• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.3
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• pp.32-38
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• 2005

Electrical discharge machining is the method of using thermal energy by electrical discharge. Generally, if the material of workpiece has conductivity even though very hard materials and complicated shape which are difficult to cut such as quenching steel, cemented carbide, diamond and conductive ceramics, the EDM process is favorable one of possible machining processes. But, the process is necessarily required of finish cut and heat treatment because of slow cutting speed, no mirror surface, brittleness and crack due to the residual stress for manufactured goods. In this experimental thesis, the super EDM drilling was developed for high precision semiconductor die steel and for minimization of leadframe width. It was possible to development of EDM drilling machine for high precision semiconductor die with the electrode guide and its modelling and stress analysis. The development of electrode with the copper pipe type was conducted to drill the hole from the diameter of 0.1mm to 3.0mm with the error of from 0.02mm to 0.12mm. From the SEM and EDX analysis, the entrance of the EDM drill was found the resolidification of not only the component of tungsten but also the component of copper.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.4
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• pp.47-54
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• 2009

In the last few years, lasers have found new applications as tools for ceramic machining which is laser-assisted machining(LAM). LAM process for the machining of difficult-to-machine materials such as structural ceramics, has recently been studied on silicon nitride workpiece for a wide range of operating condition. However, there have been few studies on rake angle in LAM process. In this paper we analyzed difference of machinability between positive and negative rake angle in tools. We have obtained interesting results that we could eliminate chattering, lower specific cutting and cutting ratio in case of positive rake angle. The results suggest that positive rake angled tools can make more plastic deformation and stable cutting of silicon nitride in comparison with negative rake angled one.

• Transactions of Materials Processing
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• v.11 no.5
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• pp.405-413
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• 2002

A process planning system for cold forging of non-axisymmetric parts of comparatively simple shape was developed in this study. Programs for the system have been written with Visual LISP in AutoCAD. Shape of the product must be drawn with the solid line and the hidden line, and with the plane and front view, as well. At the plane, the system recognizes the external shape of non-axisymmetric portions - the number of the sides of the regular polygons and the radii of circles inscribing and circumscribing the polygon. At the front view, the system cognizes the diameter of axisymmetric portions and the height of the primitive geometries such as polygon, cylinder, cone, concave, convex, etc. The system perceives that the list developed from the solid line must be formed by the operation of forward extrusion or upsetting, and that the list developed from the hidden line must be formed by the operation of backward extrusion. The system designs the intermediate geometries again by considering clearance between workpiece and die, and then finally the billet diameter, in reverse order from the finished product, on the basis of volume constancy and using the operations, the forming sequence, the number of operations and the intermediate geometries which were already designed. The design rules and knowledges for the system were extracted from the plasticity theories, handbook, relevant reference and empirical knowledge of field experts. Suitability of the process planning was analyzed using SuperForge of FVM simulation package. The results of analysis showed good formability.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.582-589
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• 2007

This paper is related to an analysis on the surface expansion in backward can extrusion process using spherical punches. It is generally known that the backward can extrusion process usually experiences severe normal pressure and heavy surface expansion. This is a reason why the backward can extrusion process is one of most difficult operations among many forging processes. Different punch nose radii have been applied to the simulation to investigate the effect of punch nose radius on the surface expansion, which is a major effort in this study. AA 2024 aluminum alloy is selected as a model material for investigation. Different frictional conditions have also been selected as a process parameter. The pressure applied on the punch has been also investigated since heavy surface expansion as well as high normal pressure on the tool usually leads to severe tribological conditions along the interface between material and tool. The simulation results are summarized in terms of surface expansion at different reduction in height, deformation patterns including strain distributions and maximum pressure exerted on the workpiece and punch, the effect of punch nose radius and the frictional condition on the surface expansion and the location and magnitude of maximum pressure exerted, respectively.

• Journal of Welding and Joining
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• v.8 no.3
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• pp.60-69
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• 1990

Plasma arc cutting is a fusion cutting process in which a gas-constricted arc is employed to produce a high-temperature, high-velocity plasma jet on the workpiece. This process provides some advantages such as increased cutting velocity, excellent working accuracy and the ability to cut special materials (widely used stainless steels and Al-alloys, for example), when compared with iconventional oxyfuel gas cutting. From the view point of price and reliability of the power source, plasma arc cutting has also some distinct advantages over laser beam cutting. High-speed machines with NC or CNC systems are needed for the plasma arc or laser beam cutting process, while for oxyfuel gas cutting, low-speed machines with copying templates or optical-shape tracking sensors can be applied. The low price and high flexibility of the microprocessor arc contributing more and more the application of CNC system in the plasma arc cutting process, as in other manufacturing fields. From these points of view, a microprocessor-based plasma arc cutting system was developed by using a reference-pulse system, and its performance was tested. The interpolating routines were programmed in the assembly language for saving the memory volume and improving the compouting speed, which has an intimate relationship with the available cutting velocity.

• Journal of the Korean Wood Science and Technology
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• v.16 no.4
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• pp.54-60
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• 1988

Machinabilities means inherent properties of pinus densiflora at Chunyang district to be CNC machined easily or not, and processing abilities of the tool and machine together. This explanation signifies that machinabilities have two phases of signification, depended on considering and stress either materials or tools preferentially. This paper discuss machinabilities, the following items are usually employed as the indices of stress distribution at the cutting tool rake face. The stress distributions on the chip - tool contact surface at the early stage of the chip forming and under the stage of fringe pattern in wood cutting were analyzed the photoelastic method. The tool used in the present experiment was the special cutting tool H.S.S. one made in laboratory. And isochromatic fringe pattern and isolinic line of work piece by chip-behavior during the cutting operation were photographed with the feed camera continuously. The effects on the stress, distribution on the rake face of the epoxy tool and the strain distribution in the work piece of wood plate by chip behavior are cleared in pre cent experiment.

• Laser Solutions
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• v.13 no.2
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• pp.10-16
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• 2010

Laser-assisted machining is dependent on absorbed energy density into workpiece. Generally, the absorptivity of laser beam is dependent on wave length of laser, materials, surface roughness, etc. Various shapes and energy densities for beam irradiation can be used to laser-assisted machining. In this thesis, efficient method of heat source modeling was developed and designed by using one fundamental experimental trials. And then, laser-assisted machining of rod-shaped cast iron was simulated by using commercial FEM code MARC. Simulations and experiments with various conditions were carried out to determine suitable condition of pre-heating for laser-assisted turning process. Temperature distribution of cutting zone could be predicted by simulation.

• Transactions of Materials Processing
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• v.17 no.1
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• pp.35-45
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• 2008

Electromagnetic Forming (EMF) technology such as magnetic pulse forming, which is one of the high velocity forming methods, has been used for the joining and forming process in various industry fields. This method could be derived a series of deformation of sheet metal by using a strong magnetic field. In this study, numerical approach by finite element simulation of the electromagnetic forming process was presented. A transient electromagnetic finite element code was used to obtain the numerical model of the time-varying currents that are discharged through the coil in order to obtain the transient magnetic forces. Also, the body forces generated in electromagnetic field were used as the loading condition to analyze deformation of thin sheet metal workpiece using explicit dynamic finite element code. In this study, after finite element analysis for thin sheet metal forming process with free surface configuration was performed, analytical approach for a dimpled shape by using EMF was carried out. Furthermore, the simulated results of the dimpled shape by EMF were compared with that by a conventional solid tool in view of the deformed shape. From the results of finite element analysis, it is confirmed that the EMF process could be applied to thin sheet metal forming.

• Transactions of Materials Processing
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• v.22 no.6
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• pp.317-322
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• 2013

A radio frequency(R/F) switch connector is widely used in wireless devices such as mobile phone and navigator to check defects of the circuit board of product. The R/F switch connector shell plays a role in protecting the switch connector. Previously, this part was machined using a turning, which is time-consuming and has poor material utilization. Furthermore, the workpiece material of brass containing lead that has excellent machinability has environmentally regulated during recent years. The purpose of the current study was to develop the connector shell by forming through progressive dies including embossing, burring and forging process in order to achieve higher productivity and dimensional accuracy without tool failure. To accomplish this objective, a strip layout was designed and finite element (FE) analysis was performed for each step in the process. Try-out for the connector shell was conducted using progressive die design based on FE-analysis results. Dimensional accuracy of developed part was investigated by scanning electron microscopy. The result of the investigation for the dimensions of the formed connector shell showed that the required dimensional accuracy was satisfied. Moreover, productivity using the progressive die increased four times compared to previous machining process.

• Laser Solutions
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• v.11 no.4
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• pp.7-12
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• 2008

Laser Transformation Hardening(LTH) is one branch of the laser surface modification processes. A lot of energy is needed for the LTH process to elevate workpiece surface to temperature of the austenite transformation($A_3$), which results from utilizing a beam with a larger size and lower power density comparatively. This study is related to the surface hardening for the rod-shaped carbon steel by the high power diode laser whose beam absorptivity is better than conventional types of lasers such as $CO_2$ or Nd:YAG laser. Because a beam proceeds on the rotating specimen, the pretreated hardened-phase can be tempered and softened by the overlapping between hardened tracks. Accordingly, the longitudinal hardness measurement and observation of the micro structure was carried out for an assessment of the hardening characteristics. In addition, a hardening characteristics as a hardenability of materials was compared in the point of view of the hardness distribution and hardening depth and width.