• 한국기계기술학회지
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• 제20권6호
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• pp.824-829
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• 2018

Molding is the root industry of the manufacturing as a means to mass-produce developed prototypes. Molds are typically divided into injection molds and press mold industries. Injection molds produce the products by injection of molten plastic into a mold, and press molds are molded and bended plate. The ejection system, such as eject pins, is used to separate the manufactured products from the mold, which involves a number of hole operations. Location, diameter and depth of holes are often tabulated and managed collectively when designing 2D drawings. The design efficiency was realized by applying CATIA Automation to the 3D model and bringing in the data of the holes in the Excel data.

• 한국생산제조학회지
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• 제18권3호
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• pp.285-293
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• 2009

Thermal infrared cameras have been conducted actively in various application areas, such as military, medical service, industries and cars. Because of their characteristic of sensing the radiant heat emitted from subjects in the range of long-wavelength($3{\sim}5{\mu}m$ or $8{\sim}12{\mu}m$), and of materializing a vision system, when general optics materials are used, they don't react to the light in the range of long-wavelength, and can't display their optic functions. Therefore, the materials with the feature of higher refractive index, reacting to the range of long-wavelength, are to be used. The kinds of materials with the characteristic of higher refractive index are limited, and their features are close to those of metals. Because of these metallic features, the existing producing method of optical systems were direct manufacturing method using grinding method or CAD/CAM, which put limit on productivity and made it difficult to properly cope with the increasing demand of markets. GASIR, a material, which can be molded easily, was selected among infrared ray optics materials in this study, and the optical system was designed with two Aspheric lenses. Because the lenses are molded in the environment of high temperature and high pressure, they require a special metallic pattern. The metallic pattern was produced with materials with ultra hardness that can stand high temperature and high pressure. As for the lens mold, GMP(Glass Molding Press) of the linear transfer method was used in order to improve the productivity of optical systems for thermal infrared cameras, which was the goal of this paper.

• 한국정밀공학회지
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• 제25권12호
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• pp.125-131
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• 2008

In the past, precision optical glass lenses were produced through multiple processes such as grinding and polishing, but mass production of aspheric lenses requiring high accuracy and having complex profile was rather difficult. In such a background, the high-precision optical GMP processes were developed with an eye to mass production of precision optical glass parts by molding press. Generally because the forming stage in a GMP process is operated at high temperature above $570^{\circ}C$, thermal stresses and deformations are generated in the aspheric glass lens mold that is used in GMP process. Thermal stresses and deformations have negative influences on the quality of a glass lens and mold, especially the height of the deformed glass lens will be different from the height of designed glass lens. To prevent the problems of a glass lens mold and the glass lens, it is very important that the thermal stresses and deformations of a glass lens mold at high forming temperature are considered at the glass molds design step. In this study as a fundamental study to develop the molds used in an aspheric glass lens fabrication, a heat transfer and a thermal stress analysis were carried out for the case of one cavity glass lens mold used in progressive GMP process. Finally using analysis results, it was predicted the height of thermally deformed guide ring and calculated the height of the guide ring to be modified, $64.5{\mu}m$. This result was referred to design the glass lens molds for GMP process in production field.

• 한국광학회:학술대회논문집
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• 한국광학회 2006년도 하계학술발표회 논문집
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• pp.197-198
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• 2006

본 연구에서 개발하는 성형렌즈는 그림1과 같이 한쪽 면이 비구면인 평볼록 형상이다. Glass렌즈의 고온압축성형을 위해서는 초정밀 가공기술로 제작된 성형Mold가 필요하며, Mold재질에 따른 성형기술의 확립이 필수적이다. 또한, 성형Mold의 표면과 융착반응이 없는 Glass소재가 요구된다. 본 실험을 위한 성형Mold는 코발트(Co) 함량 0.5 %의 초경합금(WC; 일본, Everloy社, 002K)을 초정밀 연삭가공하여 제작하였다. Glass소재는 전이점(Transformation Point; Tg) $572\;^{\circ}C$,항복점(Yielding Point; At) $630\;^{\circ}C$의 열적 특성을 갖는 K-BK7(일본, Sumita社)을 사용하였으며, d선에서 굴절률 및 아베수는 각각 1.51633, 64.1이다. 비구면 Glass렌즈 성형은 GMP(Glass Molding Press; 일본, Sumitomo社, Nano Press-S)장비를 사용하여 성형온도 $625\;^{\circ}C$, 서냉온도 $550\;^{\circ}C$로 고정하고 성형압력를 200-800 N 범위에서 변화시켰다. 표 1에 성형변수로 사용한 서냉속도와 서냉전환온도 조건을 나타낸다. 표1과 같이 각 서냉조건별로5장의 렌즈를 성형 후 특성값이 평균치에 가까운 3장을 선별하여 그 특성을 비교하였다. 각 조건에 따른 성형렌즈의 형상정도(일본, Panasonic社, UA3P, 자유곡면형상측정기), 두께(일본, Mitutoyo社, MDC-25M, 마이크로메터), 굴절률(일본, Shimatus社, KPR-200, 정밀굴절률측정기) 및 MTF[해상도](독일, Trioptics社, Image Master HR, MTF-Field)를 측정하여 각각의 광학적 특성을 비교 평가하였다. 비구면 Glass렌즈 성형장비와 형상측정기를 그림 2, 3에 각각 나타낸다.

• 한국재료학회지
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• 제33권10호
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• pp.414-421
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• 2023

Infrared radiation (IR) refers to the region of the electromagnetic radiation spectrum where wavelengths range from about 700 nm to 1 mm. Any object with a temperature above absolute zero (0 K) radiates in the infrared region, and a material that transmits radiant energy in the range of 0.74 to 1.4 um is referred to as a near-infrared optical material. Germanate-based glass is attracting attention as a glass material for infrared optical lenses because of its simple manufacturing process. With the recent development of the glass molding press (GMP) process, thermal imaging cameras using oxide-based infrared lenses can be easily mass-produced, expanding their uses. To improve the mechanical and optical properties of commercial materials consisting of ternary systems, germanate-based heavy metal oxide glasses were prepared using a melt-cooling method. The fabricated samples were evaluated for thermal, structural, and optical properties using DSC, XRD, and XRF, respectively. To derive a composition with high glass stability for lens applications, ZnO and Sb₂O₃ were substituted at 0, 1, 2, 3, and 4 mol%. The glass with 1 mol% added Sb₂O₃ was confirmed to have the optimal conditions, with an optical transmittance of 80 % or more, a glass transition temperature of 660 ℃, a refractive index of 1.810, and a Vickers hardness of 558. The possibility of its application as an alternative infrared lens material to existing commercial materials capable of GMP processing was confirmed.

• 한국공작기계학회논문집
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• 제13권1호
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• pp.48-54
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• 2004

This paper describes the development of automatic shape design program for spur gear. It produces automatically third-dimensional surface and solid model used in CAD/CAM system with inputting simple measurements. This program can maximize user's convenience and get surface and solid model quickly as accepting GUI(graphic user interface). Automatic shape design program for spur gear was developed by Visual LISP, a developer program. Besides, a geometrical method and a mathematical algerian are used in this program. Use frequency of a fine spur gear is on the increase recently and manufacture process of this gear is heat treatment after press processing with molding. In this press processing, the upper punch portion of a fine spur gear shape is drafted by CAM. Therefore, estimated that surface and solid model of spur gear used to CAM are needed in this research. In this research, after 2 ㎜ gear was modeled by auto shape design program, the upper punch portion of a fine spur gear was manufactured as giving third-dimensional model to CAM software and then, displayed the result as applying to press process.

• Design & Manufacturing
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• 제9권1호
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• pp.9-13
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• 2015

The HEV/EV Traction Motor Core manufacturing technology is a core component of Traction Motor Core is a key technology for the manufacture of eco-friendly automotive industry is essential for the competitiveness of the country must obtain the technology. This study was performed to develop a Rotor Core of the HEV/EV Traction Motor using the first time in Korea multi-gate BMC injection molding technique. Executed by the experiment of this study are as follows. Study 1: Developed a multi-gate BMC injection mold for the magnet fixed to the Rotor Core. Study 2: Developed a production implementation and manufacturing technology of the Rotor Core. In this study, the develop products and manufacturing technologies implemented by the BMC injection mold development for Magnet fixed to the Rotor Core and the results are discussed.

• 한국정밀공학회지
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• 제27권5호
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• pp.22-26
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• 2010

Recently, due to the tremendous growth of media technology, demands of the aspheric glass lens which is a high-performance and miniaturized increase gradually. Generally, the aspheric glass lens is manufactured by Glass Molding Press (GMP) method using tungsten carbide (WC) mold core. In this study, the thermal deformation which was occurred by GMP process was analyzed and applied it to compensate the aspheric glass lens. The compensated lens was satisfied that can be applied to the actual specifications.

• Metals and materials international
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• 제28권
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• pp.2356-2370
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• 2021

The conventional stamping tube forming process generally includes expanding the tube, forming the end into a specific shape by pressing, and trimming the part. However, the manufacture of the tube parts based on these conventional forming processes causes significant material loss during the trimming process after shaping. On the other hand, incremental tube forming (ITF) can reduce material loss in the entire forming process; therefore, it can be considered as an effective alternative to the conventional tube forming process and a promising method for developing tube components without using a press. The hemispherical shaped tool tip, widely used in the existing incremental sheet forming, has, however, limitations in forming complex-profiled tube parts. In this study, a novel tool tip is proposed to overcome the problem, and an S-shaped tube is successfully produced through the new ITF process. In addition, numerical analyses are conducted using the commercial FE package of Abaqus/Explicit to investigate the deformation mode during ITF. Finally, the feasibility of the novel ITF process for tube forming is confirmed by comparing the geometric accuracy and thickness variation between the target shape and the formed sample.

• 한국산학기술학회논문지
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• 제14권8호
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• pp.3625-3630
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• 2013

도어 모듈은 모듈화의 대표적인 예로 여러 부품들은 모듈형태로 완성하여 완성차 업체의 원가절감 및 조립시간 단축, 품질 향상 등에 큰 기여를 이루었다. 주요 부품중의 하나인 Door carrier plate는 주로 steel을 이용한 press 성형이 주였으나 최근에는 PP-LFT(유리 장섬유 강화PP)를 사용한 사출 공법을 적용함으로써 형상자유도를 높혀 모듈에 부착되는 많은 종류의 부품들을 통합할 수 있게 되었으며 중량 절감을 이룰 수 있게 되었다. 하지만 사출 성형시 제품의 형상 및 gate위치 설정의 한계성과, LFT의 특성에 의하여 변형이 비교적 심해 일반적으로 시사출 진행 후 보상 가공을 진행하여 조립성을 개선한다. 이러한 사후 수정 공정은 금형의 품질 저하 및 생산원가 상승의 주요인이다. 부분적으로 사출 CAE를 적용하여 warpage정도를 예측하나 그 신뢰성 확보에 어려움을 겪고 있다. 따라서 LFT를 사용하는 Door carrier plate에 대한 해석 신뢰성을 확보할 수 있는 기법으로 hyper-mesh에서 1차 mesh작업 후 moldlfow 자체 tool을 이용하여 mesh의 두께 구현성을 높혔으며, fiber orientation해석을 위하여 ARD-RSC model을 적용하였다.