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REFERENCE LINKING PLATFORM OF KOREA S&T JOURNALS
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Journal of the Korean Society of Manufacturing Process Engineers
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Journal DOI :
The Korean Society of Manufacturing Process Engineers
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Volume & Issues
Volume 11, Issue 6 - Dec 2012
Volume 11, Issue 5 - Oct 2012
Volume 11, Issue 4 - Aug 2012
Volume 11, Issue 3 - Jun 2012
Volume 11, Issue 2 - Apr 2012
Volume 11, Issue 1 - Feb 2012
Selecting the target year
Trends of Flat Mold Machining Technology with Micro Pattern
Je, Tae-Jin ; Choi, Doo-Sun ; Jeon, Eun-Chae ; Park, Eun-Suk ; Choi, Hwan-Jin ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 1~6
Recent ultra-precision machining systems have nano-scale resolution, and can machine various shapes of complex structures using five-axis driven modules. These systems are also multi-functional, which can perform various processes such as planing, milling, turning et al. in one system. Micro machining technology using these systems is being developed for machining fine patterns, hybrid patterns and high aspect-ratio patterns on large-area molds with high productivity. These technology is and will be applied continuously to the fields of optics, display, energy, bio, communications and et al. Domestic and foreign trends of micro machining technologies for flat molds were investigated in this study. Especially, we focused on the types and the characteristics of ultra-precision machining systems and application fields of micro patterns machined by the machining system.
Micro Pattern Machining on Larger Surface Roll Molds
Song, Ki-Hyeong ; Lee, Dong-Yoon ; Park, Kyung-Hee ; Lee, Seok-Woo ; Kim, Hyun-Cheol ; Je, Tae-Jin ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 7~12
In order to cope with the requirements of smaller patterns, larger surfaces and lower costs in the fields of displays, optics and energy, greater attentions are now being paid to the development of micro-pattern machining technology. Compared with flat moulds, large drums with micro patterns (roll moulds) have the advantages of short delivery, ease of manufacturing larger surfaces, and continuous moulding. This paper introduced the machining process technology of the roll moulds for display industry. The environmental effects were discussed and the importance of temperature maintenance was experimentally emphasized. The real time monitoring system for micro machining was introduced. A commercial solution was used to simulate the micro grooving and a deformation model of micro machined pattern was finally introduced.
Ultra Precision Machining Technique for Optical System Parts
Yang, Sun-Choel ; Kim, Sang-Hyuk ; Huh, Myung-Sang ; Chang, Ki-Soo ; Park, Soon-Sub ; Won, Jong-Ho ; Kim, Geon-Hee ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 13~19
Ultra Precision Machining Techniques, such as manufacturing Micro Lens Array(MLA), off-axis mirror,
lens for laser printer, are achieved, based on technologies in consequence of development of modern high-precision machining mechanism. Above all, FTS(Fast Tool Servo) and STS(Slow Tool Servo) are more innovative technologies for reducing time and development costs. In this paper, it is described that MLA machining technique by FTS, off-axis mirror machining technique by STS, optics for observing space, and development of infrared aspheric lens for a thermal imaging microscope.
Review of Recent Progress in Micromilling Process Research
Heo, Se-Gon ; Lee, Won-Kyun ; Min, Byung-Kwon ; Je, Tae-Jin ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 20~26
Recently, micromilling process has been progressed to meet the variety of the industry demands in micromolds and precision components. As a result, more and more commercialized micro tools and machines become available during last few years. This paper reviews the recent progress of micromilling technology in last five years. The results in process, machine tools, and micro tool fabrications are discussed.
The Improvement of Surface Roughness of Marine Propeller by Continuous Control of Cutter Posture in 5-Axis Machining
Son, Hwang-Jin ; Lim, Eun-Seong ; Jung, Yoon-Gyo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 27~33
A marine propeller is designed for preventing cavitation priority. Cavitation is a phenomenon which is defined as the vibration or noise by dropping the pressure on the high-speed rotation of the propeller. There has to be a enough thrust on the low-speed rotation for preventing cavitation. Thus, it has to be considered in the increasing of the number of blade and the angle of wing to design the propeller. In addition, flow resistance will be increasing by narrowing the width between blades. So high quality surface roughness of the hub to minimize flow resistance is required. Interference problems with tool and neighboring surfaces often take place from this kind of characteristics of the propeller. During 5-Axis machining of these propellers, the excessive local interference avoidance, necessary to avoid interference, leads to inconsistency of cutter posture, low quality of machined surface. Therefore, in order to increase the surface quality, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. This study, by using a MC-space algorithm for interference avoidance and a MB-spline algorithm for continuous control, is intended to create a 5-Axis machining tool path with excellent surface quality. Also, an effectiveness is confirmed through a verification manufacturing.
Prediction of Tensile Strength for Friction-Welded Magnesium Alloy Part by Acoustic Emission
Shin, Chang-Min ; Kang, Dae-Min ; Choi, Jong-Whan ; Kwak, Jae-Seob ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 34~39
In this study, the friction welding experiment was performed by using the design of experiment. And the signal data acquired by acoustic emission sensor were analyzed to predict the tensile strength of friction welding part at friction welding process for AZ31 magnesium alloy. A dimensionless coefficient(
), which consisted in the square of AE rms and variance, was defined as the characteristic of friction welding and the prediction equation was obtained by using linear regression. As the result of analysis, it was seen that the correlation between predicted and measured values became very close and on-line prediction of the ensile strength was possible in friction welding part.
A Study on Flow Characteristics in Lubrication System of Manual Transmission in a Commercial Vehicle
Yun, Ji-Hun ; Yi, Chung-Soeb ; Suh, Jeong-Se ; Song, Chul-Ki ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 40~46
In this study, numerical analysis was conducted to understand the flow characteristics of lubrication system in a manual transmission installed in a commercial vehicle. Also, the analysis was conducted with the purpose of improving the heat and lubricative condition of the transmission. Discharging flow rates on each oil hole outlet according to various engine rotating speed and the length of oil hole branch was calculated. In conclusion, as engine rotating speed is high and the length of oil hole branch is long, the discharging flow rate is high by virtue of the centrifugal force. In addition, this study proposed data for optimal design of lubrication system in manual transmission for a commercial vehicle.
Evaluation of Inner Flow Characteristics of Oxygen Sensor for Vehicle Exhaust System
Han, Dae-Kwang ; Suh, Ho-Cheol ; Yee, Jurng-Jae ; Kang, Jung-Ho ; Han, Seung-Ho ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 47~54
An oxygen sensor installed in vehicle exhaust systems enables to measure the amount of oxygen in the exhaust gas, in which the measured data are collected and analyzed in ECU(Engine Control Unit). The oxygen sensor is exposed to the high speed exhaust gas at high temperature circumstance, so that protection caps are required not only to protect the susceptible measuring part, but also to provide the real time measurement without time delay. In this study, a new oxygen sensor with one protection cap was proposed, and the CFD analysis was carried out in order to compare the performance characteristics, such as flow speed and ratio of AOA(Age of Air), for the conventional and new oxygen sensor. The numerical results of CFD analysis provided the flow speed of 1.34m/s and the ratio of AOA of 3.43. The similar features obtained from the numerical results showed that the new oxygen sensor guarantees the same performance characteristics of the conventional ones.
Stress Analysis of Helical Gear for a Railway Reducer
Lee, Seul ; Lee, Dong-Hyoung ; Hwang, Seok-Cheol ; Lee, Kwon-Hee ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 55~59
This study performs the bending and contact stress analyses for a pair of mating gears during rotation. The interested gears are used for a railway reducer. In general, the railway reducer needs high speed rotation, which leads to a large gear ratio. Thus, it is not easy to apply finite element method to investigate the strength performance, since the size of a gear is much larger than that of a pinion. In this study, the bending and contact stresses determined from FEM are compared with the values determined from the ISO code.
CAE Analysis and Optimization of Injection Molding for a Mobile Phone Cover
Park, Ki-Yoon ; Kim, Hyeon-Seong ; Kang, Jin-Hyun ; Park, Jong-Cheon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 60~65
This paper deals with an CAE analysis and optimization of injection molding for a mobile phone cover. Two design goals are established in the optimization; one is to switch over the feed system from cold runner to hot runner for the purpose of reducing material costs, and the other is to minimize the warpage in order to improve product quality. By the full-factorial experiments for design parameters, we showed that the cold runner design could be changed to the hot runner design by replacing the current resin with a new resin of higher fluidity. In addition, we could significantly reduce the warpage of the cover product under the hot runner system by optimizing packing pressure and packing time.
The Establishment of Bonding Conditions of Cu Sheet using an Ultrasonic Metal Welder
Park, Woo-Yeol ; Jang, Ho-Su ; Park, Dong-Sam ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 66~72
Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each part's shape, length and mass can affect driving frequency and vibration mode. This paper gives a description of an experimental study of the ultrasonic welding of metals. A horn suitable for 40,000Hz was attached to the ultrasonic metal welder in order to weld Cu sheet. The Cu sheet welding was done with different amplitude, pressure and welding time, and its maximum tension was measured. Maximum tension of 177.99N was obtained when the pressure was 2.5bar, amplitude was 80%, and welding time was 0.34sec. Therefore, excessive welding condition negatively influences maximum tension measurement result.
The Evaluation of the Laser Machinability for Mechanical Materials using Taguchi Experimental Method Design
Kim, Sang-Kyu ; Yoon, Yeo-Myung ; Jung, Yoon-Gyo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 73~78
Recently, the laser processing method has used as micro-machining technologies in industries of aerospace, electronics and automotive. The laser processing newly focused could be alternative to existing machining method. However, there are few practical results of research about the proper setting of the laser machining conditions and the laser machining characteristics for mechanical materials. The purposes of this study was to choose optimum machining conditions and to estimate the laser machining characteristics using taguchi experimental method for various mechanical materials that is S45C, Stainless steel, Aluminum, Copper, Titanium and Tungsten carbide. From obtained results, it was confirmed that optimum machining conditions could be found and laser machinability depends on thermal conductivity and hardness of workpiece.
A Study on the Development of Twist Wheel Type Waste Vinyl Remover (II) - Development of Tractor Attached Vinyl Remover -
Ha, Yu-Shin ; Park, Kyu-Sik ; Kim, Jin-Hyun ; Choe, Jung-Seob ; Son, Chul-Min ; Nam, Sang-Heon ; Kim, Tae-Wook ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 79~84
This study consist of two parts. One is development of a self-propelling vinyl remover which was already reported at the previous paper. This is the second part of the study. For the study, an attached vinyl remover was developed. It was consisted of connecting tractor to bucket, removing bucket from tractor, and the process was the tractor's assistance hydraulics. In the case of an attached vinyl remover, the vinyl was twisted 0.5times per 30~85cm length. The bobbin's diameter was 190mm and it's stable travelling speed was 1m/s. The revolution of the remover wheel was 90rpm to maintain the wheel's linear velocity. As seen at performance test at the field which had 950mm ridge intervals and 10 a area, the average working speed was 1m/s and the turning time was 20seconds. Therefore, the working performance was 24.5min/10a. The efficiency of used vinyl remover was 97% and working conditions were good.
Development of Exclusive System for Basic Design of Offshore Bridge Crane
Park, Se-Myoung ; Lee, Won-Kyu ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 85~91
Offshore Bridge Crane and Hoist which are used FPSO Ships that can move through self - power and have oil production, store and loading and unloading facilities are increasing demand. These equipments must use Crane safely by pitch and rolling of the high wave. For this, they have to be equipped with high durability and safety. So the advanced shipbuilding industries use a private design system which can be prompt in design and analyze in the first stage. For this study, It was developed a basic design system for "Bridge Crane and Hoist" used on FPSO ships. By developing this automated system for "Bridge Crane and Hoist" design, we will be able to make the design data easy to understand. This basic design system will help reduce the amount of working time it takes to design new systems, construct design databases and get approval for the finished design.
Collision Characteristics of an Adult Bicycle to a Car
Kang, Dae-Min ; Ahn, Seung-Mo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 92~97
In the present the usage of bicycle has increased steeply due to well-being and convenient way of movement. In car to bicycle accident, the throw distance of bicycle is very important factor for estimating collision situation. In this study, simulations and collision tests in actual car to bicycle were executed for obtaining throw distance of bicycle. The simulations were executed by PC-CRASHTM s/w with vehicle of sedan type. Sand bags were used for the behavior of bicyclist instead of dummy and factors considered were vehicle velocity, the crashed angles and part of bicycle to vehicle, and bicycle was adult type. From the results, the throw distances of tire collision of 00 was longer than that of 450 tire crash, and the throw distances of 900 frame crash were longer than those of 450 frame crash. With based on actual crash tests and simulations, restitution coefficient of between vehicle and bicycle was estimated as 0.1. Finally the increaser vehicle velocity the longer the throw distances of bicycle and the simulation results were relatively good agreement to the results of experiment.
A Study on the Precision Hole Machiningof Pre Hardened Mould Steel
Lee, Seung-Chul ; Cho, Gyu-Jae ; Park, Jong-Nam ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 98~104
In this paper, precision processing is carried out for the pre hardened steel(HRC 54), which is one of injection mould materials. Processing characteristics are estimated according to the number of tool cutting blade and roundness is observed by the 3-Dimensional measuring machine. The surface roughness affected by the wire electric discharge machining are measured. Cutting component force of STAVOX is the highest in condition of 2F processing because load per a blade of cutting tool is high. Especially, the difference in Fz is over 20N by cutting load. The slower spindle rotation speed and tool feed rate are, the better cutting component force is. The roundness of hole processed in condition of 4F is good because feed rate is able to be fast. When rotation speed is increased, the surface roughness is decreased. The surface roughness acquired in condition of 2F processing is higher about 50% than 4F processing.
Thermal Characteristics and Frequency Analysis of a High Speed Spindle for Small Tapping Center
Choi, Dae-Bong ; Kim, Soo-Tae ; Ro, Seung-Kook ; Cho, Hyun-Taek ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 105~111
High speed machining is the core technology that influences the performance of machine tools, and the high speed motor spindle is widely used for the high speed machine tools. The important problem in high speed spindle is to minimize the thermal effect by motor and bearing and frequency effect. This paper presents the thermal characteristic analysis and frequency experiment for a high speed spindle considering the flow rate of cooling oil. A high speed spindle is composed of angular contact ceramic ball bearings, high speed built-in motor, oil cooling jacket and so on. The thermal analyses of high speed spindle need to minimize the thermal effect and maximize the cooling effect and they are carried out under the various cooling conditions. Heat generations of the bearing and the high speed motor are estimated from the theoretical and experimental data. To find out the characteristic of vibration, the high speed spindle is excited in operational range. This result can be applied to the design and manufacture of a high speed tapping spindle.
Development of Stopper Mechanism for the Precision Stage with Nanometer Accuracy
Kweon, Hyun-Kyu ; Park, Chang-Yong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 112~117
This paper presents a new stopper mechanism for precision stage by using the Piezoelectric element actuator. The new stage including a new stopper mechanism has the precision positioning mechanism that was been developed for generation displacements with nanometer accuracy and a millimeter dynamic range simulataneouly. The stage is composed not of the mechanical two stopper but of only one Piezoelectric element actuator. The characteristics for the new stage and the stopper have been evaluated experimentally. As the results, we can know that the linearity error characteristics of stage is 30nm in the
measurement range. In addition, the experimental results are confirmed the possibility of the movement in millimeter range.
Modeling of Boundary Layer using Atmospheric Boundary Layer Wind Tunnel of UCD
White, Bruce R. ; Kim, Bong-Hwan ; Kim, Dae-Seong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 118~124
The simulation of the air flow over models in atmospheric boundary layer wind tunnel is a research region based on advanced scientific technologies imposed by the necessity of studying the turbulent fluid dynamics in the proximity of the Earth's surface. In this study, the atmospheric boundary layer wind tunnel of UCD is used, the mean velocities are measured by augmentation devices such as roughness blocks and spires. The experimental results of mean velocity profile are well fitted with the value of power law.
Optimization of Sheet Metal Forming Process by using Decision-Making Theory
Kim, Kyung-Mo ; Yin, Jeong-Je ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 125~136
Wrinkle and fracture are two major defects frequently found in the sheet metal forming process. In this process there are more than one design attributes to optimize and several uncontrollable factors which cannot be ignored in determining the optimal values of design variables. Therefore, attempts to reduce defects through a traditional optimization technique are often led to failures. In this research, a new design method for reducing the wrinkle and fracture under uncontrollable factors is presented by using decision-making theory. To avoid the psychological difficulties in determining the scaling constants of the multi-attribute utility function by using the ordinary lottery questions, a pair-wise comparison procedure is adapted to avoid this problem. The effectiveness of the proposed method is illustrated through a robust design of sheet metal forming process of a side member of an automotive body.
Study on Structural Analysis of Flywheel under Rotary Power
Han, Moon-Sik ; Cho, Jae-Ung ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 137~143
This study analyzes flywheel through the analyses of stress, fatigue and vibration. Maximum equivalent stress is 15.271MPa at the mid round shape and maximum deformation is 0.02264mm at the outer teeth. Among the cases of nonuniform fatigue loads, 'SAE bracket history' with the severest change of load becomes most unstable but 'Sample history' becomes most stable. In case of 'Sample history' with the average stress of -
MPa and the amplitude stress of 1000 to 2900MPa, the possibility of maximum damage becomes 30%. This stress state can be 20 times greater than the damage possibility of 'SAE bracket history' or 'SAE transmission'. The range of natural frequencies becomes 200 to 820Hz and the values of these deformations are not more than 10mm. The structural result of this study can be effectively utilized with the design of flywheel by investigating prevention and durability against its damage.
Modification of the Supporting Structure of a Wafer Polishing Machine for the Improved Stability
Ro, Seung-Hoon ; Kim, Young-Jo ; Kim, Dong-Wook ; Yi, Il-Hwan ; Park, Keun-Woo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 144~151
Polishing is not only one of the most frequently adopted processes in modern industries, but also the most critical one to the surface quality of the products such as semi conductor wafers and LED sapphire wafers. With the required specifications for the wafer surface quality getting more and more strengthened, the manufacturers are spending huge amount of cost to renew the machine to meet the enhanced surface specifications. Surface qualities of the wafers are mostly damaged by the structural vibrations of the polishing machines. In this paper, the dynamic characteristics of a wafer polishing machine have been analyzed through the frequency response test and the computer simulation. And the supporting structure of a polishing machine has been investigated to minimize the vibration transmissions, to improve the stability of the machine and further to reduce the defects of the polished products. The result of the study shows that simple design modifications of the supporting structure without altering the main structure of the machine can substantially suppress the vibrations of the machine with negligible expenses.
High-speed Machining Technology using CNC Machining Center Equipped with Attachment Type High-Speed Spindle
Lee, Yong-Chul ; Kwak, Tae-Soo ; Kim, Gyung-Nyun ; Lee, Jong-Ryul ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 152~158
A newly developed attachment type high-speed spindle can be easily attached to the conventional CNC machining center to allow high-speed machining with low investment costs. This study has focused on the application of a conventional CNC machining center equipped with an attachment type high-speed spindle. A specimen of plastic mold material has been machined to compare the cutting effectiveness of the high-speed machining center and the conventional machining center with the attachment type high-speed spindle respectively. The rotational accuracy of the spindles are measured by a transmission optic measurement system and the surface roughness of the workpiece in accordance with revolution speed(rpm) of the spindle are investigated respectively. As the experimental results, it was shown that the surface roughness of the machined workpiece was
in the case of attachment type spindle and
in the case of the high-speed machining center. Moreover, the mean rotational accuracy was
in the case of the attachment type spindle and
in the case of the high-speed machining center.
A Numerical Analysis for the Performance Improvement of a Channel Heat Exchanger
Jang, Byung-Hyun ; Kim, Si-Peom ; Lee, Kwon-Hee ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 159~164
The shell & tube heat exchanger is used throughout various industries because of its inexpensive cost and handiness when it comes to maintenance. However, it has many design elements such as the location and the shape of inlet and outlet, the numbers of tubes and baffles, etc. Also, the flow within the shell and the heat transfer are complex. This paper is performed numerical analysis to evaluate capabilities of difference in temperature and pressure drop, which are the performance of channel heat exchanger, one of different types of shell & tube exchanger. Also, factors that affect the performance of channel heat exchanger were selected through design of experiment along with key factors.
A Study on the Grinding Characteristics of Porous Ceramics
Park, Hwi-Keun ; Park, Se-Jin ; Choi, Yun-Seo ; Hwang, In-Hwan ; Lee, Jong-Chan ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 165~170
The resin bonded diamond wheel is used to grind the difficult-to-cut materials. Traditionally, the resin bonded diamond wheel is manufactured without any pores due to the characteristics of resin bond. In this study, two porous resin bonded diamond wheel were made and the grinding characteristics were compared with traditional nonporous ones. The experimental results indicate that the porous resin bond diamond wheel require less grinding forces and powers.
A Study on the Machining Characteristics of Turning Inserts of Lateral Chip Breaker Shape
Kim, Taeck-Su ; Lee, Sang-Min ; Cho, Jun-Hyun ; Park, Sang-Hyun ; Lee, Jong-Chan ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 11, issue 2, 2012, Pages 171~176
So far, carbide insert production technology was carried out using a diamond grinding wheel. This production technology has problem that raise production costs and decrease in productivity. The SIDE PRESS method to solve this problem have been developed. In this paper, the machining characteristics of lateral chip breaker turning inserts produced by the SIDE PRESS method was studied. The cutting force and the resulting surface roughness were measured at various cutting conditions. The experimental results indicate that the chip breaker inserts of three-dimensional geometry is the best cutting performance.