In this study, the various process conditions for high-power DC Magnetron Sputtering (DCMS) on the surface roughness of carbon thin films were investigated. The optimal conditions for Si/C coating were 40min for deposition time, which does not deviate from normal plasma, to obtain the maximum deposition rate, and the conditions for the best surface roughness were – 16volt bias voltage and 400watt DC power with 1.3x10-3torr chamber pressure. Under these optimal conditions, an excellent carbon thin film with a surface roughness of 1.62nm and a thickness of 724nm was obtained. As a result of XPS analysis, it was confirmed that the GLC structure ( bonding) was more dominant than the DLC structure ( bonding) in the thin film structure of the carbon composite layer formed by DC sputtering. Except in infrequent cases of relatively plasma instability, the lower bias voltage and applied power induces smaller surface roughness value due to the cooling effect and particle densification. For the optimal conditions for Graphite/C composite layer coating, a roughness of 36.3 nm and a thickness of 711 nm was obtained under the same conditions of the optimal process conditions for Si/C coating. This layer showed a immensely low roughness value compared to the roughness of bare graphite of 242 nm which verifies that carbon coating using DC sputtering is highly effective in modifying the surface of graphite molds for glass forming.

The parking gear is very important part of automotive because it is related to safety. Nonlinear gear groove of parking gear is used to enlarge the contact area between parking gear and pawl. The die has been widely applied for many industrial parts such as machine, automotive and so on. The purpose of this study is to investigate the stability of upper and lower dies by using numerical analysis. As the results, the lower die was weaker than the upper die in this study, and the lower die showed that it should be used within 500ton in terms of safety factor. Further the most weak point of lower die was low location in front of gear. Its minimum value of safety factor was 0.578 in case of 4000ton of press load, therefore, this weak point was needed to be reinforced.

In this paper, we present a case study of developing MVIS (Machine Vision Inspection System) designed for exterior quality inspection of stamping dies used in the production of automotive exterior components in a small to medium-sized factory. While the primary processes within the factory, including machining, transportation, and loading, have been automated using PLCs, CNC machines, and robots, the final quality inspection process still relies on manual labor. We implement the MVIS with general- purpose industrial cameras and Python-based open-source libraries and frameworks for rapid and low-cost development. The MVIS can play a major role on improving throughput and lead time of stamping dies. Furthermore, the processed inspection images can be leveraged for future process monitoring and improvement by applying deep learning techniques.

Injection molding is a process of shaping resin materials by heating them to a temperature above their melting point and then using a mold. The resin material is injected into and cooled within the mold cavity, solidifying into the desired shape. The core and cavity components that make up the mold cavity are crucial elements for the precision molding in injection molding. In the case of precision mold production, the application of 5-axis machining technology is required to ensure high machining quality for complex shapes, and among these factors, the tool angle is a critical machining condition that determines the surface roughness of the workpiece. In this study, we aim to measure the surface roughness of the machined surface of KP4A specimens during machining processes with variations in the tool angle and analyze the correlation between the tool angle and surface roughness.

본 연구는 베트남 내 금형 회사 종사자들의 셀프리더십이 혁신행동에 미치는 영향에 대한 자기효능감의 매개효과를 규명하는데 연구의 목적이 있다. 연구 방법은 선행연구를 기반으로 설문지를 작성하였으며, 회수 된 197부의 설문지를 대상으로 통계분석을 실시하였고 SPSS 20.0 프로그 램을 이용하여 분석하였다. 베트남의 금형 관련 회사 종사자들의 셀프리 더십이 혁신행동에 미치는 영향과 자기효능감의 매개효과를 검증하였다. 그 결과 셀프리더십은 혁신행동에 유의미한 정(+)의 영향을 미쳤으며, 자 기효능감은 매개효과가 있는 것으로 나타났다. 이에 따라 베트남 내 금 형 회사 종사자의 셀프리더십이 강화될수록 혁신행동에 미치는 영향이 있는 것을 알 수 있었다. 이는 교육과 훈련을 통하여 셀프리더십 스킬을 강화시킴으로써 혁신행동을 향상시킬 수 있는 가능성을 시사한 것으로 볼 수 있다.

Recently, halogen lamps for vehicle exterior lamp systems are being replaced by LEDs (Light Emitting Diode) in consideration of miniaturization, power consumption, life, luminance, and eco-friendliness. Due to regulations on the amount of light required, luminance, light uniformity, and glare prevention, it is required to develop a light guide for controlling a light source of an LED lamp for a vehicle. For the development of the light guides, the development of machining technology that can cut micro patterns of hundreds of micrometers scale into surface roughness of tens of nanometers scale must be preceded. In this study, the effect of variations in cutting conditions on surface roughness was analyzed through experiments. The micro patterns was manufactured by cutting into STAVAX material, and the surface of the micro patterns was super-finished using a ball-shaped PCD (polycrystalline diamond) tool without flutes. In experiments, the cutting conditions of the super-finishing process were varied, and the varied cutting conditions were feed rate, radial depth of cut, and spindle speed

In order to manufacture a mask to prepare for infectious diseases such as COVID-19 and yellow dust, it is manufactured through the process of input, fusion, cutting, band attachment, defect inspection, and packaging. Domestic mask producers introduced Chinese facilities to keep up with explosive demand due to the rapid spread of COVID-19 in 2020, but serious problems arise in durability. Therefore, domestic processing and tooling companies have developed and supplied molds, but since supply is not smooth compared to demand, research on the development of mask molds with durability reliability is urgently needed to supply masks stably. This technology development aims to supply a mask with excellent quality to a market by applying dots capable of welding and re-painting to a mold for cutting applied to a mask manufacturing process and developing dots optimized for paper angles.

Phosphate coating is applied to the surface of the round bar material used in the multi-stage cold forging process for the purpose of lubrication. The film characteristics are determined according to the conditions of the phosphate film treatment process. In this study, the film properties according to the phosphate treatment conditions were defined as the coefficient of repeated friction and quantitative analysis was performed. Different friction behaviors were exhibited depending on the film properties, suggesting that optimization of the phosphate film treatment conditions is possible based on this. Finally, as a practical example, friction behavior according to the film characteristics was applied to the automotive engine bolt forming process. As a final conclusion, the need for linkage analysis with phosphating conditions for optimizing the forging process was raised. In addition, it can be seen that damage to the phosphate film should be considered in the process of predicting the limiting life of the die.

Most of automobile steering parts are manufactured through the multi-stage cold forging process using round-bar drawn materials. The same process is applied to the ball stud parts of the outer ball joint, and various research activities are being carried out to reduce the extreme manufacturing cost in order to survive in the limitless competition. In this paper, we present a quantitative prediction method for the limiting life of the die as a method for cost reduction in the multi-stage cold forging process. The load on the die was minimized by distributing the forming load based on process optimization through finite element analysis. In addition, based on the quantitative prediction algorithm of the limiting life of the die, the application of the split die and the optimization of the phosphate treatment of the material surface are presented as a conclusion as a method to improve the limiting life of the die.

Reheat treatment process of mold is necessary when partial machining of the mold is required, such as shape correction for an existing mold. If defects such as cracks or significant deterioration of mechanical properties of the mold occur during reheat treatment, it is impossible to reuse the mold. In this study, reheat treatment was performed up to two times for STD11 tool steel, and microstructure and mechanical properties according to the reheat treatment were evaluated. Carbide fraction and grain size of prior austenite were almost unchanged after the reheat treatment. Hardness and impact toughness increased significantly after QT treatment, and these properties were maintained without significant change even after the reheat treatment. It is concluded that up to two iterations of reheat treatment does not cause deterioration of properties of STD11 tool steel. Based on these results, a mold for a face-lifted front bumper was manufactured through machining and reheat-treating of an existing mold.

Molds are actively used for mass production of products such as mobile phones. Molds are required to be durable and have a high level of surface roughness. Therefore, the optimization of mold processing is essential. In this study, the cutting processing of SDP20 steel used in molds was analyzed and optimized. This study is expected to contribute to the improvement of product productivity to which plastics are applied.

When the product is taken out after the injection process, the surface of the product and the mold are attached and to separate them, it is necessary to consider the frictional force between the mold surface and the product surface. Therefore, to reduce the frictional force, a subtraction gradient for the rib shape is generally applied, and a lapping process is performed to improve the surface roughness of the rib shape surface of the processed mold. Therefore, research is needed to improve the surface roughness when processing the rib. In this study, slotting processing was applied to improve surface roughness when processing ribs. Slotting processing is a processing method that removes material through the feed motion of the tool, and processing is possible regardless of the aspect ratio of the processing shape. A slotting tool was developed for rib machining and a comparative experiment with electric discharge machining was performed. Also after processing, the surface roughness and processing time were compared and analyzed, and the improved surface roughness and fast processing time characteristics of the slotting processing compared to electric discharge processing were confirmed.

Recently, the demand for reliability verification is increasing while designing and manufacturing molds using injection molding computer aided engineering(CAE). When performing flow analysis verification, a spiral mold is produced and compared with CAE. Because of the spiral shape, we needed a comparative evaluation with the flow distance of products with different forms. So, we compared the weight and flowed length using CAE. Variables are the change in the width of the spiral shape and the shape of the bar and plate. When the width of the spiral shape is 23mm rather than 15mm, the flow distance flows 30∼70mm more, with a maximum difference of 13%. As a result of comparing the spiral shape and the long square shape with the same width, the spiral shape had a flow distance of 60 to 105mm further, and a difference of up to 28% was found. As a result of comparing the plate shape and the spiral shape with a 15mm width product, the spiral shape has a flow distance of 310∼380mm further, and a difference of up to 82% is different.

The longest process in the injection molding process is the cooling process of the molded product. Therefore, shortening the cooling time is key to reducing the injection molding cycle time. For fast cooling time, the production of conformal cooling channels using metal 3D printing instead of the conventional linear cooling channels is continuously increasing. In this study, the cooling effect of the conventional linear cooling channel application and the conformal cooling channel application using metal 3D printing was compared in the design of the back cover molding mold of the circulator that has been widely used recently. The comparison of the cooling effect was based on the mold temperature and the molded product temperature for a certain period of time after completion of molding. It was confirmed that the time required to eject from the mold with the conformal cooling channel to the ejecting temperature of the molded product was reduced by 28.7%, and the maximum temperature of the mold was also reduced by 40%.

In this study, the fatigue properties of press die steel, such as SKD11, and three high-durability die steel for the cold forming of ultra-high-strength steel sheets are evaluated. Specimens for fatigue, tensile, and hardness tests are manufactured through the heat treatment recommended by steelmakers and ultra-high precision processing. The general mechanical properties and fatigue properties are derived from hardness, tensile, and fatigue tests for four die steel. The tensile and fatigue properties of die steel derived through the tests are compared and analyzed. In particular, the correlation between the fatigue limit and the general mechanical properties such as tensile strength and elongation is analyzed, which allows relational expressions to be obtained through regression analysis. Finally, the study confirms that applying high-durability die steel is necessary for improving the die life in the manufacturing of press dies for ultra-high-strength steel sheets.

In this study, in order of to reflect the mold deformation in the injection molding process to design of mold, the mold deformation was analyzed by performing flow and structural analysis. The 5 inch LGP(light guide plate) mold, platen and tie bar were modeled and applied to the analysis. The result of melt pressure from flow analysis was extracted for use as boundary conditions acting on the mold surface in the structural analysis. In order to evaluate the accuracy of simulation analysis results, injection molding was performed under the process conditions of simulation. As a results, the mold deformation during injection molding tends to be similar that of injection pressure, and it is confirmed that it shows the behavior and properties of melt resins. Compared with the simulation and experiment, the error of the maximum mold deformation in the injection phase was 4.20%.

The global trend is the application of heat-treated omission materials to reduce the manufacturing cost of automobile steering parts. Attempts have been made to apply heat-treated omission materials in domestic, but they are delayed due to concerns over rising cold forging process costs. For quantitative prediction of cold forging process cost, fatigue properties of forging die materials were evaluated. Based on this, the die life and cost were predicted quantitatively, and the manufacturing cost reduction of automobile steering parts using heat-treated material was found to be about 11%. Also, various methods to improve die life were additionally presented.