• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.159-162
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• 2008

High pressure is involved during injection molding operation specially packing phase. Cracks in the mold are often occurred by high cavity pressure. In this study, structural analysis of mold has been performed using commercial softwares, Abaqus and Ansys, to investigate cause of crack in the injection mold. Structural analysis contains four cases: stress distribution according to the cavity pressure, stress concentration according to the boundary conditions, stress concentration for inter-locking design of mold, and stress concentration for distributed cavity pressure. Through this study it was observed that the locations of stress concentrations were coincident with locations of crack. Robust mold design is being required to withstand high cavity pressure.

• Journal of Korea Foundry Society
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• v.34 no.5
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• pp.162-169
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• 2014

The effect of the mold preheat temperature on the solidification crack strength was investigated in AC2B aluminum alloy. A tension type apparatus as part of a solidification crack test which could measure the stress-strain relationship quantitatively was utilized. The evaluation of the solidification crack strength with varying mold preheat temperatures was performed by the test procedure established in this research. When the mold preheat temperatures were $250^{\circ}C$, $150^{\circ}C$ and $50^{\circ}C$, the solidification crack strengths were found to be $7.8Kgf/cm^2$, $12.9Kgf/cm^2$ and $28.6Kgf/cm^2$, respectively. In the same way, when the mold preheat temperatures were $250^{\circ}C$, $150^{\circ}C$ and $50^{\circ}C$, the corresponding temperatures of the failure sites were $610^{\circ}C$, $600^{\circ}C$ and $571^{\circ}C$, and the calculated solid fractions were 14.0%, 29.3% and 50.8% when the specimens failed, respectively. The solidification crack strength increased in proportion to the solid fraction of the failure site. The solidification crack strength obtained in this test is assumed to reflect the effects of metallurgical factors on the thermo-plastic characteristics of a solidifying alloy such as the grain size of the solid, the grain morphology, and the distribution of solid grain.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.297-300
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• 2008

High pressure is involved during injection molding operation specially packing phase. Cracks in the mold are often occurred by high cavity pressure. In this study, structural analysis of mold has been performed using commercial softwares, Abaqus and Ansys, to investigate cause of crack in the injection mold. Structural analysis contains four cases: stress distribution according to the cavity pressure, stress concentration according to the boundary conditions, stress concentration for inter-locking design of mold, and stress concentration for distributed cavity pressure. Through this study it was observed that the locations of stress concentrations were coincident with locations of crack. Robust mold design is being required to withstand high cavity pressure.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.4
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• pp.478-483
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• 2011

Cast mold has low wear-resistance comparing with other alloyed molds which result in lower production rate and high cost of products. Recently, various weld methods are being applied to increase the wear-resistance of molds and to extend mold life. Among them, nickel alloy weld process increases the hardness irrelevant to its machinability and creates very uniform structures. In addition, it causes better wear-resistance and reduces shrinkage defects. In this paper, we analyze the mold surface cracks welded by nickel alloy and propose the methods to improve the mold surface and its wear-resistance. It has been found that nickel alloy weld does not affect the inside crack of mold but has an influence on the surface crack seriously. Results show that the start and growth of fatigue cracks have been delayed about 3 times and reduced approximately 75%, respectively, and the mold surface cracks are decreased about 5.7 times.

• Journal of Korea Foundry Society
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• v.21 no.4
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• pp.253-259
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• 2001

There are many methods to produce metal foams, which can be classified into three groups according to the state of the starting metal i.e. liquid or powder or solid. Three types of defects such as cell closing, cell deformation or breakdown and cell misrun are thought to be occurred when we make the open cell aluminum foams by precision casting. Filling ability of the mold slurry between preform is related with cell closing, mold collapsibility is related with cell deformation or breakdown, mold temperature and pouring pressure are related with cell misrun. These factors can be evaluated by measuring slurry fluidity, burnout strength and permeability of the mold. Properties of the plaster mold were evaluated to find optimum mold conditions for high quality open cell aluminum foam in this study. Permeability was almost zero independent of burnout conditions, however, crack initiation was found on the surface of all specimens one or two minutes after taking out from the furnace. Crack has grown and disappeared with time. This crack may facilitate the mold filling when molten metal is poured, because of the improved mold permeability. It was considered that crack initiation and disappearance was closely related with temperature difference between the surface and inner part. Knocking-out the mold is a difficult problem due to the small cell size, because continuous mesh structure of the metal foam is not strong. It is not easy to remove molding material after pouring. We can expect that water quenching can facilitate the knocking-out the mold after solidification without damaging cell structures. Collapsed particles after water quenching became bigger with the increase in time.

• Design & Manufacturing
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• v.9 no.2
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• pp.16-19
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• 2015

In this paper, The experimental study on the crack during press forming of the door latch assembly for a vehicle door is performed. Length to be inserted into the conventional mold upper die punch is 20 mm, wherein the cracks are generated on the product surface and causes a secondary quality problem. In this study, the length to be inserted in the mold upper die punch 0 mm, 10 mm, 20 mm, which was changed to perform the experiment. Through the experiment, the length inserted into the mold can be seen that the upper die punch of the press forming conditions optimized when the 0 mm.

• Journal of Korea Foundry Society
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• v.26 no.5
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• pp.227-231
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• 2006

Liquid formability of bulk amorphous alloys is known to be very poor due to their high viscosity comparing with conventional metallic materials. It is important to have the fabricating technology of bulk amorphous alloys in order to make the components with complicated shape. Liquid formability includes the mold cavity filling ability and the hot tear(crack) resistance during solidification. A mold made of a commercial tool steel for the formability test was designed. Melting was performed by the arc melting furnace with melting capacity of 200 g in an argon atmosphere. Liquid formability and glass forming ability of Cu base and Ni base bulk amorphous alloys were measured and evaluated. Mold filling ability of Ni-Zr-Ti-Si-Sn alloy was better than that of Cu-Ni-Zr-Ti alloy, however the reverse is the hot tear resistance. Bulk amorphous alloy is very susceptible to crack if partial crystallization occurs during solidification. Crack resistance was thought to be closely related with the glass forming ability.

• Design & Manufacturing
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• v.6 no.2
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• pp.64-69
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• 2012

This study looks at plastic mold design for robots and mold manufacture, which is an injection mold branch at The Korea-China-Japan University Grand Prize Contest. Product analysis and layout, molding analysis, and upper and lower core design are carried out to design molds in 2D and 3D. After the design of the cores, NC machining software is used for simulation before actual manufacture. Before the production of end-product, test injection is done to troubleshoot problems like bad dimensions, burr, cracks and stepped pulley.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.3
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• pp.261-265
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• 2012

In this study, glassy carbon was ground for lens core of glass mold press. Ultraprecision grinding process was applied for machining of core surfaces. During the process, brittle crack occurred because of hard-brittleness of glassy carbon. Author investigated optimized grinding conditions from the viewpoint of ductile mode grinding. Geometrical undeformed chip thickness was adopted for critical chip thickness that enables crack free surface. Machined cores are utilized for biaspheric glass lens fabrication and surfaces of lens were compared for verification of ground surface.

• Journal of Technologic Dentistry
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• v.32 no.4
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• pp.307-315
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• 2010

Purpose: The purpose of this study was to investigate the change of microstructures and mechanical properties of pure titanium casting specimens as a function of mold temperatures. Methods: The pure titanium castings were fabricated using the centrifugal vacuum casting method with different mold temperatures of $200{\sim}500^{\circ}C$. The resulting castings were characterized by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy and vicker,s hardness tester. Results: In case of the mold temperatures over $400^{\circ}C$, the porosity, surface crack and large grain size were observed in resulting castings. Conclusion: In this work, The most suitable mold temperature in casting of pure titanium was $300^{\circ}C$.