• 한국기계가공학회지
• /
• 제4권4호
• /
• pp.7-13
• /
• 2005

In the case of fabricating micro pole structures such as column, square-pole and gear shaft by the micro end-milling process, it can be useful in the fields of industry, for example, micro parts, electrode for electrical discharge machining and micro mold for injection molding. In this study, machining factors and the process were analyzed. Machining experiments of various micro pole configurations were performed. Analysis of the change and effect of the cutting force according to the machining conditions was carried out. An analytical study of the deformation of the micro pole caused cutting conditions and cutting force through the finite element method and ANSYS program was carried out. As a result, this research presented a method of fabricating the column pole of below $100{\mu}m$ diameter with high aspect ratio by using micro end-milling process, and based on that, a method of fabricating a variety of applicable structures. Also the minimum size of the pole capable of fabricating through theory and experiment were demonstrated.

• 한국기계가공학회지
• /
• 제4권4호
• /
• pp.28-33
• /
• 2005

Recently, trends of TFT-LCD toward larger scale and thinner thickness continue. so, demands of Light Guide Panel (LGP) which is to substitute for prism sheet are appeared. Functions of LGP obtaining polarization of light of the prism sheet as well as the incidence and reflection of light are demanded. This prism type LGP to complete functions of the existing LGP and polarization at once must be supported by micro machining technology of LGP surface. In this research, the machining characteristics of the various materials were analysed by shaping using V-shaped single crystal diamond tool. The characteristics are machined surface, machining force due to the variation of cutting depth. Used specimens are engineering materials, which are 6:4 brass, oxygen-free copper, Al6061, PC, PMMA. The FFT analysis of the measured cutting force was conducted. The cutting characteristics were analyzed and the optimum cutting conditions with materials were established.

• 한국기계가공학회지
• /
• 제9권4호
• /
• pp.14-25
• /
• 2010

Small cracks or chips of a product appear very frequently in the course of continuous production of an automatic press process system. These phenomena became the cause of not only defective product but also damage of a press mold. In order to solve this problem AE(Acoustic emission) system was introduced. AE system was expected to be very effective to real time detection of the defective product and for the prevention of the damage in the press molds In this study, for the pick and analysis of AE signals generated from the press process, AE sensors/pre-amplifier/analysis and processing board were used as frequently found in the other similar cases. For the analysis and processing the AE signals picked in real time from the normal or the detective products, specialized software called AE-win(software for processing AE signal from Physical Acoustics Corporation) was used. As a result of this work it was conformed that intensity and shape of the various AE signals differ depending on the weight of the press and thickness of sheet and process type.

• 한국기계가공학회지
• /
• 제16권3호
• /
• pp.125-130
• /
• 2017

In this study, the influence of various factors on surface roughness was investigated using the Taguchi experimental method through high-speed machining processing. Feed rate, pitch, tool diameter, and depth of cut are widely applied to high-speed machining conditions for mold production. Each of these factors was implemented and classified into three levels; then, after high speed machining, surface roughness was measured, the S/N ratio was analyzed, and the influence on the surface roughness of control factors was analyzed quantitatively by ANOVA. Using this information, a mathematical model for predicting surface roughness was derived from multiple regression analysis. This mathematical model enables the surface roughness value after high-speed machining to be predicted at the production stage, before machining, for a wide range of machining conditions.

• 한국기계가공학회지
• /
• 제19권8호
• /
• pp.35-42
• /
• 2020

In discharge machining, material is removed by electrical discharge between the electrode and the workpiece. An important consideration in EDM is that the wear of the electrodes decreases the final precision of the workpiece. The edge wear of the electrodes proceeds very quickly because sparks occur more frequently at the edges with high local electrical strength. In this study, mold steel was discharged with a wedge-shaped graphite electrode to measure the edge wear of the electrode according to the depth. The electrode edge wear increased with depth during EDM and a wear model was developed. The model predicted that the edge wear can be reduced by approximately 70% using two electrodes instead of a single electrode. The model was supported by the experimental comparison of the dual electrode method and the single electrode method.

• 한국기계가공학회지
• /
• 제19권8호
• /
• pp.50-55
• /
• 2020

This study investigates the injection molding of a plastic rack gear and focuses on deflections in the part. The causes of deflections were found and resolved through a trade-off study by injection molding analysis. Based on a warpage analysis, the fiber orientation was found to be a dominant factor in the occurrence of deflections. Changes in the part design and various injection conditions were analyzed for their effects in reducing deflections. Based on the trade-off study, a new part bottom design, injection time, and melt temperature were recommended. A trial injection was done for the new plastic rack gear, and measurements showed that its flatness surpassed that of the original part and met the specified requirement. The short injection time, low melt temperature, and symmetric similar configuration of the part contributed to the reduction in deflections. Therefore, optimized gate design and injection conditions as well as a new part design were validated through injection molding analysis in this study.

• 한국공작기계학회논문집
• /
• 제15권4호
• /
• pp.1-7
• /
• 2006

Injection molding is a very important industrial process for the manufacturing of plastics objects. During an injection molding process of composites, the fiber-matrix separation and fiber orientation are caused by the flow of molten polymer/fiber mixture. As a result, the product tends to be nonhomogeneous and anisotropic. Hence, it is very important to clarify the relations between separation orientation and injection molding conditions. So far, there is no research on the measurement of fiber orientation using image processing. In this study, the effects of fiber content ratio and molding condition on the fiber orientation-angle distributions are studied experimentally. Using the image processing method, the fiber orientation distribution of weld-line in injection-molded products is assessed. And the effects of fiber content and injection mold-gate conditions on the fiber orientation are also discussed.

• 한국기계가공학회지
• /
• 제3권3호
• /
• pp.5-10
• /
• 2004

The effect of bronze sintered friction materials on frictional and mechanical properties is studied with the content(8~18 wt,%) and shapes (flake and irregular) of graphite that is used as solid lubricants to meet diverse characteristics such as low coefficient of friction, low wear rate and high bending strength. The content and shapes of graphite are optimized by statistical experiments. Friction test was carried out measure friction coefficient, temperature dependence and wear rate. As a result of experiments, the density, hardness and bending strength with a shape of flake graphite are lower and decrease rapidly than that of Irregular, as the content of graphite increases up to 18 wt% Aftei friction test, coefficient of friction is 0.3~0 4 and wear rate is $0.32{\sim}2.98{\times}10^{-7}cm^3/kg{\cdot}m$. When the content of graphite increases, coefficient of friction increases In a shape of flake graphite and decreases in a shape of irregular graphite.

• 한국공작기계학회논문집
• /
• 제15권3호
• /
• pp.53-58
• /
• 2006

This study deals with the method of post-processing in the automatic tool path generation for 5-axis NC machining. The 5-axis NC machining cannot only cope with the manufacturing of complicated shapes, but also offers numerous advantages such as reasonable tool employment, great reduction of set-up process and so on. Thus 5-axis NC machining has been used for aircraft parts, mold and die as well as for complicated shapes such as impeller, propeller and rotor. However, most of the present CAM systems for 5-axis NC machining have limited functions in terms of tool collision, machine limits and post-processing. Especially 5-axis machine configurations are various according to the method which the rotational axes are adapted with the table and spindle. For that reason, In many cases the optimal numerical control (NC) data cannot be obtained or considerable time is consumed. To solve this problem, we applied a general post-processor for 5-axis NC machining. The validity of this post-processor should be experimentally confirmed by successfully milling to a helix shaped workpiece.

• 한국생산제조학회지
• /
• 제24권1호
• /
• pp.38-42
• /
• 2015

Polydimethylsiloxane (PDMS) is a widely used material for replicating micro-structures because of its transparency, deformability, and easy fabrication. At the nanoscale, however, it is hard to fill a nanohole template with uncured PDMS. This paper introduces several simple methods by changing the surface energy of a nanohole template and PDMS elastomer for replicating 100nm-scale structures. In the case of template, pristine anodic aluminum oxide (AAO), hydrophobically treated AAO, and hydrophillically treated AAO are used. For the surface energy change of the PDMS elastomer, a hydrophilic additive and dilution solvent are added in the PDMS prepolymer. During the molding process, a simple casting method is used for all combinations of the treated template and modified PDMS. The nanostructured PDMS surface was investigated with a scanning electron microscope after the molding process for verification.