• Journal of Korea Foundry Society
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• v.36 no.6
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• pp.202-207
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• 2016

The effects of Fe and Si additions on the microstructures and mechanical properties of aluminum bronze have been investigated. In a bar-type specimen cast in a die mold, the addition of Fe promoted the dendritic solidification of the ${\alpha}$ phase. The hardness values increased slightly in the Fe-added specimen with heat treatment, while these values was increased significantly in the specimens with Si or with combined additions of Fe and Si. When a centrifugal casting bush with combined addition of Fe and Si was heat treated, the FeSi compound within the matrix was finely dispersed, and was observed to be the origin of cup-cone type conical dimple failure in the tensile fracture surface. The mechanical properties of the heat treated centrifugal casting bushes, whose nominal alloy compositions were (Cu-7.0Al-0.8Fe-3.0Si)wt%, exhibited tensile strength of $703-781N/mm^2$, elongation of 6.6-11.7% and hardness of Hv 222.6-249.2. These high values of strength and elongation were attributed to the strengthening of the matrix due to the combined addition of Fe and Si, and to precipitation of fine the FeSi compound.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.5
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• pp.75-84
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• 2010

The aim of this paper is to design the blank shape of SPFH 590 high strength steel for stamping of the center hinge of automotive via numerical analyses and experiments for multi-stages transfer forming process. Three-dimensional elasto-plastic finite element analyses for the transfer forming process with six stages were performed using a commercial code AUTOFORM V4.2. The influence of the blank shape on the formability and the shape conformity were quantitatively examined through the FE analyses. From the results of the FE analysis, a feasible shape of the blank and the forming load were estimated. Stamping experiments were carried out using the proposed blank shape. The results of experiments were shown that the center hinge parts with the desired shapes can be manufactured successfully as the proposed blank shape is used. Through the comparison of the results of the experiments with those of the analyses, it was shown that the estimation of blank shape using the FE analysis is a proper methodology to create a feasible shape of the blank for the center hinge of automotive.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.6
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• pp.513-519
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• 2014

For depth machining in die and mold, Electrical Discharge Machining (EDM) is used generally. To make deep hole and deep shape efficiently, cemented carbide endmill for depth machining is necessary. For this purpose, cemented carbide endmill was designed using design of experiment (DOE). To improve cutting performance, endmill was coated with multilayer surface treatment, TiAlCrSiN and TiAlCrN, for higher wear resistance. In order to evaluate the endmill, Transverse Rupture Strength (TRS) test was tried for investigating the relationship between surface treatment and strength in endmill body. Scratch test was also used for measuring adhesion force of each surface treatment. To evaluate hardness of surface treatment, Atomic Force Microscope (AFM) analysis was carried out. Wear test was executed for characteristics of each surface treatment in high temperature. Consequently, TiAlCrSiN was superior to the TiAlCrN coating in case of high temperature environment such as cutting.

• Journal of Dental Rehabilitation and Applied Science
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• v.19 no.3
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• pp.219-237
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• 2003

he purpose of this study was to compare the fracture resistance of the IPS Empress ceramic crown with 1.0mm width rounded shoulder, which is usually recommended in all ceramic crown, and 0.5mm width chamfer finish lines on the maxillary first premolar. 30 sound maxillary first premolars were selected and then storaged in 5% NaOCl and saline. 15 teeth were performed preparation for each group(1.0mm rounded shoulder, 0.5mm chamfer). After 30 stone dies were made for each group, the IPS Empress ceramic crowns were fabricated and cemented with resin cement(Bistite resin cement, Tokuyama Soda Co. LTD., Japan) on the natural teeth. The cemented crowns were mounted on the positioning jig and the universal testing machine(Zwick Z020, Zwick Co., Germany)was used to measure the fracture strength, with stress loading on the occlusal surface between buccal and lingual cusp. And also, three-dimensional finite element model was used to measure the stress distribution with two types of the finish lines(1.0mm rounded shoulder, 0.5mm chamfer) and two loading conditions(both buccal and lingual cusp inclination, lingual cusp inclination only). The result of the this study were as follows. In the fracture resistance experiment according to the finish line, the mean fracture strength of rounded shoulder(842N) showed higher value than that of the chamfer(590N) (p<0.05). In the three dimensional finite element analysis of all ceramic crown, metal die and natural teeth model did not show any differences in stress distribution between finish lines. Generally, when force was loaded on the occlusal inclination of buccal and lingual cusp, the stress was concentrated on the loading point and the central groove of occlusal surface. When force was loaded only on the occlusal inclination of lingual cusp, the stress was concentrated on the lingual finish line and loading point.

• Journal of Surface Science and Engineering
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• v.38 no.3
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• pp.126-135
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• 2005

SKD 11 steel has been widely used for tools, metallic mold and die for press working because of its favorable mechanical properties such as high toughness and creep strength as well as excellent oxidation resistance. The ion nitrided tool steel containing Mo results in improvement of corrosion resistance, strength at high temperature and pitting resistance, especially in $Cl^-$ contained environment. But the Mo addition causes a disadvantage such as lower oxidation resistance at elevated temperature. In this study, several effects of ion-disadvantage on the oxidation characteristics for SKD 11 steel with various oxidation temperature were investigated. SKD 11 steels were manufactured by using vacuum furnace and solutionized for 1 hr at $1,050^{\circ}C$. Steel surface was ion nitrided at $500^{\circ}C$ for 1 hr and 5 hr by ion nitriding equipment. ion nitrided specimen were investigated by SEM, OM and hardness tester. Oxidation was carried out by using muffle furnace in air at $500^{\circ}C,\;700^{\circ}C\;and\;900^{\circ}C$ for 1hr, respectively. Oxidation behavior of the ion nitrided specimen was investigated by SEM, EDX and surface roughness tester. The conclusions of this study are as follows: It was found that plasma nitriding for 5 hr at $500^{\circ}C$, compared with ion nitriding for 1 hr at $500^{\circ}C$, had a thick nitrided layer and produced a layer with good wear, corrosion resistance and hardness as nitriding time increased. Nitrided SKD 11 alloy for 1hr showed that wear resistance and hardness decreased, whereas surface roughness increased, compared with nitrided SKD 11 alloy for 5 hr. The oxidation surface at $900^{\circ}C$ showed a good corrosion resistance.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.10
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• pp.44-49
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• 2021

Seats in autonomous vehicles must be able to rotate to fully utilize the interior space. Generally, ultra-high strength steel is used for the rotation module because it should have high strength and high rigidity. In addition, the rotating parts are difficult to form because they have complex shapes. In this study, the upper plate of the rotating module, whose complex shape makes it difficult to form, was formed by applying the hot stamping method. The drawing method and the form-drawing method, which are generally used to form components of complex shapes, were compared. We showed that the form-drawing method increased the degree of freedom of the material flow to improve the formability, thus enabling the forming of the plate. In addition, the die and blank shapes were found to be important factors in determining the success of the hot stamping. The validity of the analysis results was confirmed through forming analysis and experiments.

• The Journal of Advanced Prosthodontics
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• v.13 no.1
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• pp.36-45
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• 2021

Purpose. To investigate the fracture resistance of monolithic CAD-CAM all-ceramic surveyed crowns with two different occlusal rest seat designs. Materials and Methods. Two maxillary first premolar were prepared for all-ceramic surveyed crowns with wide (2/3rd of buccolingual width of an unprepared tooth) or narrow (1/3rd of buccolingual width of an unprepared tooth) disto-occlusal rest seat (ORS) designs. Eighty monolithic CAD-CAM all-ceramic surveyed crowns were prepared and divided into 4 groups - Group CR, Composite resin material as a control; Group LDS, Lithium disilicate based material; Group ZIPS, zirconia-material (IPS ZirCAD); and Group ZLHT, zirconia- material (CeramillZolidht+). Crowns were cemented on an epoxy resin die with adhesive resin cement. The fracture resistance of crowns was tested with the universal machine. Univariate regression analysis was used. Results. The mean ± standard deviation of maximum failure force values varied from 3476.10 ± 285.97 N for the narrow ORS subgroup of group ZIPS to 687.89 ± 167.63 N for the wide ORS subgroup of group CR. The mean ± standard deviation of maximum force was 1075 ± 77.0 N for group CR, 1309.3 ± 283.9 N for group LDS, 3476.1 ± 285.97 N for group ZIPS, and 2666.7 ± 228.21 N for group ZLHT, with narrow occlusal rest seat design. The results of the intergroup comparison showed significant differences in fracture strength with various material groups and occlusal rest seat designs (P<.001). Conclusion. The zirconia-based all-ceramic surveyed crowns fractured at more than double the load of Lithium disilicate based crowns. The crowns with narrow base occlusal rest seat design had statistically significantly higher fracture resistance than surveyed crowns with wide occlusal rest seat design. The use of narrow occlusal rest seat design in CAD-CAM all ceramic surveyed crowns provides higher fracture resistance, and therefore narrow occlusal rest design can be used for providing esthetics with high strength.

• Design & Manufacturing
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• v.14 no.4
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• pp.11-16
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• 2020

In this study, forming of carbon composite parts was performed using an injection/compression molding process. An impregnation of matrix is determined by ability of wet and flow rate between the matrix and reinforcement. The flow rate of matrix passing through the reinforcements is a function of permeability of reinforcement, a viscosity of matrix and pressure gradient on molding, and the viscosity of the matrix depends on the mold temperature, molding pressure and shear strain of matrix. Therefore, compression molding experiment was conducted using a heating mold in order to confirm the possibility of matrix impregnation. The impregnation of the matrix through the porosities between the woven yarns was confirmed by the cross-sectional SEM image of compression molded parts. An injection molding process was also performed at a short cycle time, high molding pressure and low mold temperature than those of compression experiment conditions. Deterioration of impregnation on the surface of molded parts were caused by these injection conditions and it could be the reason of decreasing the maximum tensile strength. In order to improve impregnation of matrix on the surface, injection/compression molding and insert-over molding were applied. As a result of applying injection/compression molding and insert-over molding, it was shown that the improvement of impregnation on the surface and the maximum tensile strength was increased about 2.8 times than the virgin matrix.

• Design & Manufacturing
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• v.18 no.2
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• pp.17-22
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• 2024

Lightweight of plastic containers is becoming an important issue due to increasing environmental legislation and consumer awareness. In this study, the CAE analysis was conducted to optimize the shape of a 500 ml lightweight square polyethylene terephthalate(PET) bottle. First, the linear buckling alaysis using the finite element method was performed to analyze the correlation between the primary geometric parameters of the bottle and the buckling critical load. Then, the optimal geometry parameters were derived, and the actual buckling load was predicted by non-linear buckling simulation. The validity of the simulation results was verified by top-loading tests of PET bottles molded with the optimized geometry. The elastic modulus and tensile yield strength of PET through tensile tests were measured to improve the accuracy of the simulation. As a result of the tensile tests, the modulus of elasticity of PET increased from 2,900 MPa to 4,275 MPa, and the tensile yield strength increased from 52.4 MPa to 88.1 MPa. Finally the buckling load of the optimized PET bottle was found to be approximately 236 N, which is very similar to the simulation precition of 238 N. This study shows the feasibility and accuracy of the CAE analysis approach for the lightweight design of PET bottles, and will provide useful guidelines for the design of PET bottles.

• Journal of Powder Materials
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• v.15 no.5
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• pp.359-364
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• 2008

To satisfy the demand of higher cutting performance, mechanical properties with tungsten carbide (WC-Co) tool materials were investigated. Hardness and transverse rupture strength with WC grain size, Co content and density were measured. Compared to H, K, and S manufacture maker as tungsten carbide (WC-Co) tool materials were used for high-speed machining of end-milling operation. The three tungsten carbide (WC-Co) tool materials were evaluated by cutting of STD 11 cold-worked die steel (HRC25) under high-speed cutting condition. Also, tool life was obtained from measuring flank wear by CCD wear measuring system. Tool dynamometer was used to measure cutting force. The cutting force and tool wear are discussed along with tool material characteristics. Consequently, the end-mill of K, H manufacture maker showed higher wear-resistance due to its higher hardness, while the S maker endmill tool showed better performance for high metal removal.