• Transactions of the Korean Society of Automotive Engineers
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• v.5 no.4
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• pp.199-206
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• 1997

The inner pulley is an automobile component used as air conditioner clutch assembly. In cold forging of inner pulley, the design requirements are to keep the same height of the inner rib and outer one, and to make uniform the hardness distribution in the forged product. In industry, the design of forging processes is performed based on experience-oriented technology, that is, designers experience and expensive trial and error. Using the rigid-plastic finite element simulations. we design the optimal process conditions, which has a preforming operation. Also the final product configuration of forging has to be designed again in view of metal flow involved in the operation, derived from the finite element simulations. The forged pulley is investigated by checking the hardness distribution and it is noted that distribution has improved to be even and high enough for industrial application.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1784-1788
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• 2003

For the improvement of geometrical accuracy in end milling, cutting method and cutting condition selection are investigated in this paper. As machining processes are composed of several steps such as roughing, semi-finishing. and finishing, cutting forces and tool deflection are calculated considering surface shape generated by the previous cutting. The effects of tool teeth numbers, tool geometry, and cutting conditions on the form error are analyzed. Using the from error prediction method from tool deflection, cutting condition for geometrical accuracy improvement is discussed. The characteristics and the difference of generated surface shape in up and down milling are dealt with and over-cut free condition in up milling is presented. The form error reduction method by alternating up and down milling is also suggested. The effectiveness of the presented method is examined from a set of cutting tests under various cutting conditions. This research contributes to cutting process optimization for the geometrical accuracy improvement in die and mold manufacture.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.45-48
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• 2001

SL(Stereolithogrphy) part is made by piling up thin layers which causes the stair stepping effect at the surface of SL parts. This effect causes excessive surface roughness and requires additional postprocess finishing such as abrasive basting which is detrimental to part geometry and time consuming. Hence paraffin coating and grinding postprocess is proposed to raise the surface quality of SL part. The paraffin which has suitable properties for the proposed postprocess is coated all over the part surface. By grinding the thin layer of coated on the SL part only, the surface roughness can be improved without any damage on the part. From the experimental result, It is verified as very practical for die casting with silicon rubber mold.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1811-1815
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• 2003

Investigated is the relationship between tool deflection and geometrical accuracy in side wall machining. Form error is predicted directly from the tool deflection without surface generation. Developed model can predict the surface form error about three hundred times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error, and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacture. This study contributes to real time surface shape estimation and cutting process planning for the improvement of geometrical accuracy.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.4
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• pp.5-10
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• 2003

This paper presents the formed tool to machine a milli-structure mold. The formed tool is used to machine the geometrical shape of bearing rubber seal for precision machining. The bearing rubber seal has milli-sized complex geometry. Because it is difficult to machine the unique shape exactly by the conventional tool, the formed tool is used in machining die of the bearing seal. In this paper, it is performed to investigate properties of the formed tool; tool wear, cutting force and machined surface roughness. Tool wear increases rapidly with clearance angle Increase. Thus, the dimension accuracy is affected by the clearance angle.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2000.04a
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• pp.52-57
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• 2000

STD11 is one of difficult-to-cut materials and its cutting characteristic data is not built enough. A bad cutting condition of it leads to low productivity of die and mould, so it is necessary to evaluate the machining characteristics of STD11. In this paper, the relations of the geometry of ball-end mill and mechanics of machining with it are studied. The helix angle of ball-end mill varies according to a location of elemental cutting edge in the cutting process are difficult to calculate accurately. To calculate instantaneous cutting forces, it is supposed that the tangential, radial and axial cutting force coefficients are functions of elemental cutting edge location. Elemental cutting forces in the x,y and z direction are calculated by coordinate transformation. The total cutting forces are calculated by integrating the elemental cutting forces of engaged cutting edge elements. This model is verified by slot and side cutting experiments of STD11 workpiece which was heat-treated to HRC45.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.71-76
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• 2020

Various machining methods are being studied to improve the processing quality of the spherical R shape in press die. In this paper, we confirmed that changes in machining quality were associated with changes in cutting direction, path, and cutting angle, which are commonly used in the machining of molds. We obtained a surface roughness graph with each condition change in one specimen using an instrument that measured geometry and surface roughness simultaneously. The results of the study showed that the best surface roughness in the finish cut of the spherical surface was obtained using upward pick feed machining.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.10a
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• pp.29-37
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• 1996

A ductile fracture criterion, which has already proposed, namely, ($\Delta$1/1o)f at $\Delta$$\sigma$ m=(($\Delta$1/1o)f+(-1/tan$\theta$)$\Delta$$\sigma$m(where ($\Delta$1/1o)f is fracture elongation, $\Delta$$\sigma$m is mean stress variation) was made use of to study the working limit in axisymmetric extrusion. The present investigation is concerned with the application of theory on flow and fracture to the prediction of workability of materials in axisymmetric bar extrusion, with special reference to central bursting. The influenced of die geometry and manufacturing conditions on the central bursting are predicted.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.06a
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• pp.16-27
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• 1997

A semi-solid forming has a lot of advantages compared to the die casting, squeeze costing and convenctional forging, therefore, semi-solid forming process are now becoming of industial interest for the production of metal components and metal matrix composites. However, the material behaviour in the semi-solid temperature range is not sufficiently known although it controls the whole process through forces and geometry evolutions bcause the behaviour of metal slurries is complex. The semi-solid materials(SSM) fabricated under electric-magnetic stirring condition is necessary to be applicate in forming process. A reheating conditions were studied with the reheating time, holing time and reheating temperatures. The microstructure of SSM (which specimen size:d 40${\times}$i60) on condition of heating time 10min and heating temperature 590$^{\circ}C$ is most globular and finest one. The microstructure of SSM(specimen size:d75${\times}$i60) reheated under the three step reheating conditions is most globular and finest.

• International Journal of Precision Engineering and Manufacturing
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• v.6 no.2
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• pp.26-33
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• 2005

In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effect of process variables such as gap height, relative gap width and die comer radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.