• Design & Manufacturing
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• 제16권2호
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• pp.53-59
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• 2022

Unlike other press forming processes, ISF (Incremental sheet forming) doesn't require a punch and die set. However, during the ISF processes unwanted bending deformation occurred around the target geometry. This paper is aimed to analyze the effect of the die structure, which is supported by bolts, on the geometric accuracy of the ISF processes. In this research, the ISF processes with Al5052 sheet of 0.5 mm, the tool diameter of 6 mm and the stepdown of 0.4 mm was employed. L-shaped, step-shaped, relief-shaped geometry were employed in experiments. Sectional view and the plastic strain were compared. From this research we find out that the bolt supported ISF processes increases the geometric accuracy of products very effectively.

• 대한기계학회논문집A
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• 제24권5호
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• pp.1323-1330
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• 2000

Recently, injection molding process became more popular than ever to produce large quantities of high precision products or optical products. Especially, optical disk that was made by injection mol ding process has been used for many years as a music play media or computer sub-device. The density of data in disk media has been increased continuously. But those optical disks can cause sensorial problems because of high birefringence or deformation from the residual stresses in the media. Therefore, it is necessary to study the effects of various process conditions on the final bireffingence structure in injection-molded disks for producing precision injection-molded products. In the present paper we have focussed on the effect of holding and compression pressures on the optical anisotropy remaining in the MOD by examining the gapwise distribution of birefringence and extinction angle. The effect of holding pressure was found to form the inner two bireffingence peaks. But the effect of compression pressure on the bireffingence distribution was found to make the uniform distribution near the center in the gapwise direction. Finally, the value of the birefringence near the wall decreased as the mold temperature increased.

• Design & Manufacturing
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• 제17권3호
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• pp.28-33
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• 2023

The conventional FRP (Fiber Reinforced Plastic) manufacturing process used thermoset resins for ease of molding but faced the issue of non-recyclability. To address these shortcomings, a new process utilizing thermal plastic resin was developed. However, due to the high viscosity of thermal plastic resin, problems such as fiber deformation and a reduced fiber volume fraction occurred during the high-temperature, high-pressure process. In this study, to overcome the limitations of the conventional process, fiber-reinforced composite materials were manufactured through in-situ polymerization using PLA (Poly L-Lactide) resin in the VA-RTM (Vacuum Assistance Resin Transfer Molding) process. The fiber volume of the produced specimens was calculated, and resin impregnation and porosity were confirmed through optical microscopy. Additionally, molecular weight analysis using GPC (Gel Permission Chromatography) demonstrated improvements over the conventional process and emphasized the essential requirement of temperature control.

• 한국재료학회지
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• 제15권4호
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• pp.281-284
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• 2005

Room and high temperature deformation behaviors of Cu-Zr-Ti-Pd bulk metallic glasses produced by copper mold casting were investigated. The addition of Pd was shown to enhance the glass forming ability and thermal stability of Cu-Zr-Ti base bulk metallic glass. The compressive strength of $Cu_{55}Zr_{30}Ti_{10}Pd_5$ bulk metallic glass was 2230 MPa with 1.8 plastic strain. The stress overshoot and yield drop phenomenon were observed below $487^{\circ}C$ and a drastic decrease in the flow stress was observed at $487^{\circ}C$. The stress overshoot is thought to be associated with stress-induced structural relaxation.

• 실천공학교육논문지
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• 제10권2호
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• pp.89-94
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• 2018

사출 성형에서 금형 온도는 성형품의 품질에 큰 영향을 준다. 어느 정도의 온도가 적정한가는 성형 재료, 성형품에서 요구되는 품질에 의해서 결정되고 중요한 것은 그 온도가 안정적이어야 한다. 먼저 그 수지에 적합한 금형 온도 조건 범위 내에서 성형품이 요구하는 품질에 맞는 금형 온도를 설정해야 한다. 즉, 성형품의 표면 광택, 성형 사이클의 단축, 변형 방지, 수축 및 수지 흐름의 용이성 등의 중요성에 의해서 금형 온도는 변화한다. 실질적인 금형 기술 향상을 위해서 사출 금형을 설계하고 제작하는 산업체에서 적용할 수 있는 온도 제어에 대한 애로 기술 과정의 훈련 모형을 제시하고자 한다.

• 소성∙가공
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• 제13권4호
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• pp.326-333
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• 2004

The nanoprobe based on lithography, mainly represented by SPM based technologies, has been recognized as a potential application to fabricate the surface nanosctructures because of its operational versatility and simplicity. However, nanoprobe based on lithography itself is not suitable for mass production because it is time a consuming method and not economical for commercial applications. One solution is to fabricate a mold that will be used for mass production processes such as nanoimprint, PDMS casting, and others. The objective of this study is to fabricate the silicon stamper for PDMS casting process by a mastless fabrication technique using the combination of nano/micro machining by Nanoindenter XP and KOH wet etching. Effect of the Berkovich tip alignment on the deformation was investigated. Grooves were machined on a silicon surface, which has native oxide on it, by constant load scratch (CLS), and they were etched in KOH solutions to investigate chemical characteristics of the machined silicon surface. After the etching process, the convex structures was made because of the etch mask effect of the mechanically affected layer generated by nanoscratch. On the basis of this fact, some line patterns with convex structures were fabricated. Achieved groove and convex structures were used as a stamper for PDMS casting process.

• 한국공작기계학회논문집
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• 제16권5호
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• pp.77-83
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• 2007

The study on damaged layer is necessary for machinability improvement in micro machining. The damaged layer in metal cutting is derived from plastic deformation and transformation of metal structure. The damaged layer affects micro mold life and micro machine parts. In this study, the damaged layer of micro machined surface of copper is evaluated according to various machining condition. The damaged layer structure and metallurgical characteristics are measured by optical microscope, and evaluated by cutting forces and surface roughness. The scale of this damaged layer depends on cutting process parameters and machining environments. By experimental results, depth of damaged layer was increased with increasing of cutting depth, also the damaged layer is less occurred in down-milling compared to up-milling during micro endmilling operation.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.43-46
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• 2005

Micro molding technology is a promising mass production technology for polymer based microstructures. Mass production technologies such as the micro injection/compression molding, hot embossing, and micro reaction molding are already in use. In the present study, we have developed a numerical analysis system to simulate three-dimensional non-isothermal cavity filling for hot embossing, with a special emphasis on the free surface capturing. Precise free surface capturing has been successfully accomplished with the level set method, which is solved by means of the Runge-Kutta discontinuous Galerkin (RKDG) method. The RKDG method turns out to be excellent from the viewpoint of both numerical stability and accuracy of volume conservation. The Stokes equations are solved by the stabilized finite element method using the equal order tri-linear interpolation function. To prevent possible numerical oscillation in temperature Held we employ the streamline upwind Petrov-Galerkin (SUPG) method. With the developed code we investigated the detailed change of free surface shape in time during the mold filling. In the filling simulation of a simple rectangular cavity with repeating protruded parts, we find out that filling patterns are significantly influenced by the geometric characteristics such as the thickness of base plate and the aspect ratio and pitch of repeating microstructures. The numerical analysis system enables us to understand the basic flow and material deformation taking place during the cavity filling stage in microstructure fabrications.

• 한국지반공학회:학술대회논문집
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• 한국지반공학회 2008년도 춘계 학술발표회 초청강연 및 논문집
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• pp.894-904
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• 2008

In this study, soil samples from the Antarctic and Vladivostok, Siberia were tested in the laboratory, and specific gravity, compaction curve and grain size distribution were determined. The effect of temperature change on the thermal conductivity, unfrozen water content and compressive strength were investigated. Samples for the compressive strength test were prepared in a mold with a fixed volume to prevent swelling and the effect of temperature and water content change on the strength were compared. Results from the thermal conductivity test showed that thermal conductivity values for both soils were larger at temperatures below freezing than above freezing. The unfrozen water content dropped sharply within a temperature range of $0{\sim}-5^{\circ}C$ and then gradually decreased further up to $-20^{\circ}C$. Compressive strength test results showed various stress/deformation curves with a change in water content. Sandy soil had much larger strength than pure ice at an identical temperature, while clayey soil had a smaller strength than ice near the freezing point, but showed a larger strength at temperatures belows $-15^{\circ}C$.

• 유변학
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• 제11권1호
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• pp.18-27
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• 1999

본 연구에서는 3차원 열성형 공정 알고리듬과 이에 membrane approximation을 도입한 근사적인 알고리듬을 개발하였고, 이 알고리듬을 이용하여 몇몇 열성형계에 대한 수치모사를 수행하여 그 결과를 비교 분석하였다. 3차원 알고리듬의 경우에는 구성한 유한요소 평형 방정식에 벌칙함수를 도입하여 비압축성 조건을 만족시켜 해를 얻었으며, membrane approximation을 도입한 알고리듬의 경우에는 두께 방향의 응력을 무시하여 구성한 방정식으로부터 해를 얻었다. 구성방정식은 2nd Piola-Kirchhoff 응력 텐서와 Cauchy-Green 변형 텐서를 사용하여 표현하였고 수지의 물질 모델식으로는 2항의 Mooney-Rivlin 모델을 사용하였으며, total Lagrangian coordinate를 도입하여 지배방정식을 유한요소화함으로써 알고리듬을 구성하였다. 대상계로 선정한 사각평판 수지의 자유 부풀림 거동과 금형이 있는 경우에서의 수지의 부풀림 거동을 3차원 알고리듬과 membrane approximation 알고리듬을 각각 이용하여 분석하였으며 3차원 알고리듬의 경우 clamping 부분의 경계조건을 달리하여 결과를 비교하였다. 금형이 있는 계에 대해서는 slip 경계조건과 no-slip 경계조건을 각각 부여하여 수치모사를 수행, 수지의 변형거동과 응력분포를 비교 분석하였으며, 두께를 달리 한 수지에 대해 두께 방향의 응력을 비교 분석함으로써 membrane approximation 알고리듬의 한계에 대하여 논하였다. 한편 수지 온도 변화에 따른 성형품의 두께 분포의 변화를 살펴보기 위하여 ABS 수지를 대상으로 하여 $137.8^{\circ}C$에서 $171.1^{\circ}C$사이의 온도에서 수행한 인장실험 데이터를 수치모사에 사용하였다. 그 결과 수지의 온도가 높을수록 두께의 표준편차가감소하여 균일한 두께 분포를 얻을 수 있음을 확인하였고 이는 수지의 흐름성이 증가함으로써 나타나는 현상으로 해석할 수 있다.