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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 14, Issue 6 - Dec 2015
Volume 14, Issue 5 - Oct 2015
Volume 14, Issue 4 - Aug 2015
Volume 14, Issue 3 - Jun 2015
Volume 14, Issue 2 - Apr 2015
Volume 14, Issue 1 - Feb 2015
Selecting the target year
Manufacturing of Micromolds for Plastic Molding Technologies via Synchrotron LIGA Process
Lee, Bong-Kee ; Kim, Jong-Hyun ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 1~7
DOI : 10.14775/ksmpe.2015.14.4.001
In the present study, copper micromolds with a microhole array were precisely manufactured by a synchrotron LIGA process. Like in the traditional LIGA process, a deep X-ray lithography based on a synchrotron radiation was employed as the first manufacturing step. Due to the excellent optical performance of the synchrotron X-ray used, cylindrical micropillar arrays with high aspect ratio could be efficiently obtained. The fabricated microfeatures were then used as a master of the subsequent copper electroforming process, thereby resulting in copper micromolds with a microhole array. Thermoplastic hot embossing experiments with the copper micromolds were carried out for imprinting cylindrical microfeatures onto a polystyrene sheet. Through the hot embossing, the effect of embossing temperature and usefulness of the present manufacturing method could be verified.
A Study on Plastic Injection Molding of NanosStructured Surface with a Local Mold Heating System
La, Moon Woo ; Park, Jang Min ; Kim, Dong Earn ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 8~13
DOI : 10.14775/ksmpe.2015.14.4.008
In this study, we fabricated and characterized a nanostructured surface based on a plastic injection molding with a local mold heating (LMH) system. A metal mold core with a closed packed nano convex array (CVA) was achieved by integrated engineering procedures: (1) master template fabrication by anodic aluminum oxidation (AAO), (2) nickel electroforming (NE) process, and (3) post-processing by precision machining. The nickel mold core was utilized to replicate a surface with a closed packed nano concave-array (CCA) based on injection molding using cyclic olefin copolymer (COC) as a plastic material. In particular, an LMH system was introduced to enhance transcription quality of the nano structures by delaying solidification of molten polymer near the surface of the mold core.
A Review of Numerical Simulation Methods for Molding Processes of Plastic Microstructures
Park, Jang Min ; Cha, Kyoung Je ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 14~20
DOI : 10.14775/ksmpe.2015.14.4.014
Molding technologies for plastic microstructures have been extensively investigated during the last two decades, and theoretical and numerical studies on the micro molding process have provided efficient tools for the development of such molding technologies. In this paper, we present a review of numerical simulation methods for the micro molding process. Basic models for a description of the material property, governing equations of the flow and heat transfer during the molding process, and numerical methods will be described. Particularly, numerical simulations for micro injection molding and hot embossing processes will be presented, and their main features noted and compared to those for conventional molding processes.
Study on Optimization of Temperature Jump-Bending Process for Reducing Thickness Attenuation of Large-Diameter Steel Pipe
Xu, Zhe-Zhu ; Kim, Lae-Sung ; Jeon, Jeong-Hwan ; Liang, Long-Jun ; Choi, Hyo-Gyu ; Lyu, Sung-Ki ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 21~27
DOI : 10.14775/ksmpe.2015.14.4.021
Induction bending is a method that allows the bending of any material that conducts electricity. This technology applies a bending force to a material that has been locally heated by an eddy current induced by a fluctuating electromagnetic field. Induction bending uses an inductor to locally heat steel through induction. This results in a narrow heat band in the shape to be bent. In general, the reduction of thickness attenuation of a large-diameter steel pipe is not allowed to exceed 12.5%. In this paper, in order to meet the standard of thickness attenuation reduction, a non-uniform heating temperature jump-bending process was investigated. As a result, the developed bending technique meets the requirements of thickness attenuation reduction for large-diameter steel pipes.
Optimum Design of the Agricultural Support and Binder for Stretching Device
Lee, Man-Gi ; Kim, Jin-Ho ; Shin, Ki-Yeol ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 28~33
DOI : 10.14775/ksmpe.2015.14.4.028
In this study, the optimal design for the support and the binding device for the protection of crops for the maximum allowable stress of the shape necessary to minimize volume has been proposed. Optimization of the support and the binding device for the crops should be designed to support businesses in terms of profit, in part to reduce the material, and to profit from the ease and speed of working that part of the farmers. We used CATIA for the mechanical design and the ANSYS program for the structural analysis. Additionally, the optimization was performed by PIAnO with seven design variables for the binding device and three parameters for the support. The weight method using a multi-objective function was also determined by the Pareto optimal solution. The volume of the binding device in the optimum design result was found to be reduced by 16%, from
. From the result, we confirmed the effectiveness of the design method proposed as a multi-objective function optimization problem.
Development of Hardware-linked Simulation Platform for Automation Mechanism Training
Kim, Hyun-Hee ; Park, Sung-Su ; Lee, Kyung-Chang ; Hwang, Yeong-Yeun ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 34~42
DOI : 10.14775/ksmpe.2015.14.4.034
As the industry environment is changing to automated systems, engineering education at university has changed with industrial development. Industry technology will be developed, and the industry environment will become more complicated. Therefore, the knowledge that undergraduates have to acquire in university will be extensive. Industries need a person with expertise to react quickly to rapidly changing technology. Therefore, universities need to endeavor to cultivate manpower in technical fields. This is difficult because the contents of engineering education must react quickly to rapidly changing industry technology. This paper proposes a hardware-linked simulation platform for engineering education on the well-used systems in industrial sites.
Optimum Design and Characterization of F-Theta Lens by a 3D Printer(I)
Shin, Hyun-Myung ; Yoon, Sung-Chul ; Choi, Hae-Woon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 43~48
DOI : 10.14775/ksmpe.2015.14.4.043
A focal length-correcting lens called the F-theta lens is required to compensate for the different focus on spot size due to the deflected incident laser beam. The F-theta lens was designed by the ray tracing method and fabricated by a 3D printer with polymer-based material. The designed F-theta lens is able to compensate for the focus on spot size by an incidence angle of 0 to 2 degrees. Based on the analysis of the simulation, there was almost no aberration in the
incidence angle, and the maximum of
of aberration was observed at the incidence angle of
. Diffraction-encircled energy was analyzed to characterize the designed optics, and an image simulation was performed to confirm the actual image resolution.
Optimum Design and Characterization of F-theta lens by a 3D Printer(II)
Yoon, Sung-Chul ; Shin, Hyun Myung ; Choi, Hae-Woon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 49~54
DOI : 10.14775/ksmpe.2015.14.4.049
The fabrication of a focal length-correcting lens called the F-theta lens was performed by a 3D printer. The fabricated lenses were characterized by transmittance and reflectance measurements. The optical properties of the lens, such as scattering or transmittance efficiency, were analyzed with respect to the wavelength (red, green, and blue) and the surface roughness of the lens. There was almost no shape aberration on the focus location of 0 degrees, but elliptical focus shapes were found at 1 and 2 degrees of the laser incidence angle. The developed process is expected to be used for the quick fabrication of lenses with low costs and quick turn-out. By improving the surface roughness during postprocessing, the optical properties are expected to be comparable to commercial lens quality.
A Study on the Internal Thrust Grinding by Machining Center
Choi, Hwan ; Seo, Chang-Yeon ; Park, Won-Kyue ; Lee, Choong-Seok ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 55~61
DOI : 10.14775/ksmpe.2015.14.4.055
In this paper, the grinding characteristics of internal thrust grinding were studied with vitreous CBN wheels using a machining center. Grinding experiments were performed according to grinding conditions, such as wheel feed speed and depth of cut, workpiece speed, and rate of grinding width. Additionally, the grinding force and grinding ratio were investigated though these experiments. Based on the experimental results, the grinding characteristics of internal thrust grinding were discussed.
Design and Analysis of Aluminum Melting Machine in Fused Deposition Modeling Method
Lee, Hyun-Seok ; Na, Yeong-Min ; Kang, Tae-Hun ; Park, Jong-Kyu ; Park, Tae-Gone ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 62~72
DOI : 10.14775/ksmpe.2015.14.4.062
Interest in three-dimensional (3D) printing processes has grown significantly, and several types have been developed. These 3D printing processes are classified as Selective Laser Sintering (SLS), Stereo-Lithography Apparatus (SLA), and Fused Deposition Modeling (FDM). SLS can be applied to many materials, but because it uses a laser-based material removal process, it is expensive. SLA enables fast and precise manufacturing, but available materials are limited. FDM printing`s benefits are its reasonable price and easy accessibility. However, metal printing using FDM can involve technical problems, such as suitable component supply or the thermal expansion of the heating part. Thus, FDM printing primarily uses materials with low melting points, such as acrylonitrile butadiene styrene (ABS) or polylactic acid (PLA) resin. In this study, an FDM process for enabling metal printing is suggested. Particularly, the nozzle and heatsink for this process are focused for stable printing. To design the nozzle and heatsink, multi-physical phenomena, including thermal expansion and heat transfer, had to be considered. Therefore, COMSOL Multiphysics, an FEM analysis program, was used to analyze the maximum temperature, thermal expansion, and principal stress. Finally, its performance was confirmed through an experiment.
The Design and Experiment of Piezoelectric Energy-Harvesting Device Imitating Seaweed
Kang, Tae-Hun ; Na, Yeong-Min ; Lee, Hyun-Seok ; Park, Jong-Kyu ; Park, Tae-Gone ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 73~84
DOI : 10.14775/ksmpe.2015.14.4.073
Electricity generation using fossil fuels has caused environmental pollution. To solve this problem, research on new renewable energy sources (solar, wind power, geothermal heat, etc.) to replace fossil fuels is ongoing. These devices are able to generate power consistently. However, they have many weaknesses, such as high installation costs and limits to possible setup environments. Therefore, an active study on piezoelectric harvesting technology that is able to surmount the limitations of existing energy technologies is underway. Piezoelectric harvesting technology uses the piezoelectric effect, which occurs in crystals that generate voltage when stress is applied. Therefore, it has advantages, such as a wider installation base and lower technological costs. In this study, a piezoelectric harvesting device imitating seaweed, which has a consistent motion caused by fluid, is used. Thus, it can regenerate electricity at sea or on a bridge pillar, which has a constant turbulent flow. The components of the device include circuitry, springs, an electric generator, and balancing and buoyancy elements. Additionally, multiphysics analysis coupled with fluid, structure, and piezoelectric elements is conducted using COMSOL Multiphysics to evaluate performance. Through this program, displacement and electric power were analyzed, and the actual performance was confirmed by the experiment.
A Study on Surface Roughness of Aluminum 7075 to Nose Radius and Cooling Method in CNC Lathe Machining
Noh, Young-Ho ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 85~91
DOI : 10.14775/ksmpe.2015.14.4.085
Current world aircraft industry studies on the precision of the product are in active progress. Particularly in terms of improving the quality of processed products in terms of the surface roughness of the dimensional accuracy, fatigue strength, and corrosion resistance, which affect a lot of research on surface roughness, has been investigated. In this study of aluminum alloy, 7075 aircraft aluminum is used in a cutting CNC lathe machine for the cutting speed and feed rate according to the cutting experiments that were conducted. Additionally, the machine tool of the cooling method soluble cutting oil, insoluble cutting oil by cooling, and cooling the workpiece by cutting surface roughness will be investigated. Through the method and soluble cutting oil coolant cooled by the cutting speed increases, the value of surface roughness showed a regular result. Tool nose radius of 0.8 mm than 0.4 mm picture of when approximately 50 of the surface roughness values were less.
Effect of Flow Pattern of Coolant for Injection Mold on the Deformation of Injection Molding
Choi, Kye-Kwang ; Hong, Seok-Moo ; Han, Seong-Ryeol ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 92~99
DOI : 10.14775/ksmpe.2015.14.4.092
The deformation of injection molding is seriously affected by injection molding conditions, such as melt and mold temperature and injection and holding pressure. In these conditions, the mold temperature is controlled by flowing coolant, which can be classified by the Reynolds number in the mold-cooling channel. In this study, the deformation of the automotive side molding according to the variation of the Reynolds number in the coolant was simulated by Moldflow. In the results, as the Reynolds number was increased, the mold cooling was also increased. However, when the Reynolds number exceeded a certain range, the mold cooling was not increased further. In addition to the Moldflow verification, the mold cooling by the coolant was simulated by CFX. The CFX results confirmed that the Reynolds number significantly influenced the mold cooling. The coolant, which has a high Reynolds number value, quickly cooled the mold. However, the coolant, which has a low Reynolds number value, such as 0 points, hardly cooled the mold. In an injection molding experiment, as the Reynolds number was high, the deformation of the moldings was reduced. The declining tendency of the deformation was similar to the Moldflow results.
Characteristics of Surface Roughness According to Wire Vibration Wire-cut Electric Discharge Machining of Aluminum Alloy 6061(II)
Ryu, Cheong-Won ; Choi, Seong-Dae ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 100~107
DOI : 10.14775/ksmpe.2015.14.4.100
Recently, high-efficiency machining in the production of high-value products with a complex shape has constantly been required with the need for hybrid machining. In this study, in addition to the wire-cut E.D.M. and vibration used to present the possibility of a hybrid process by carrying out the aluminum alloy experiment, the hybrid process determines the nature of the surface. The selected experimental parameters are horizontality, waveform, amplitude, peak current, and frequency. The experimental results give guidelines for selecting reasonable machining parameters. The surface roughness was improved by about 20% with increases in the amplitude of the vibration.
A Study on the Analysis Method of the Basic Design Process of a FPSO Crane using ERD
Lee, Won-Kyu ; Park, Se-Myoung ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 108~117
DOI : 10.14775/ksmpe.2015.14.4.108
In this paper, as a previous step of software development, through an analysis step in the basic design process of the FPSO crane, ERD, which could help develop common understanding between its developer and the user, was introduced. From the flowchart of the design process, the overall work flow in its development was understood. Then, after the design process of the crane was divided into many entities, the attributes of each entity were defined and the relationships between the entities were established, followed by ERD creation through the use of IDEF1X notation. The results of the analysis can be readily understood even by users who lack of software knowledge, and then their change requirements can be immediately reflected in the developed system that requires modification.
Development of a Roll-Forming Process of Linearly Variable Symmetric Hat-type Cross-section
Kim, Kwang-Heui ; Yoon, Moon-Chul ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 118~125
DOI : 10.14775/ksmpe.2015.14.4.118
The roll-forming process is a highly productive incremental forming process and is suitable for manufacturing thin, high-strength steel products. Recently, this process has been considered one of the most productive processes in manufacturing high-strength steel automotive structural parts. However, it is very difficult to develop the roll-forming process when the cross-sectional shape of the product changes in the longitudinal direction. In this study, a roll-forming process for manufacturing high-strength steel automotive parts with a linearly variable symmetric hat-type cross-section was developed. The forming rolls were designed by the 3D CAD system, CATIA. Additionally, the designed forming rolls were modified by the simulation through the 3D elastic-plastic finite element analysis software, MARC. The results of the finite element analysis show that the final roll-forming roll can successfully produce the desired high-strength steel automotive part with a variable cross-section.
Development of the Compound Die Forming Technology United between Semi-Progressive and Transfer Die
Park, Dong-Hwan ; Kwon, Hyuk-Hong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 126~133
DOI : 10.14775/ksmpe.2015.14.4.126
To enhance the productivity and quality of the compound process of progressive dies and transfer dies, the semi-progressive method is applied in the material supply step to produce blanks, and then the transfer method is applied. Parts are transferred among processes by means of the finger and transfer bar in the transfer die, and the final seat cushion panel is produced. The main challenge in the current study is how to deform a seat cushion panel while meeting the design specifications without any defects. In order to obtain this technology, a sheet metal-forming simulation and die forming of the seat cushion panel were adopted; as a result, a compound die-forming technology for the automotive seat cushion panel, combining both semi-progressive die and transfer die for continuous production, was successfully developed.
Finite Element Analysis for Fracture Criterion of PolyJet Materials
Kim, Dong Bum ; Lee, Geun Tae ; Lee, In Hwan ; Cho, Hae Yong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 134~139
DOI : 10.14775/ksmpe.2015.14.4.134
PolyJet technology is an additive manufacturing (AM) technology commonly used for modeling, prototyping, and production applications. It is one of the techniques used for 3D printing. The PolyJet technique is a process that joins materials to fabricate a product from 3D CAD data in a layer-by-layer manner. The orientation of a layer can affect the mechanical properties of the product manufactured by the PolyJet technique because of its anisotropy. In this paper, tensile and shearing tests of specimens were developed with the PolyJet technique in order to study the mechanical properties according to the orientation of a layer. The mechanical properties of the specimens were determined on the basis of true stress-strain curves from tensile and shearing tests. In addition, the tensile and shearing tests were simulated under the same conditions as those of experiment, and the experiment and simulated results were compared. Through this study, the fracture criteria could be established.
Study of Structural Reliability of Pipe-Fitting Collet Tool
Kim, Chang-Uk ; Park, Jin-Chul ; Song, Jung-Il ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 140~145
DOI : 10.14775/ksmpe.2015.14.4.140
In the present study, the structural safety of the bolt portion and collet tool structure of the pipe-fitting tool is analyzed by using the finite element technique. Two forces as piston forces with the magnitude of 187.5 Tons are applied to the inner and outer portions of the collet tool, respectively. A structural load of 750 Tons is applied to the bolt portion. In the analysis results, it is found that the structure becomes safe under the current loading conditions. The reliability rating of the pipe is calculated in this study. The material properties of the actual material are evaluated by using mechanical testing. Therefore, the material properties are used to carry out static structural and optimization analysis.
Development of Side Trimmer with Line Non-Stop
Kim, Sun-Ho ; Lee, Jeom-Pan ; Cho, Hang-Deuk ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 146~150
DOI : 10.14775/ksmpe.2015.14.4.146
Steel is produced through the steel-making process with a desired shape by a rolling press. Scrap is removed according to the sheet edge to improve the quality of the product. This machine is called a side trimmer. This study aimed to develop a side trimmer for automatically changing the width of the trimming knife without line stopping. This machine consists of a housing opening device and a turning device. The measuring technologies of sheet width, trimming knife rotation angle, and knife gap for increasing the control accuracy. This experiment was conducted to evaluate the performance of the developed technologies. It was reduced by 10% compared with the operation time of the conventional method.
Development of Contact-Type Thickness Measurement Machine using LVDT Sensors
Shin, Ki-Yeol ; Hwang, Seon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 151~159
DOI : 10.14775/ksmpe.2015.14.4.151
In this study, we developed an automated contact-type thickness measurement machine that continuously and precisely measures the thickness of a PCB module product using multi-LVDT sensors. The system contains a measurement part to automatically measure the thickness in real time according to the set conditions with an alignment supply unit and unloading unit to separate OK and NG products. The sensors were calibrated before assembly in the measuring machine, and precision and accuracy performance tests were also performed to reduce uncertainty errors in the measurement machine. In the calibration test, the precision errors of the LVDT sensor were determined to be
as 0.1% at the measuring range. A measurement error of 0.8 mm and 1.0 mm thickness test standards were found to be
, and the standard deviations of two 1.0 mm products were measured as
, respectively. In the measurement system analysis, the accuracies of test PCB standards were found to be
, respectively. From the results of gage repeatability and reproducibility (R & R) crossed, we found that the machine is suitable for the measurement and process control in the mass production line as 7.92% of total gage R & R and in seven distinct categories. The maximum operating speed was limited at 13 pcs/min, showing a value good enough to measure.
A Study on the Development of Rotary Ultrasonic Machining Spindle
Li, Chang-Ping ; Kim, Min-Yeop ; Park, Jong-Kweon ; Ko, Tae-Jo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 4, 2015, Pages 160~166
DOI : 10.14775/ksmpe.2015.14.4.160
Ultrasonic machining (USM) has been considered a new, cutting-edge technology that presents no heating or electrochemical effects, with low surface damage and small residual stresses on brittle workpieces. However, nowadays, many researchers are paying careful attention to the disadvantages of USM, such as low productivity and tool wear. On the other hand, in this study, a high-performance rotary ultrasonic drilling (RUD) spindle is designed and assembled. In this system, the core technology is the design of an ultrasonic vibration horn for the spindle using finite element analysis (FEA). The maximum spindle speed of RUM is 9,600 rpm, and the highest harmonic displacement is
noted at the frequency of 40 kHz. Through various drilling experiments on glass workpieces using a CVD diamond-coated drill, the cutting force and cracking of the hole entrance and exit side in the glass have been greatly reduced by this system.