and 71.9% respectively compared to the conventional method.