• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.4
• /
• pp.30-37
• /
• 1997

This thesis is concerned with the study on the characteristics of the tool failure occuring at the beginning of cutting in finish machining of hardened steels such as carbon tool steel and alloy tool steel by a ceramic tool (Al$_{2}$O$_{3}$+TiC) with nose radius. In the machining of hardened carbon steel STC3, the wear mechanism on the flank face of the ceramic tool is abrasion wear. The mode of tool failure is developed into catastropic fracture with flaking. It is thought that the fracture caused by FeO and TiO$_{2}$ results from the oxidation of Fe in the workpice and TiC in the ceramic tool and the deposit of Fe formed on the surface of the ceramic tool. In the machining of hardened alloy steel STD11, the wear mechanism on the flank face of the ceramic tool is that abrasion and adhesion wear exist simultaneously. The mode of tool failure at the beginning of cutting features is DOC notch wear. It is thought that the DOC notch wear caused by FeO and TiO$_{2}$results from the oxidation of Fe and TiC in the workpiece and ceramic tool, respectively.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.516-519
• /
• 2004

As the optical communication industry is developed, the demand of optical communication part is increasing. ZrO$_2$ ceramic ferrule is very important part which can determines the transmission efficiency and information quality to connect the optical fibers. In general ZrO$_2$ ceramic ferrule is manufactured by grinding process because the demands precision is very high. And the co-axle grinding process of ZrO$_2$ ceramic ferrule is to make its concentricity all of uniform before centerless grinding. This paper deals with the analysis of the process parameters such as grinding wheel speed, grinding feedrate and regulating wheel speed as influential factors, on the concentricity and surface finish developed based on Taguchi's experimental design methods. Taguchi s tools such as orthogonal array, signal-to-noise ratio, factor effect analysis, etc. have been used for this purpose optimal condition has been found out. Thus, if possible be finding highly efficient and quality grinding conditions.

• Journal of Powder Materials
• /
• v.24 no.3
• /
• pp.223-228
• /
• 2017

Nanopowders provide better details for micro features and surface finish in powder injection molding processes. However, the small size of such powders induces processing challenges, such as low solid loading, high feedstock viscosity, difficulty in debinding, and distinctive sintering behavior. Therefore, the optimization of process conditions for nanopowder injection molding is essential, and it should be carefully performed. In this study, the powder injection molding process for Fe nanopowder has been optimized. The feedstock has been formulated using commercially available Fe nanopowder and a wax-based binder system. The optimal solid loading has been determined from the critical solid loading, measured by a torque rheometer. The homogeneously mixed feedstock is injected as a cylindrical green body, and solvent and thermal debinding conditions are determined by observing the weight change of the sample. The influence of the sintering temperature and holding time on the density has also been investigated. Thereafter, the Vickers hardness and grain size of the sintered samples have been measured to optimize the sintering conditions.

• 제어로봇시스템학회:학술대회논문집
• /
• 2005.06a
• /
• pp.2160-2163
• /
• 2005

Solid freeform fabrication (SFF) technology plays a major role in industry and represents a reasonable percentage of industrial rapid prototyping/tooling/manufacturing (RP/RT/RM) development applications. However, SFF technology still has long way to progress to achieve satisfactory process speed, surface finish and overall quality improvement of its application. Today, three dimensional printing (3DP) technique that is one of SFF technology is receiving many interests, and is applied by various fields. It can fabricate three dimensional objects of solid freeform with high speed and low cost using ink jet printing technology. However, need long curing time after manufacture completion. And it must do post-processing process necessarily to heighten strength of objects because strength of fabricated objects is very weak. Therefore, in this study, we proposed an improved 3DP process that can solve problems of conventional 3DP process. The general 3DP process is method to spout binder simply through printer head on powder, but proposed process is method to cure jetted UV resin by UV lamp after jet UV resin using printhead on powder. The hardening of resin is achieved strongly at early time by UV lamp in proposed method. So, the proposed process can fabricate three dimensional objects with high speed without any post-processing.

• Korean Journal of Computational Design and Engineering
• /
• v.11 no.3
• /
• pp.223-233
• /
• 2006

Layered manufacturing(LM) is emerging as a new technology that enables the fabrication of three dimensional heterogeneous objects such as Multi-materials and Functionally Gradient Materials (FGMs). Among various types of heterogeneous objects, more attention has recently paid on the fabrication of FGMs because of their potentials in engineering applications. The necessary steps for LM fabrication of FGMs include representation and process planning of material information inside an FGM. This paper introduces a new process planning algorithm that takes into account the processing of material information. The detailed tasks are discretization (i.e., decomposition-based approximation of volume fraction), orientation (build direction selection), and adaptive slicing of heterogeneous objects. In particular, this paper focuses on the discretization process that converts all of the material information inside an FGM into material features like geometric features. It is thus possible to choose an optimal build direction among various pre-selected ones by approximately estimating build time. This is because total build time depends on the complexity of features. This discretization process also allows adaptive slicing of heterogeneous objects to minimize surface finish and material composition error. In addition, tool path planning can be simplified into fill pattern generation. Specific examples are shown to illustrate the overall procedure.

• Transactions of the Korean Society for Noise and Vibration Engineering
• /
• v.18 no.8
• /
• pp.849-855
• /
• 2008

An experimental method based on contact resonance is developed to extract the contact parameters of mechanical joints under various clamped conditions. Mechanical joint parameters of shear contact stiffness and damping were extracted for different physical joint parameters such as surface finish of the mating surfaces, the presence of lubrication, the effect of the clamping pressure, and shear load. It was found that the shear contact stiffness values decreased with increasing clamping load and increased with increasing shear loading. Contact damping ratio values were almost constant with clamping load, but decreased with increasing shear load. Moreover, rough surfaces exhibited the highest shear stiffness and contact damping compared to smooth surfaces.

• Journal of the Microelectronics and Packaging Society
• /
• v.17 no.2
• /
• pp.11-20
• /
• 2010

The effects of heat treatment on matte pure tin-plated Cu leadframes at high temperature and humidity conditions were investigated. After 1800 hrs of storage at $55^{\circ}C/85%$ RH, approximately 14.5 ${\mu}m$ long striation-shaped whiskers were observed on the surface of the without postbake treatment (WOPB) samples, while no whiskers were found in with postbake treatment (WPB) samples. The preferred orientations of Sn grains in WOPB and WPB sample did not change after the postbake treatment at $125^{\circ}C$ for 1 hr. However, both changed from (112) to (321) and (101), respectively, after 1800 hrs of storage at $55^{\circ}C/85%$ RH. The tensile stress of 8 MPa generated in as-plated sample was changed to a compression stress of 17 MPa after 2 days in room temperature storage. Due to the grain growth during postbake treatment, the WPB samples have more regular grains than the WOPB samples. In the as-plated sample, 0.32 ${\mu}m$ thickness of planar intermetallic compound (IMC) was observed. The IMCs in the WOPB and WPB samples had two distinct layers with large grains of $Cu_6Sn_5$ and with small grains of ${\eta}-Cu_{6.26}Sn_5$.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2003.06a
• /
• pp.113-116
• /
• 2003

To maximize the productivity in machining molds and dies, machine tools should operate at high speeds. During the high speed operation of moving frames or spindles, vibration problems are apt to occur if the machine tool structures are made of conventional steel materials with inferior damping characteristics. However, self-excited vibration or chatter is bound to occur during high speed machining when cutting speed exceeds the stability limit of machine tool. Chatter is undesirable because of its adverse effect on surface finish, machining accuracy, and tool lift. Furthermore, chatter is a major cause of reducing production rate because, if no remedy can be found, metal removal rates have to be lowered until vibration-free performances is obtained. Also, the resonant vibration of machine tools frequently occurs when operating frequency approaches one of their natural frequencies because machine tools have several natural frequencies due to their many continuous structural elements. However, these vibration problems are closely related to damping characteristics of machine tool structures. This paper presents the use of polymer concrete and sandwich structures to overcome vibration problems. The polymer concrete has high potential for machine tool bed due to its good damping characteristics with moderate stiffness. In this study, a polymer concrete bed combined with welded steel structure i.e., a hybrid structure was designed and manufactured for a high-speed gantry-type milling. Also. its dynamic characteristics were measured by modal tests.

• International Journal of Precision Engineering and Manufacturing
• /
• v.9 no.3
• /
• pp.3-6
• /
• 2008

Electrolytic in-process dressing (ELID) grinding is a new technique for achieving a nanoscale surface finish on hard and brittle materials such as optical glass and ceramics. This process applies an electrochemical dressing on the metal-bonded diamond wheels to ensure constant protrusion of sharp cutting grits throughout the grinding cycle. In conventional ELID grinding, a constant source of pulsed DC power is supplied to the ELID cell, but a feedback mechanism is necessary to control the dressing power and obtain better performance. In this study, we propose a new closed-loop wheel dressing technique for grinding wheel truing that addresses the efficient correction of eccentric wheel rotation and the nonuniformity in the grinding wheel profile. The technique relies on an iterative control algorithm for the ELID power supply. An inductive sensor is used to measure the wheel profile based on the gap between the sensor head and wheel edge, and this is used as the feedback signal to control the pulse width of the power supply. We discuss the detailed mathematical design of the control algorithm and provide simulation results that were confirmed experimentally.

• International Journal of Quality Innovation
• /
• v.6 no.3
• /
• pp.204-215
• /
• 2005

This paper explores innovative manufacturing processes, which can be used to manufacture the national musical instrument of Trinidad and Tobago, the Musical Steel Drum or Steel Pan. The main manufacturing process used today is the manual hand-forming technique. In order to achieve more consistent and deeper formed components while maintaining the high quality of the instrument, it is proposed that the Marforming process and the Flow-forming process, an adaptation of the Spinforming process, be used more frequently in the future to replace the traditional Hand-forming method. In the traditional Spinforming technique material is pushed from the outer circumference of the metal disc to the center in progressive passes of the former. This results in a thinning of the outer region of the formed component with thickening of the center, however the opposite is required for the musical steel drum and by adapting the process the required strain distributions were achieved. Evaluation took the form of strain analyses of pre-formed steel drums and visual inspection of the quality of the surface finish. It was found that the Marformed components had the smallest range of strain values while the Spinformed components had the largest range.