• Transactions of Materials Processing
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• v.26 no.5
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• pp.271-276
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• 2017

A tee is the most common pipefitting used to combine or divide fluid flow. Tees can connect pipes of different diameters or change the direction of a pipe run. To manufacture tee type of stainless steel pipe, combinations of punch piercing and burr forming have been widely used in the industry. However, such method is considerably time consuming with regard to performing empirical work necessary to attain process conditions to prevent upper end tearing of the tee product and meet target tee height. Numerous experiments have shown that the piercing profile is the main cause of defects mentioned above. Furthermore, the mold design is formed through trial and error according to pipe diameters and changes in requirements. Thus, the objective of this study was to perform piercing and burring process analysis via finite element analysis using DYNAFORM to resolve problems mentioned above. An optimization design method was used to determine the piercing punch profile. Three radii of the piercing punch (i.e., large, small, and joined radii) were selected as design variables to minimize thinning of a tee pipe. Based on results of correlation and multiple regression analyses, we developed a predictive approximation model to satisfy requirements for both thickness reduction and target height. The new piercing punch profile was then applied to actual tee forming using the developed prediction equation. Model results were found to be in good agreement with experimental results.

• Journal of the Korean Society for Railway
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• v.18 no.4
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• pp.301-308
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• 2015

To reduce the weight of a railroad vehicle, a bogie frame skin is considered for manufacture using an RTM process and composite material. Compared to other processes, RTM has merits in that it demands only simple manufacturing facilities and can produce a large and complex structure in a short cycle time. On the other hand, it is important to determine the proper number and locations of gates and vents to prevent void formation inside a structure. In this study, we numerically predicted the flow pattern in a bogie frame skin during the RTM process by distinguishing the permeability of a fiber mat as isotropic or anisotropic. Using the results, we analyzed the RTM process conditions of the bogie frame to predict skin void formation, mold filling time, and optimum location of vents depending on the permeability conditions.

• Journal of Korea Foundry Society
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• v.27 no.1
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• pp.31-35
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• 2007

In order to develop the semi-solid forming technology for magnesium alloy the rheological and thixotropic behavior of Mg alloy slurry with varying shear rates and cooling rates was investigated and simulated with considering the viscosity based on microstructures and processing variables. The viscosity of slurry of Mg alloy (AZ91D) in semi-solid region was exponentially increased with a solid fraction, and was decreased with increasing a shear rate. In order to analyze precisely the rheological behavior, the ANYCAST program modified with the Carreau model and the different heat transfer coefficient between the cast and mold was used to simulate the flow behavior of Mg semi-solid slurry during the injection into a casting mold in a high pressure diecasting machine. The simulated rheological behavior of Mg alloy slurry was matched well with the experimental results.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.1
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• pp.39-46
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• 2013

This study aims to develop a plastic aspheric lens for a 13-megapixel mobile phone camera by injection-compression molding. A mold for injection-compression molding experiments was fabricated with a movable upper plate and four springs. During cavity filling for an aspheric lens with a thickness ratio of 2, a weldline was formed under conventional injection molding, whereas no weldline was formed under injection-compression molding with a compression stroke of 0.3 mm. The flow patterns were in good agreement with the simulation results. The birefringence decreased as the compression stroke increased, and the birefringence produced by injection-compression molding was very low and more uniform compared with that produced by injection molding. In addition, the bulk birefringence of an assembly composed of four plastic lenses was significantly affected by the orientation of the lenses to be mounted.

• Design & Manufacturing
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• v.13 no.2
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• pp.37-43
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• 2019

This study conducted a research as to condensation heat transfer friction loss headby using three types of flat micro multi-channel tubes with different processing of micro-fin and number of channels inside the pipes and different sizes of appearances. In addition, identical studies were conducted by using smoothing circular tubes with 5mm external diameter to study heat enhancement factor and pressure drop penalty factor. 1) The friction head loss showed an increase as the vapor quality and mass flux increased. In case of saturation temperature, it shows an increase as it gets lower. These factors are the reason occurring as the lower the saturation temperature is, the higher the density of refrigerant vapor gets. The influence of heat flux is similar as the dryness is low, but as it gets higher, it lowers in heat flux, and as the high temperature of high heat flux, it is a factor that occurs as the density gets lower. 2) RMS error of the in case of friction head loss, it showed to be predicted as 0.45~0.67 by Chisholm, Friedel, Lockhart and Martinelli. 3) As forfriction head loss penalty factor, the smaller the aspect ratio is, the larger the penalty factor gets, and as for the effect of micro-fin, the penalty factor increased because it decreases to the gas fluid the way groove for the refrigerant's flow.

• Composites Research
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• v.30 no.3
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• pp.202-208
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• 2017

Resin transfer molding (RTM) is a mass production process that allows the fabrication of composites ranging in size from small to large. Recently, fast curing resins with a curing time of less than about 10 minutes have been used in the automotive and aerospace industries. The viscosity of resin is bound up with the degree of cure, and it can be changed rapidly in the fast-cure resin system during the mold filling process. Therefore, it is advantageous to experimentally measure and evaluate the degree of cure because it requires much effort to predict the flow characteristics and cure of the fast curing resin. DMA and dielectric technique are the typical methods to measure the degree of cure of composite materials. In this paper, the resin flow and degree of cure were measured through the multi-channel dielectric system. A total of 8 channels of dielectric sensors were used and resin flow and degree of cure were measured and compared with each other under various pressure conditions.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2017.05a
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• pp.109-109
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• 2017

알지네이트 하이드로 젤은 해조류에서 추출되는 천연 고분자인 알지네이트가 칼슘 또는 마그네슘 양이온과 이온가교(Ioninc cross linking)를 형성할 때 알지네이트의 고분자 구조가 칼슘, 마그네슘 양이온을 감싸면서 형성되는 고분자이다. 알지네이트 하이드로 젤은 높은 생체적합성(Biocompatibility)으로 인해 세포 재생을 위한 조직공학 및 재생의학, 약물전달 등의 제약 관련 분야에 광범위하게 적용될 수 있는 물질로 많은 연구가 이루어지고 있다. 본 연구에서는 마이크로 플루이딕 칩을 이용하여 알지네이트 튜브를 제조하였다. 먼저 유동 포커싱 방식(flow focussing)을 유도할 수 있는 PDMS(Polydimethylsiloxane) 마이크로 플루이딕 칩을 제조하였다. 마이크로 플루이딕 칩은 CNC(Computer Numeric Control) milling machine을 이용한 template를 만들고 NOA mold를 이용하여 최종 PDMS 칩을 제작하였다. 튜브를 만들기 위한 마이크로 채널은 내부 채널 ($200{\times}200um$), 중간 채널 ($200{\times}200um$) 및 외부 채널 ($200{\times}200um$)로 구성되며 내부, 중간, 외부의 유체가 합류하는 수집채널은 폭 500 um, 깊이 200 um로 구성되었다. 운반체로는 5%의 acetic acid를 함유한 mineral oil를 이용하였으며 내부의 core flow는 $H_2O$로 하였다. 중간 유체인 2% 알지네이트 프리폴리머는 칼슘 이온의 존재 하에서 젤화 과정이 매우 빠르기 때문에 마이크로 채널 내부에서의 반응을 제어하고 막힘을 방지하기 위해 수용성 복합 칼슘-에틸렌 디아민 테트라 아세트산 (EDTA)을 사용하였다. 본 마이크로 플루이딕 칩에 각각의 유체를 이동시켰을 때, 운반체인 oil phase의 수소이온은 중간 유체인 알지네이트 프리폴리머와의 계면을 통해 확산되어 Ca-EDTA 복합체로부터 칼슘 양이온의 방출을 유발하게 된다. 방출된 칼슘 양이온은 알지네이트 고분자와의 이온 가교를 통해 알지네이트 하이드로 젤을 형성하여, 각 유체의 flow에 따라 알지네이트 튜브를 쉽고 빠르게 제조 가능하였다. 본 연구에서 제조된 알지네이트 튜브는 인체 내 장기간 약물 전달을 위한 나노섬유로 활용하거나 인공혈관을 구성하는 extracellular matrix로 활용될 잠재력을 가지고 있어 추후 활발한 연구개발이 진행될 예정이다.

• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.109-113
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• 2002

A good fluidity of high strength Al-alloys is required to cast thin wall castings needed to reduce the weight of cast parts. The fluidity, measured as the length to which the metal flows in a standard channel, is affected by many factors, such as the pouring temperature, solidification type of the alloy, the channel thickness, melt head, mold materials and temperature, coating etc. Therefore the experimentally measured fluidity scatters very much and makes it difficult to estimate the fluidity of a melt with a few measurements. The effect of Ti content and grain refinement on the fluidity of high strength aluminum alloy was investigated with a test casting with 8 thin flow channels to reduce the scattering of the fluidity results. The fluidity of Al-4.8%Cu-0.6%Mn Al-6.2%Zn-1.6%Mg-1.0%Cu and well-known commercial aluminum alloy, A356 was tested. Initial content of Ti was varied from 0 to 0.2wt% and Al-5Ti-B master alloy was added for grain refinement. The flow length varied linearly with superheat. By adding Ti and Al-5Ti-B, the fluidity increased. The grain size decreased by adding grain refiner at the same time. The fluidity depended on the degree of grain refinement. The fluidity of the alloy solidifying in mushy type is improved by grain refinement, because grain refinement increases the solid fraction at the time of flow stoppage.

• Korean Chemical Engineering Research
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• v.60 no.2
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• pp.295-299
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• 2022

In this paper, paint-free metallic plastic material, polypropylene (PP) and acrylonitrile styrene acrylate (ASA) materials were investigated on the applications for bumper skid plate and outside mirror housing parts. In order to maximize metallic effect, type, size and content of aluminum pigment were optimized based on flop index. Hybrid aluminum pigments with different aspect ratios were used to conceal weld lines. By controlling the fluidity of the material, the flow mark problem, generated on the surface of the part, was resolved. We also investigated the surface defects of flow and weld lines by using the developed modeling and simulation.

• Journal of Korea Foundry Society
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• v.42 no.6
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• pp.331-336
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• 2022

In this study, we investigated the casting designs for fuel tank valves for LPG automobiles. The valves we studied have two cavities inside the part. There is inevitable air entrapment inside the cavities. In order to reduce this kind of casting defect, we carried out computer simulations of molten metal flow during the diecasting process of the target products. The main process parameters were the ingate position, product direction, and injection velocity. We also examined the possible use of vacuum diecasting. The position of the air entrapment was almost identical for all the ingate positions and product directions. We found that the change of the injection velocity affects the position of the air entrapment. In case of vacuum diecasting, the position of the air entrapment was similar to the previous cases, but it is expected that the air entrapment will be highly reduced in a real situation due to the vacuumed space.