• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.215-218
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• 2005

For the production of cold forged parts with near-net-shape attributes, the quality of the tool system is responsible for an essential portion of costs fer the finished components. Therefore, a tool lift is one of the important issues on cold forging industry. There are many complicated variables related with tool life, such as material, heat-treatment, coating, lubricant, process design. In this study, heat-treatment of tool material and lubricant are investigated to improve the tool life. Deep cryogenic treatment of tool steel is very efficient to improve the wear resistance due to the fine carbide. And, friction factor of lubricants for cold forging are measured by the ring compression test. Zinc-Phosphate and $MoS_2$ lubricant is effective to sustain the friction factor under 0.1.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.93-100
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• 2000

Die-casting burr due to casting process is removed by post-process for assembly and quality control of product. Though robot has been widely used for deburring job before, CNC exclusive machine is currently developed f3r high power, high speed machining and quick tool change. Deburring tool path with complex 3D curve type is defined to make out deburring NC program. But there is no efficient method to define it currently used methods with teaching probe on machine. In this study the efficient method to make out deburring NC program is developed. 5-axis digitizing machine is used to receive data of deburring path. And the post processor for NC program generation is developed in consideration of the machining conditions. The developed system is not dependent on the skill of operator and has the advantage to maintain the flexibility of job to modify NC program due to the wear of tool and aging of the die casting.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.12
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• pp.3899-3908
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• 1996

In order to clarify the effects of nonmetallic inclusion contents insteels (SM45C & SCM440) on the tool life, cutting experiment was performed under various cutting conditions. Tool life, cutting force, roughness of machined surface and cutting mechanism are examined on these two kinds of steel. The following conclusions were obtained from the analysis (1) Cutting force of the steels was not affected by chemical component and nonmetallic inclusion. (2) If the rate of amount, Ca/S has a value grater than about 0.2 and addition of less amount of Al, Mn, tool wear of tips decreasesinturning. (3) It is also proved that higher contents of nonmetallic inclusion improve roughness of the surface. (4) Less amount of Ca, higher amount of S, Mn and Al improve the chip breakability.

• Design & Manufacturing
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• v.15 no.4
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• pp.51-56
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• 2021

Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.

• Design & Manufacturing
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• v.16 no.1
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• pp.9-14
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• 2022

A lot of research is being done on metal materials to improve the lifespan of molded parts. As a result, excellent mold materials have been developed that withstand high hardness at high temperatures and frictional heat generated from high-speed cutting. In this study, the press mold life of powder high-speed tool steel and general high-speed tool steel was compared. Powdered high-speed steel is composed of alloying elements such as tungsten, maldividene, cobalt, chromium, and vanadium in steel, which improves wear resistance compared to high-hardness and high-speed tool steels. The mold parts of both steel types were manufactured in the same way from heat treatment to machining, and the powder high-speed tool steel was 66HRC and the high-speed tool steel was 61HRC. As a result of the experiment, it was observed that the number of punching of powder high-speed tool steel was improved by 40-50%, and powder high-speed tool steel had fewer impurities, uniform texture, and excellent surface structure. It has a microscopic structure.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.424-429
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• 2004

The high speed machining center(HMC) has been widely applied to manufacture a die and trial product in many machine industry. Because the evaluation for HMC is not sufficiently performed and the efficient cutting conditions can't be selected, a peat loss has been caused in the cost aspect. In this study, the need of preliminary running time and unstable spindle speed is presented by the analysis of acceleration in idling. The Machinability for the TiA1N coated flat end mill and STD11 (H$\sub$R/C60) is evaluated from the trends of tool wear and cutting force according to cutting conditions . The resonance spindle speed is identified through the tool wear and natural frequency test.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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• pp.352-357
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• 2004

The high speed machining center(HMC) has been widely applied to manufacture a die and machine elements product in industrial field. Because the evaluation for HMC is not sufficiently performed, ineffective machining is occasionally conducted in machining industry. In this study, the dynamic characteristics of newly developed machining center is evaluated under running condition and the machinability is investigated experimentally. Also, the in-process measuring instrument which can measure the tool wear on the machine were developed by using the CCD and exclusive jig and calibration instrument for tool wear measurement.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.4
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• pp.104-112
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• 2017

In the sand casting process, the flow of liquid metal affects the quality of casting products and their die life. To determine the optimal bush part design process, this study performed various analyses using commercial finite element analysis S/W. The simulation focused on the molten metal behaviors during the mold filling and solidification stages of sand casting. This study aims to develop methods to reduce the cost and increase the tool life of the continuous hot zinc plating roll.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.2
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• pp.58-65
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• 2003

The conventional forming process such as squeeze casting or die casting for fabricating metal matrix composites products have a disadvantage such as non homogenous distribution of reinforcement, weak bonding between matrix and reinforcement and cost increase in parts fabrication. Thixoforming process has been accepted as a new method for fabricating the net shaped metal matrix composites with lightweight and wear resistance. In this paper, the effect of volume fraction and reinforcement sizes on mechanical properties in cylinder liner part of metal matrix composites has been investigated with processes parameters such as pressure and velocity. Moreover, the methods to obtain the thixoforged composites cylinder liner with high quality has been proposed. To evaluate the composites cylinder linear fabricated at the conditions proposed in this study, mechanical properties of fabricated composites cylinder linear were compared with those of commercial composites cylinder linear.

• Elastomers and Composites
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• v.55 no.3
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• pp.176-183
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• 2020

Silica-styrene butadiene rubber (Silica-SBR) compounds have been used in the preparation of tire treads. The silica dispersibility of silica-SBR compounds is related to the processability, mechanical properties, and wear resistance of tires. Recently, in order to improve the silica dispersibility of the silica-SBR compounds, the wet masterbatch (WMB) process was introduced, which is a method of mixing rubber in the water phase. We aimed to improve the silica dispersibility of the silica-SBR compounds by preparing a silica dispersant applicable to the WMB process. For this purpose, cellulose, 2-hydroxyethyl cellulose, and cellulose acetate were employed as a silica dispersant. The silica dispersibility of the compounds was measured by a moving die rheometer. Improvement in the processability of silica-SBR compounds was evaluated by the Mooney viscometer. The wear resistance of silica-SBR compounds using a cellulose dispersant was improved by up to 29%.