• 펄프종이기술
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• 제41권4호
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• pp.43-51
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• 2009

Paper mill sludges are discharged around 870,000 M/T annually. Only 30% of the paper mill sludge have been recycled and the rest has been disposed by land fill, incineration, ocean abandonment and other ways. Because of overall prohibition of sludge disposal by London Dumping Convention in 2012, a urgent counter measure for paper mill sludge must be provided. In this paper, some basic experiments were carried out to develop a tray cell pot using paper mill sludge for increasing the recycling potential of the wasted sludge. To establish the manufacturing parameters, the tray cell pots were made with three types of materials including virgin pulp, old news paper and corrugated board mixed in a blend tank of a molding machine. The bending force and moisture content of the produced tray cell pots was measured to confirm the application capability. The tray cell pot could be manufactured under the condition of over 20% of virgin pulp, 40% of old news paper added. However, the corrugated board could not be used because of the glutinous substance included. The produced tray cell pot absorbed water very easily and the bending force decreased rapidly. The waterproof material must be used to applicate the produced tray cell pot in plant growing fields.

• 한국주조공학회지
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• 제35권4호
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• pp.80-87
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• 2015

The Al die casting process has been widely used in the manufacturing of automotive parts when the process requires near-net shape casting and a high productive rate. However, porosity arises in the casting process, and this hampers the wider use of this method for the creation of high-durability automotive components. The porosity can be controlled by the shot condition, but, it is critical to set the shot condition in the sleeve, and it remains difficult to optimize the shot condition to avoid air entrapment efficiently. In this study, the 4.5 mm, 2.0 mm plate die castings were fabricated under various shot conditions, such as plunger velocities of 0.7 m/s ~ 3.0 m/s and fast shot set points of the cavity of -25%, 0%, 25%, and 50%. The mold filling behavior of Al melts in the cavity was analyzed by a numerical method. Also, according to the shot conditions, the results of numerical analyses were compared to those of die-casting experiments. The porosity levels of the plate castings were analyzed by X-ray CT images and by density and microstructural analyses. The effects of the porosity on the mechanical properties were analyzed by tensile tests and hardness tests. The simulation results are in good general agreements with the die-casting experimental results. When plunger velocity and fast shot set point are 1.0 m/s and cavity 25% position, castings had optimum condition for good mechanical properties and a low level of porosity.

• 한국주조공학회지
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• 제37권3호
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• pp.71-77
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• 2017

Casting defects produced during the casting process seriously affect the mechanical properties of the resulting products, reduce the performance capabilities of the product, and also result in economic losses. Therefore, this paper mainly investigates the causes of defects and methods by which to reduce these defects stemming from molten metal flows in a runner system of the type widely used in the sand mold casting process. The flow characteristics of a molten alloy are difficult to observe during the actual casting process. For this reason, a water model was used to observe the flow in the casting process, and the flow in each case was recorded using high-speed cameras as part of the experimental process of this study. Several repetitive experiments were performed to improve the accuracy of the experimental results. The traditional casting system was modified according to the design rules proposed by Campbell, and the system was termed flow-adaptive gating system with a water model. Comparing the flow characteristics of traditional and adaptive gating systems with a water model shows that the bubbles in the water in the latter case are reduced more significantly than in the former case. A ceramic filter system was adapted to the flow-adaptive gating system to minimize the instability of the flow during filling, which occurs as the fluid velocity in the runner increases. In additional, the flow behavior with and without the filter system were compared. The water model system in this work was shown to be able to verify that the adaptation of the filter system brings improvements by stabilizing the flow and reducing the amount of bubbles in the runner system. Moreover, using the flow-adaptive runner system with the filter system leads to considerably stable flows in the runner system.

• 한국공작기계학회논문집
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• 제17권1호
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• pp.7-15
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• 2008

Currently existing high-accuracy and high-speed die sets used in reciprocal press create scratches at the surface of guide posts, steel balls, and bushes due to vertical movement of balls with point-contacts between inner surface of bushes and guide posts. Consequently, accuracy of the die set and the life span of the metal mold are reduced. However, those scratches could reduce the pre-load of the steel ball. This research designed and developed a groove-type die set which improves life span of the die set by eliminating point-contacts of steel balls with guide posts. The guide post consisted of a steel-ball retainer, a steel-ball retainer stopper, a guide bush, a guide pin, a snap ring, and a spring. The steel-ball retainer has 72 holes with 8 columns of 9 holes in each column. The inner surface of the guide bush was grinded(surface roughness: $Ra\;\\;0.2{\mu}m$, accuracy: $0\;{\sim}\;-0.002mm$) after NC turning and heat treatment. Also, a line of small intermediate pocket was processed inside of the guide bush for lubrication and elimination of foreign materials. Guide grooves of steel balls were processed using a wire EDM(Electrical Discharge Machining) after heat treatment. With such a design of the guide post stated above, loads against steel balls could be dispersed greatly by the line contacts through the guide groove between the guide post and the guide bush, and the life span of the guide post could be expanded semi-permanently.

• 소성∙가공
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• 제29권4호
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• pp.194-202
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• 2020

In this paper, experimental and numerical study on a combined sheet metal forming and plate forging of a seal part of a passenger car's hub bearing is conducted to develop the new process of which target is to remove machining process by plate forging and to achieve near-net shape manufacturing. The previous process of a sheet metal forming inevitably needed a machining process for making stepped sheet after conventional sheet metal forming in a progressive way. The stepped sheet is intended to be formed by plate forging in this study. Through the systematic way of developing the combined forming process using solid elements based-elastoplastic finite element method (FEM), several conceptual designs are made and an optimized process design in terms of geometric dimensioning and tolerance of straightness of the thin part is found, which is exposed to bending in metal forming of axisymmetric part. The predicted straightness measured by the slope angle of the tilted thin region is compared with the experimental straightness, showing that they are in a good agreement with each other. Through this study, a systematic approach to optimal process design, based on elastoplastic FEM with solid elements, is established, which will contribute to innovating the conventional small-scaled sheet metal forming processes which can be dealt with by solid elements.

• 대한기계학회논문집
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• 제17권6호
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• pp.1465-1477
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• 1993

본 연구에서는 분말혼합체의 특성인 항복응력을 포함한 Generalized Newtonian Fluid의 구성 방정식을 도입하고 미끄럼현상을 고려한 신소재의 사출성형 충전과정 해석용 CAE(computer aided engineering)시스템을 개발하였다. 수치모사를 위한 수치해석방법으로는, 유한요소법(finite element method)과 유한차분법(finite difference method)을 함께 사용하였다. 유한요소법과 검사체적법(control volume technique) 을 병용하여 유동의 진행을 수치모사 하였으며, 유한차분법을 사용하여 온도분포를 계산하였다.

• 대한기계학회논문집A
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• 제36권10호
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• pp.1221-1226
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• 2012

핫 스탬핑은 오스테나이트 변태 온도 이상에서 프레스 성형 후 급속히 냉각되는 고강도 부품을 제조하는 성형 방법이다. 매우 적은 양의 보론 성분을 가지고 있는 보론강은 핫 스탬핑에 사용되는 재료 중의 하나이다. 본 연구의 목적은 열처리 조건에 따르는 기계적 성질과 에릭슨 커핑 시험에 의하여 성형성을 조사하는 것이다. 다양한 온도에서 다이��칭은 대기 시간을 달리하여 실시하였다. 1173 K-0s에서 ��칭 후 TWB는 1203 MPa의 인장 강도를 얻었다. 이것은 모재 인장강도(1,522 MPA)의 79 %이다. 금형 온도(298, 523, 673 K)에 따른 보론강 TWB의 성형성은 차이가 크지 않았다. 그러나 성형 속도가 증가함에 따라 성형성이 감소하는 것을 확인할 수 있었다.

• 한국산업보건학회지
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• 제24권3호
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• pp.272-280
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• 2014

Objectives: The purpose of this study was to evaluate the characteristics of worker exposure to hazardous chemical substances and propose the direction of work environment management for protecting worker's health in the semiconductor assembly process. Methods: Four assembly lines at two semiconductor manufacturing companies were selected for this study. We investigated the types of chemicals that were used and generated during the assembly process, and evaluated the workers' exposure levels to hazardous chemicals such as benzene and formaldehyde and the current work environment management in the semiconductor assembly process. Results: Most of the chemicals used at the assembly process are complex mixtures with high molecular weight such as adhesives and epoxy molding compounds(EMCs). These complex mixtures are stable when they are used at room temperature. However workers can be exposed to volatile organic compounds(VOCs) such as benzene and formaldehyde when they are used at high temperature over $100^{\circ}C$. The concentration levels of benzene and formaldehyde in chip molding process were higher than other processes. The reason was that by-products were generated during the mold process due to thermal decomposition of EMC and machine cleaner at the process temperature($180^{\circ}C$). Conclusions: Most of the employees working at semiconductor assembly process are exposed directly or indirectly to various chemicals. Although the concentration levels are very lower than occupational exposure limits, workers can be exposed to carcinogens such as benzene and formaldehyde. Therefore, workers employed in the semiconductor assembly process should be informed of these exposure characteristics.

• 한국자동차공학회논문집
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• 제23권4호
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• pp.388-395
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• 2015

The waste gate valve (WGV) for gasoline vehicles operate in a harsh high-temperature environment. Hence, WGVs are typically made of Inconel 713C, which is a type of Ni-based superalloy. Recently, the metal injection molding (MIM) process has attracted considerable attention for parts used under high-temperature conditions. In this study, an MIM analysis for the head and other parts of the WGV is conducted using a commercial CAE program Moldflow. Further, optimal manufacturing conditions are determined by analyzing flow characteristics at various injection times and locations. Moreover, to improve the accuracy of the analysis results, we compare the actual temperature of the mold during injection processing with that observed through the analysis. As the results, metal injection patterns of analysis are well in accord with these of short shot test. And the temperature variations of analysis is also very similar with those of feedstock when metal injection molding.

• 폴리머
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• 제35권1호
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• pp.1-6
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• 2011

사출성형은 고온의 수지를 고압으로 금형에 충전하고 냉각하여 제품을 만드는 공정으로 큰 온도차이와 고압에 의해 성형품에 잔류응력이 형성된다. 이러한 잔류응력은 시간이 지남에 따라 이완되면서 제품에 변형을 일으켜 형상 품질을 저하시킨다. 본 연구에서는 광탄성 장치를 이용하여 투명한 사출성형품의 잔류응력을 측정하는 방법을 연구하였다. 빛은 전자파처럼 진행하는데 편광필름을 통과하면 하나의 파장만이 진행하게 된다. 그 파장이 시편을 통과하면서 시편에 존재하는 잔류응력 때문에 복굴절이 형성되고 두 번째 편광필름을 통과하면서 다양한 색의 패턴을 보이게 된다. 이 색의 패턴을 이용하여 사출성형으로 제작된 사각평판의 잔류응력을 정량적으로 측정하였다. 또한 컴퓨터 해석을 통해 사출성형품의 광학적 특성을 예측하였으며 실험과 비교하였다.