• Journal of the Korean Society for Precision Engineering
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• v.33 no.12
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• pp.993-998
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• 2016

In today's manufacturing industries, the demand for light non-ferrous materials is considerable due to the need to improve productivity and manufacturability. Since the surface roughness of a material is important for improving the functionality of machined parts, various techniques for surface treatments have been developed to obtain non-ferrous materials with low roughness. A superfinishing method utilizing polishing films is generally applied to the anodized surface of Al7075 in order to improve its roughness. The objective of this research is to determine through experiment the parameters that facilitate the shortest processing time, using a superfinishing method, for reaching a roughness of Ra $0.2{\mu}m$. This objective is met by applying the Taguchi method in the experiments. Through the experiments of superfinishing, the effectiveness of the parameters adopted for the surface treatment is demonstrated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.593-597
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• 2005

FIB equipment can perform sputtering and chemical vapor deposition simultaneously. It is very advantageously used to fabricate a micro structure part having 3D shape because the minimum beam size of ${\phi}$ 10nm and smaller is available. Currently FIB is not being applied in the fabrication of this micro part because of some problems to redeposition and charging effect of the substrate causing reduction of accuracy with regards to shape and productivity. Furthermore, the prediction of the material removal rate information should be required but it has been insufficient for micro part fabrication. The paper have the targets that are FIB-CVD characteristic analysis and minimum line pattern resolution achievement fur 3D micro fabrication. We make conclusions with the analysis of the results of the experiment according to beam current, pattern size and scanning parameters. CVD of 8 pico ampere shows superior CVD yield but CVD of 1318 pico ampere shows the pattern sputtered. And dwell time is dominant parameter relating to CVD yield.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.8
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• pp.51-59
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• 2019

Flow forming is an eco-friendly and high-efficiency plastic deformation process with fewer chips during a process which is specifically used to manufacture seamless tubular products like tire wheels, rocket motor cases etc. On the development of mortar barrel using Inconel718 tube, some flow formed products had dimensional errors on their thickness. In this study, our purpose is to optimize the process conditions with the smallest dimensional error. In order to find an optimum process condition, 2D axisymmetric FEM simulation analyses with Taguchi method were conducted. Geometric variables (attack angle, flatting angle, roller nose radius) and operating parameters (depth of forming, feed rate) are considered as control factors. Forward flow forming with single roller was first analyzed to determine the effective factors using AFDEX software and attack angle of the roller was identified as the most influential factor. Also, the nose radius of the rollers was confirmed as a significant factor in multi-rollers flow forming system. The effect of rollers offset values are also studied and finally, we proposed optimal conditions to improve the accuracy of flow forming process with Inconel718 tube for mortar barrel manufacturing.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.2
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• pp.126-134
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• 2007

Although there has been substantial research on the squeal noise for the automotive brake system, robust design issues with respect to control factors equivalent to design variables in optimization, noise factors due to system uncertainties, and signal factors designed to accommodate a user-adjustable setting still need to be addressed. For the purpose, the robust design applied to the disk brake system has been investigated by DOE (Design of Experiments) based Taguchi analysis with dynamic characteristics. The specific goal of this methodology is to identify a design with linear signal-response relationship, and variability minimization. The finite element models of the disk brake assembly have been constructed, and the squeal noise problems have been solved by complex eigenvalue analysis. As the practical robust design to reduce the brake squeal noise, material properties of pad, disk, and backplate, thickness and geometry of pad are selected as control factors, material properties of pad and disk, and the contact stiffness have been considered as noise factors, and friction coefficient between pad and disk is chosen as a signal factor. Through the DOE based robust design, the signal-to-noise ratio and the sensitivity for each orthogonal array experiment have been analyzed. Also, it has been proved that the proposed robust design is effective and adequate to reduce the brake squeal noise.

• Transactions of Materials Processing
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• v.30 no.6
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• pp.291-300
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• 2021

Currently, starting with electric vehicles, the application of ultra-high-strength steel sheets and light metals has expanded to improve mileage by reducing vehicle weight. At a time when internal combustion engine vehicles are rapidly changing to electric vehicles, the application of ultra-high-strength steel is expanding to satisfy both weight reductions and the performance safety of the chassis parts. There is an urgent need to improve the quality of parts without defects. It is particularly difficult to estimate the part formability through the finite element method (FEM) in the burring operation, so product design has been based on the hole expansion ratio (HER) and experience. In this study, design of experiment (DOE), analysis of variance (ANOVA), and regression analysis were combined to optimize the formability by adjusting the process variables affecting the burring formability of ultra-high-strength steel parts. The optimal variables were derived by analyzing the influence of variables and the correlation between the variables through FE analysis. Finally, the optimized process parameters were verified by comparing experiment with simulation. As for the main influence of each process variable, the initial hole diameter of the piercing process and the shape height of the preforming process had the greatest effects on burring formability, while the effect of a lower round of punching in the burring process was the least. Moreover, as the diameter of the initial hole increased, the thickness reduction rate in the burring part decreased, and the final burring height increased as the shape height during preforming increased.

• Journal of the Korean Vacuum Society
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• v.10 no.4
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• pp.431-439
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• 2001

In this paper, the a-Diamond films were synthesized using filtered vacuum arc source (FVAS), FVAS was composed of a torus structure with bending angle of 60 degree. The radius of torus was 266 mm, the radius of plasma duct was 80 mm and the total length was 600 mm. The magnet parts were composed of one permanent magnet and five solenoid magnets. The plasma duct was electrically isolated from the ground so that a bias voltage could be applied. The baffles inside plasma duct were installed in order to prevent the recoil effect of macro-particles. Cathode was made of graphite with 80 mm in diameter. The effects of solenoid magnet on plasma extraction were investigated by computer simulation and experiment using Taguchi's methode. The source and extraction magnet affected the arc stabilization. The extraction beam current was maximized with low value of the source magnet current and high value of the filtering magnet current. The beam current density was 3.2 mA/$\textrm{cm}^2$ and average deposition rate was 5 $\AA$/sec when the currents of arc discharge, source, extraction, bending, deflection and outlet magnet were 30 A, 1 A, 3 A, 5 A, 5 A, and 5 A, respectively. The beam current density and the efficiency of beam transportation were increased with the positive bias voltage of the plasma duct.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.10
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• pp.1367-1375
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• 2010

In this study, optimization of the process parameters of the resistance spot welding of a sheet of aluminum-coated boron alloyed steel, 22MnB5, used in hot stamping has been performed by a Taguchi method to increase the strength of the weld joint. The process parameters selected were current, electrode force, and weld time. The heating temperature and heating time of 22MnB5 are considered to be noise factors. It was known that the variation in the thickness of the intermetallic compound layer between the aluminum-coated layer and the substrate, which influences on the formation of nugget, was generated due to the difference of diffusion reaction according to heating conditions. From the results of spot weld experiment, the optimum weld condition was determined to be when the current, electrode force, and weld time were 8kA, 4kN, and 18 cycles, respectively. The result of a test performed to verify the optimized weld condition showed that the tensile strength of the weld joint was over 32kN, which is considerably higher than the required strength, i.e., 23kN.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.1
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• pp.107-114
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• 2017

A turbocharger is an engine supercharger that is driven by exhaust gas. It improves the output and fuel efficiency by increasing the charging efficiency of the mixture gas, which is achieved by changing the rotatory power of the turbine connected to the exhaust passage. It is important to control the supercharging for this purpose. A nozzle slide joint is one of the core parts. Austenitic stainless steel is currently used as the material for this part, and its excellent mechanical properties include high heat resistance and corrosion resistance. However, because of its poor machinability, there are many difficulties in producing products with complicated shapes. Machining is used in the production of nozzle slide joints for high dimensional accuracy after metal powder injection molding. As design variables in this study, we investigated the sintering temperature, product stress, deformation rate, radius of curvature of the punch, and angle of the chamfer punch, which are related to the strain and shapes. The goal is to suggest a forming process using Nitronic 60 that does not require machining to manufacture a nozzle slide joint for a turbocharger. Accordingly, we determined the best process environment using finite-element analysis, the signal-noise ratio, and the Taguchi method for experiment design. The relative density and hydrostatic pressure of the final product were in accordance with the results of the finite element analysis. Therefore, we conclude that the Taguchi method can be applied to the design process of metal powder injection molding.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.12
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• pp.793-798
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• 2017

In modern naval ships, an infrared signature suppression (IRSS) system is used to reduce the metal surface temperature of the heated exhaust pipe and high-temperature exhaust gases generated from the propulsion system. Generally, the IRSS systems used in Korean naval ships consist of an eductor, mixing tube, and diffuser. The diffuser reduces the temperature of the metal surface by creating an air film due to a pressure difference between the internal gas and the external air. In this study, design variables were selected by analyzing the shapes of a diffuser designed by an advanced overseas engineering company. The characteristics of the design variables that affect the performance of the IRSS were investigated through the Taguchi experimental method. A heat flow analysis technique for IRSS systems established in previous studies was used analyze the performance of the diffuser. The performance evaluation was based on the area-averaged value of the metal surface temperature and exhaust gas temperature at the outlet of the diffuser, which are directly related to the intensity of the infrared signature. The results show that the temperature of the exhaust gas was significantly affected by changes in the diameter of the diffuser outlet, and the temperature of the diffuser's metal surface was significantly affected by changes in the number of diffuser rings.

• Proceedings of the Korean Vacuum Society Conference
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• 2010.02a
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• pp.44-45
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• 2010

We are currently conducting studies on culturing and biocompatibility assessment of various cells such as neural stem cells and induced pluripotent stem cells(IPS cells) on carbon nanotube (CNT), on nerve regeneration electrodes, and on silicon wafers with a focus on developing nerve integrated CNT based bio devices for interfacing with living organisms, in order to develop brain-machine interfaces (BMI). In addition, we are carried out the chemical modification of carbon nanotube (mainly SWCNTs)-based bio-nanosensors by the plasma ion irradiation (plasma activation) method, and provide a characteristic evaluation of a bio-nanosensor using bovine serum albumin (BSA)/anti-BSA binding and oligonucleotide hybridization. On the other hand, the researches in the case of "novel plasma" have been widely conducted in the fields of chemistry, solid physics, and nanomaterial science. From the above-mentioned background, we are conducting basic experiments on direct irradiation of body tissues and cells using a micro-spot atmospheric pressure plasma source. The device is a coaxial structure having a tungsten wire installed inside a glass capillary, and a grounded ring electrode wrapped on the outside. The conditions of plasma generation are as follows: applied voltage: 5-9 kV, frequency: 1-3 kHz, helium (He) gas flow: 1-1.5 L/min, and plasma irradiation time: 1-300 sec. The experiment was conducted by preparing a culture medium containing mouse fibroblasts (NIH3T3) on a culture dish. A culture dish irradiated with plasma was introduced into a $CO_2$-incubator. The small animals used in the experiment involving plasma irradiation into living tissue were rat, rabbit, and pick and are deeply anesthetized with the gas anesthesia. According to the dependency of cell numbers against the plasma irradiation time, when only He gas was flowed, the growth of cells was inhibited as the floatation of cells caused by gas agitation inside the culture was promoted. On the other hand, there was no floatation of cells and healthy growth was observed when plasma was irradiated. Furthermore, in an experiment testing the effects of plasma irradiation on rats that were artificially given burn wounds, no evidence of electric shock injuries was found in the irradiated areas. In fact, the observed evidence of healing and improvements of the burn wounds suggested the presence of healing effects due to the growth factors in the tissues. Therefore, it appears that the interaction due to ion/radicalcollisions causes a substantial effect on the proliferation of growth factors such as epidermal growth factor (EGF), nerve growth factor (NGF), and transforming growth factor (TGF) that are present in the cells.