• Design & Manufacturing
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• v.12 no.2
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• pp.40-45
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• 2018

Recently, in construction equipment machinery production, development has focused on environmentally-friendly functions to improve existing production capacity. For excavators as well, emphasis has been placed on response to environmental regulations, miniaturization, and noise reduction, while technology is being developed considering cost reduction and safety.Accordingly, the front support, an inner reinforcement part of the excavator, as well as high-strength steel plates to improve safety and reduce weight, are being applied.However, in the case of high-strength materials, Springback occurs in the final formed part due to high residual stress during product forming. Derivation of a forming or product shaping process to reduce springback is needed. Accordingly, regarding the front support, an inner reinforcement part of the excavator, this study derived a method to improve springback and secure shape stiffness through analysis of the springback occurrence rate and springback causes through a forming analysis.As for the results of analyzing the springback occurrence rate of existing products through forming analysis, springback of -22.6 mm < z < 27.35 mm occurred on the z-axis, and it was confirmed that springback occurred due to the stiffness reinforcing bead of the upper and middle parts of the product.To control product residual stress and springback, we confirmed a tendency of springback reduction through local pre-cutting and stiffness reinforcement bead relocation.In the local pre-cutting model, springback was slightly reduced by 5.3% compared with the existing model, an insignificant reduction effect. In the stiffness reinforcement bead relocation model, when an X-shaped stiffness reinforcement bead was added to each corner portion of the product, springback was reduced by at least 80%.The X-shaped bead addition model was selected as the springback reduction model, and the level of stiffness compared to the existing model was confirmed through a structural analysis.The X-shaped bead additional model showed a stress springback of 90% and springback reduction of 7.4% compared with the existing model, indicating that springback and stiffness will be reinforced.

• Design & Manufacturing
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• v.12 no.1
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• pp.52-57
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• 2018

With the recent strengthening of environmental regulations and the need for cost reduction, excavators, a type of construction equipment, are being miniaturized while components are being developed in consideration of stability. In the case of excavator press parts, mainly high-strength steel sheets are being used to enhance stability and reduce weight. However, in the case of high-strength materials, there is a need to research product forming methods to reduce Springback in defects arising in parts assembly due to Springback that result from the internal residual stress that occurs in press forming being released after product forming. Accordingly, regarding the tank cover, an excavator press-forming part, this study selected a method to reduce distortion through analysis of the Springback occurrence rate and Springback causes through a forming analysis. A forming analysis was conducted for the Springback of the tank cover. Deformations of 13.714 mm in the upper part and 6.244 mm in the inner part of the product occurred, while wrinkles occurred on the sides of the product due to uneven thickness. A forming analysis was conducted for the major shapes of the product to investigate the causes of Springback. Distortion deformation due to the bead in the center of the product was confirmed to be a large factor. A Springback reduction method of correcting uneven thickness in the product sides, a Springback reduction method of removing the bead, and a correction method of restriking after the final forming were used in a forming analysis to determine the degree of Springback reduction. For the forming method to correct uneven thickness in the sides, deformation was reduced by 12% in the upper side compared to the existing model, but deformation in the inner side increased by 1%. For the restriking forming method, deformation decreased by 25% in the upper side and 13% in the inner side. For the bead removal method, deformation decreased by 28% in the upper side and 13% in the inner side, the largest Springback correction results. This indicates that the bead has a large affect on Springback.

• The Journal of Korean Academy of Prosthodontics
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• v.34 no.4
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• pp.746-754
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• 1996

The purpose of this study was to evaluate the fracture strength of porcelain laminate veneer with various lingual extention length when incisal restoring. Sixty recently extracted, intact maxillary incisors were used and stored in a physiologic saline solution from the time of extraction. Seating form was preparation at the labial surface of each tooth with a water-cooled round diamond bur. Standard block was formed with 32 gauge and 24 gauge wax at tooth labial and lingual surface. Lingual extention length differed according to each group. (group I : 0.5mm, group II : 1 mm, group III : 2mm, group IV : 0mm) All tooth specimens were impressioned with examix(GC Inc., Japan). Refractory cast were maked with refractory die material(Ceramco Inc., U.S.A.) Laminate porcelain (Ceramco II Veneer porcelain, Ceramco Inc., U.S.A.) was condensed in refractory die cast and baked according to the manufacturer's recommendations. Each surface was contoured with low speed diamond bur according to guide block. All porcelain specimens were sandblasted and ultrasonically cleaned in distlled water for 3 minutes. Then, all porcelain specimen were etched with 8% hydrofluoric acid for 5 minutes. Sixty specimens were bonded with composite resin cement(Choice Porcelain Veneer System, Bisco Inc., U.S.A.) according to manufacture's directions. The fracture loads of the specimen were measured by Instron universal testing machine. The mean values of fracture loads for the groups were statistically compared by Duncan's multiful range test. The result were as follows : Mean fracture strengths of each group were 86.95Mpa in no lingual extention group, 44.98Mpa in 0.5mm lingual extention group, 27.47Mpa in 1mm lingual extention group, 19.61Mpa in 2mm lingual extention group. There was a statistically significant difference between all group(p<0.01).

• The Journal of Advanced Prosthodontics
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• v.10 no.2
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• pp.79-84
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• 2018

PURPOSE. All-ceramic restorations required extensive tooth preparation. The purpose of this in vitro study was to investigate a minimally invasive preparation and thickness of monolithic zirconia crowns, which would provide sufficient mechanical endurance and strength. MATERIALS AND METHODS. Crowns with thickness of 0.2 mm (group 0.2, n=32) or of 0.5 mm (group 0.5, n=32) were milled from zirconia and fixed with resin-based adhesives (groups 0.2A, 0.5A) or zinc phosphate cements (groups 0.2C, 0.5C). Half of the samples in each subgroup (n=8) underwent thermal cycling and mechanical loading (TCML)(TC: $5^{\circ}C$ and $55^{\circ}C$, $2{\times}3,000cycles$, 2 min/cycle; ML: 50 N, $1.2{\times}10^6cycles$), while the other samples were stored in water ($37^{\circ}C/24h$). Survival rates were compared (Kaplan-Maier). The specimens surviving TCML were loaded to fracture and the maximal fracture force was determined (ANOVA; Bonferroni; ${\alpha}=.05$). The fracture mode was analyzed. RESULTS. In both 0.5 groups, all crowns survived TCML, and the comparison of fracture strength among crowns with and without TCML showed no significant difference (P=.628). Four crowns in group 0.2A and all of the crowns in group 0.2C failed during TCML. The fracture strength after 24 hours of the cemented 0.2 mm-thick crowns was significantly lower than that of adhesive bonded crowns. All cemented crowns provided fracture in the crown, while about 80% of the adhesively bonded crowns fractured through crown and die. CONCLUSION. 0.5 mm thick monolithic crowns possessed sufficient strength to endure physiologic performance, regardless of the type of cementation. Fracture strength of the 0.2 mm cemented crowns was too low for clinical application.

• Korean Journal of Materials Research
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• v.25 no.5
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• pp.226-232
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• 2015

High temperature plasma coating technology has been applied to recover damaged aluminum dies from wear by spraying pure aluminum and alumina powder. However, the coated mixed powder layer composed of aluminum and alumina often undergoes a detachment from the substrate, making the coated substrate die unable to maintain its expected life span. In this study, in order to increase the bonding strength between the substrate and the coating layer, a pure aluminum layer was applied as an intermediate bond layer. In order to prepare the specimen with variable bond coating conditions, the bond coat layers with a various gun speed from 10 cm/sec to 30 cm/sec were prepared with coating cycle variations ranging from three to nine cycles. The specimen with a bond coat layer coated with a gun speed of 20 cm/sec and three coating cycles exhibited ~13MPa of adhesion strength, while the specimen without a bond coat layer showed ~6 MPa of adhesion strength. The adhesion strength with a variation of bond coat layer thickness is discussed in terms of coating parameters.

• Elastomers and Composites
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• v.43 no.1
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• pp.39-48
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• 2008

Peel strength of epoxy adhesives can be increased by adding some amounts of XNBR. In this case, thermal resistance of the adhesive will be decreased by decrease of glass transition temperature of the adhesive. Epoxy resin modified with siloxane-imide was synthesized to improve thermal resistance and peel strength of the adhesive, after that the properties of modified epoxy resin were compared with the commercial epoxy resin. When 5% XNBR was added to 30% modified epoxy resin, this adhesive showed 0.42 N/mm of peel strength and $155^{\circ}C$ of glass transition temperature. These properties are enough compared to the required properties by the industry, i.e., 0.3 N/mm and $150^{\circ}C$, respectively. Weight loss of the modified epoxy resin by the treatment of nitric acid and 0.1N NaOH was reduced, but weight gain by the humid condition was increased by the presence of benzene ring and imide ring. 30% modified epoxy resin blended with 5% XNBR showed 220% improvement in tensile strength and elongation compared to the case of common epoxy resin. This is due to the flexibility of the siloxane in the modified epoxy resin.

• Korean Journal of Materials Research
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• v.22 no.9
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• pp.454-458
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• 2012

Various adhesive materials are used in flip chip packaging for electrical interconnection and structural reinforcement. In cases of COF(chip on film) packages, low temperature bonding adhesive is currently needed for the utilization of low thermal resistance substrate films, such as PEN(polyethylene naphthalate) and PET(polyethylene terephthalate). In this study, the effects of anhydride and dihydrazide hardeners on the low-temperature snap cure behavior of epoxy based non-conductive pastes(NCPs) were investigated to reduce flip chip bonding temperature. Dynamic DSC(differential scanning calorimetry) and isothermal DEA(dielectric analysis) results showed that the curing rate of MHHPA(hexahydro-4-methylphthalic anhydride) at $160^{\circ}C$ was faster than that of ADH(adipic dihydrazide) when considering the onset and peak curing temperatures. In a die shear test performed after flip chip bonding, however, ADH-containing formulations indicated faster trends in reaching saturated bond strength values due to the post curing effect. More enhanced HAST(highly accelerated stress test) reliability could be achieved in an assembly having a higher initial bond strength and, thus, MHHPA is considered to be a more effective hardener than ADH for low temperature snap cure NCPs.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.1
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• pp.86-92
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• 2008

Recently, the use of tubes in the manufacturing of the automobile parts has increased and therefore many automotive manufactures have tried to use hydro-forming technology. The hydro-forming technology may cause many advantages to automotive applications in terms of better structural integrity of the parts, lower cost from fewer part count, material saving, weight reduction, lower spring-back, improved strength and durability and design flexibility. In this study, the whole process of front engine cradle (or front sub-frame) parts development by tube hydro-forming using steel material having tensile strength of 440MPa grade is presented. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydro-formability in details. Effects of parameters such as internal pressure, axial feeding and geometry shape on automotive sub-frame by hydro-forming process were carefully investigated. Overall possibility of hydro-formable sub-frame parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydro-forming. At the die design stage, all the components of prototyping tools are designed and interference with press is examined from the point of geometry and thinning.

• Korean Journal of Materials Research
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• v.10 no.1
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• pp.69-76
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• 2000

Despite the improved formability and processing advantages, the use of semi-solid metals is greatly limited due to the difficulties in controlling the optimum forming parameters. In the present study, the tensile properties of closed die, pressure formed semi-solid A356 alloy were examined. It was demonstrated that the tensile strength of thixoformed A356 alloy could be greatly reduced when the forming parameters were not rigorously controlled. The reduced strength of unappropriately formed products appeared to be related to the coarsening of the primary phases. The possibility of improving tensile properties of as-formed products by simple post heat treatment was also assessed.

• Journal of Korea Foundry Society
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• v.33 no.3
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• pp.103-112
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• 2013

Effect of Fe and Mn contents on the tensile properties of Al-4 wt%Mg-0.9 wt%Si alloy system has been studied. Common phases of Al-4 wt%Mg-0.9 wt%Si alloy system were ${\alpha}$-Al, $Mg_2Si$, ${\alpha}-Al_{12}(Fe,Mn)_3Si$ and ${\beta}-Al_5FeSi$. As Fe content of Al-4 wt%Mg-0.9 wt%Si alloy system increased from 0.15 wt% to above 0.3 wt%, ${\beta}-Al_5FeSi$ compound appeared. When Mn content of the alloy increased from 0.3 wt% to 0.5 wt%, morphology of plate shaped ${\beta}-Al_5FeSi$ compound changed to chinese script ${\alpha}-Al_{12}(Fe,Mn)_3Si$. As Fe content of Al-4 wt%Mg-0.9 wt%Si-0.3 wt%Mn alloy increased from 0.15 wt% to 0.4 wt%, tensile strength of the as-cast alloy decreased from 191 MPa to 183 MPa and, elongation of the alloy also decreased from 8.0% to 6.2%. Decrease of these properties can be explained as the formation of plate shape, ${\beta}-Al_5FeSi$ phase with low Mn/Fe ratio of the alloy. However, when Mn content of Al-4 wt%Mg-0.9 wt%Si-0.3 wt%Fe alloy increased from 0.3 wt% to 0.5 wt%, tensile strength of as-cast alloy increased from 181 MPa to 194 MPa and, elongation of the alloy increased from 6.8% to 7.0%. These improvements attribute to the morphology change from ${\beta}-Al_5FeSi$ phase to chinese script, ${\alpha}-Al_{15}(Fe,Mn)_3Si_2$ phase shape-modified from with high Mn/Fe ratio of the alloy.