• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.811-814
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• 1997

The injection molding process has been developed as a very important technology for the automotive and electric industries in recent years. But, in the injection molding products with rib-web structures, partial deformation by thermal volumetric shrinkage called Sink Mark, is occurred. In this study, to make explicitly characteristics of sink mechanism, an experimental approach was taken by using multi T-shaped mold cavity and FEM simulation. As a result, pressure on the packing process and the rib thickness are the most effective on sink mark depth. On the other hand, melt temperature has no effect on sink mark depth fot the same rib thickness.

• Journal of Powder Materials
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• v.9 no.6
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• pp.381-393
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• 2002

Recent developments in nanocrystalline and nanocomposite rare earth-transition metal magnets are reviewed and emphasis is placed on research work at IFW Dresden. Principal synthesis methods include high energy ball milling, melt spinning, mold casting and hydrogen assisted methods such as reactive milling and hydrogenation-disproportionation-desorption-recombination. These techniques are applied to NdFeB-, PrFeB- and SmCo-type systems with the aim to produce high remanence magnets with high coercivity. Concepts of maximizing the energy density in nanostructured magnets by either inducing a texture via anisotropic HDDR or hot deformation or enhancing the remanence via magnetic exchange coupling are evaluated. With respect to high temperature applications melt spun $Sm(Co_{0.74}Fe_{0.1}Cu_{0.12}Zr_{0.04})_{7.5}$ ribbons were prepared, which showed coercivities of up to 0.53 T at 50$0^{\circ}C$. Partially amorphous $Nd_{60}Fe_xCo_{30-x}Al_{10}(0{\leq}x{\leq}30)$ alloys were prepared by copper mold casting. The effect of transition metal content on the glass-forming ability and the magnetic properties was investigated. The $Nd_{60}Co_{30}Al_{10}$ alloy exhibits an amorphous structure shown by the corresponding diffraction pattern. A small substitution of Co by 2.5 at.% Fe results In the formation of Fe-rich crystallites embedded in the Nd-rich amorphous matrix. The Fe-rich crystallites show hard magnetic behaviour at room temperature with a coercivity value of about 0.4 T, relatively low saturation magnetization and a Curie temperature of 500 K.

• Korean Journal of Materials Research
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• v.19 no.9
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• pp.457-461
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• 2009

Recently, metal molding has become essential not only for automobile parts, but also mass production, and has greatly influenced production costs as well as the quality of products. Its surface has been treated by carburizing, nitriding and induction hardening, but these existing treatments cause considerable deformation and increase the expense of postprocessing after treatment; furthermore, these treatments cannot be easily applied to parts that requiring the hardening of only a certain section. This is because the treatment cannot heat the material homogeneously, nor can it heat all of it. Laser surface treatment was developed to overcome these disadvantages, and, when the laser beam is irradiated on the surface and laser speed is appropriate, the laser focal position is rapidly heated and the thermal energy of surface penetrates the material after irradiation, finally imbuing it with a new mechanical characteristic by the process of self-quenching. This research estimates the material characteristic after efficient and functional surface treatment using HPDL, which is more efficient than the existing CW Nd:YAG laser heat source. To estimate this, microstructural changes and hardness characteristics of three parts (the surface treatment part, heat affect zone, and parental material) are observed with the change of laser beam speed and surface temperature. Moreover, the depth of the hardened area is observed with the change of the laser beam speed and temperature.

• Design & Manufacturing
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• v.14 no.4
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• pp.65-70
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• 2020

Partial reinforcement of sheet metal parts with CFRP patch is a technology that can realize ultra-lightweight body parts while overcoming the high material cost of carbon fiber. Performing these patchworks with highly productive press equipment solves another issue of CFRP: high process costs. The A-pillar is the main body part and has an undercut shape for fastening with other parts such as roof panels and doors. Therefore, it is difficult to bond CFRP patches to the A-pillar with a general press forming tool. In this paper, a flexible system that applies uniform pressure to complex shapes using ceramic particles and silicone rubber is proposed. By benchmarking various A-pillars, a reference model with an undercut shape was designed, and the system was configured to realize a uniform pressure distribution in the model. The ceramic spherical particles failed to realize the uniform distribution of high pressure due to their high hardness and point contact characteristics, which caused damage to the CFRP patch. Compression equipment made of silicone rubber was able to achieve the required pressure level for curing the epoxy. Non-adhesion defects between the metal and the CFRP patch were confirmed in the area where the bending deformation occurred. This defect could be eliminated by optimizing the process conditions suitable for the newly developed flexible system.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.12
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• pp.1303-1312
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• 2013

We report an ultra-precision lathe designed to machine micron-scale features on a large-area roll mold. The lathe can machine rolls up to 600 mm in diameter and 2,500 mm in length. All axes use hydrostatic oil bearings to exploit the high-precision, stiffness, and damping characteristics. The headstock spindle and rotary tooling table are driven by frameless direct drive motors, while coreless linear motors are used for the two linear axes. Finite element method modeling reveals that the effects of structural deformation on the machining accuracy are less than $1{\mu}m$. The results of thermal testing show that the maximum temperature rise at the spindle outer surface is approximately $0.5^{\circ}C$. Finally, performance evaluations of the error motion, micro-positioning capability, and fine-pitch machining demonstrate that the lathe is capable of producing optical-quality surfaces with micron-scale patterns with feature sizes as small as $20{\mu}m$ on a large-area roll mold.

• Design & Manufacturing
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• v.16 no.4
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• pp.24-33
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• 2022

Fiber-reinforced plastics(FRPs) have excellent specific stiffness and strength, so they are usually used as automotive parts that require high rigidity and lightweight instead of metal. However, it is difficult to predict the mechanical properties of injection molded parts due to the fiber orientation and breakage of FRPs. In this paper, the fiber orientation characteristics and mechanical properties of injection molded specimens were evaluated in order to fabricate automotive transmission side covers with FRPs and design a rib structure for improvement of their rigidity. The test molds were designed and manufactured to confirm the fiber orientation characteristics of each position of the injection molded standard plate-shaped specimens, and the tensile properties of the specimens were evaluated according to the injection molding conditions and directions of specimens. A gusset-rib structure was designed to improve the additional structural rigidity of the target products, and a proper rib structure was selected through the flexural tests of the rib-structured specimens. Based on the evaluation of fiber orientation and mechanical characteristics, the optimization analyses of gate location were performed to minimize the warpage of target products. Also, the deformation analyses against the internal pressure of target product were performed to confirm the rigidity improvement by gusset-rib structure. As a result, it could be confirmed that the deformation was reduced by 27~37% compared to the previous model, when the gusset-rib structure was applied to the joining part of the target products.

• Geomechanics and Engineering
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• v.27 no.6
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• pp.537-550
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• 2021

There are various technical problems need to be solved in the construction process of pre-setting an isolation wall into a double lane in the outburst prone mine. This study presents a methodology that pre-setting an isolation wall into a double lane without a coal pillar. This requires the excavation of two small section roadways to dig a wide section roadway, followed by construction of the separation wall. During this process the connecting lane is reserved. In order to ensure the stability of the separation wall, the required bearing capacity of the isolation wall is 4.66 MN/m and the deformation of the isolation wall is approximately 25 cm. To reduce the difficulty of implementing support the roadway is driven by 5 m/d. After the construction of the separation wall, the left side coal wall is brushed 1.5 m to make the width of the gas roadway reach 2.5 m and the roadway support utilizes anchor rod, ladder beam, anchor cable beam and net configuration. During construction, the concrete pump and removable self-propelled hydraulic wall mold are used to pump and pour the concrete of the isolation wall. In the process of mining, the stress distribution of coal body and isolation wall is detected and measured on site. The results demonstrate that the deformation of the surrounding rock of roadway and separation of roof in the roadway is small. The stress of the bolt and anchor cable is within equipment tolerance validating their selection. The roadway is well supported and the intended goal is achieved. The methodology can be used for reference for similar mine gas control.

• Journal of the Korea Convergence Society
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• v.12 no.1
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• pp.199-204
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• 2021

In this study, the configurations of the two engine exhaust manifolds were designed. And the strengths and durabilities were analyzed through the structural analysis and natural frequency analyses of these models. As the result of structural analysis, the strength of model A is much better than that of model B because the maximum stress and deformation of model B are considerably greater than those of model A by more than 9 and 39 times, respectively. It can also be confirmed that model A has the durability better than model B because the maximum frequency of model A is greater than the natural frequency of model B and its maximum deformation is smaller than model B. The result of this study can be used to investigate the durability due to the exhaust manifold shape of medium-sized car without actual test. It also seems to be helpful in the aesthetic convergent design of small car muffler.

• Journal of the Korea Convergence Society
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• v.12 no.2
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• pp.173-177
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• 2021

In this study, the torsional rigidity and durability of the stabilizer models with the hollow axis of light and large sized cars were compared and investigated each other. Model 1 was applied with the moment more than three times as much as model 2, but the maximum deformation of model 1 was seen to be about 2.6 times larger than that of model 2. Commonly, models 1 and 2 are seen to get the most stress at the neck of stabilizer bar link. Also, the maximum stress of model 1 was about 2.9 times larger than that of model 2. Model 1 at large car showed more than 20 times more deformed energy than model 2 at small car. Overall, it could be examined that the deformation energy of the bracket part on the side where the moment fixing the stabilizer bar was applied was greater than that of the stabilizer. It is thought that the analysis results in this study can be helped at the design of its convergent research as a durable component of the stabilizer at a light or large sized car.

• Transactions of Materials Processing
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• v.32 no.6
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• pp.344-351
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• 2023

The use of Zn-Al-Mg alloy coatings for enhancing the corrosion resistance of steel sheets is gaining prominence over traditional Zn coatings. There is a growing demand for the development of thermal spray wires made from Zn-Al-Mg alloys, as a replacement for the existing wires produced using Al and Zn. This is particularly crucial to secure corrosion resistance and durability in the damaged areas of coated steel sheets caused by deformation and welding. This study focuses on the casting and extrusion processes of Zn-2Al-1Mg alloy for the fabrication of such spray wires and analyzes the changes in microstructure during the extrusion process. The Zn-2Al-1Mg alloy, cast in molds, was subjected to a heat treatment at 250 ℃ for 3 hours prior to extrusion. The extrusion process was carried out by heating both the material and the mold up to 300 ℃. Microstructural analysis was conducted using FE-SEM and EDS to differentiate each phase. The mechanical properties of the cast specimen were evaluated through compression tests at temperatures ranging from 200 to 300 ℃, with strain rates of 0.1 to 5 sec^-1. Vickers hardness testing was utilized to assess the inhomogeneity of mechanical properties in the radial direction of the extruded material. Finite Element Analysis (FEA) was employed to understand the inhomogeneity in stress and strain distribution during extrusion, which aids in understanding the impact of heterogeneous deformation on the microstructure during the process.