To improve life time of machine components, higher alloy grade materials are used by adding more metal alloy components and content. Also production processes are further complicated and subdivided such as the forging, preliminary heat treatment, quality heat treatment, rough machining and finished machining process. Those reasons become major cause of large stress in the materials, and the residual stress generated during the manufacturing process causes fatal defects, such as crack, surface tear, warping and deformation of the products. It is necessary to evaluate the residual stress on the entire processes, from forging process to final finished machining process. Also in order to avoid those problems caused by residual stresses, it is necessary to know in advance what process is important to be controlled and what parameters affect residual stress. By the hole drilling method, residual stress was measured in each manufacturing process step. In this study, the hardness of the surface, the cutting force test and the metal analysis were performed to clarify the influence of manufacturing process parameters.

계면중합법은 혼합되지 않은 두 용액에 용해되어 있는 반응성 단량체들이 계면에서 중합되는 기술로 다양한 분야 에 응용되고 있다. 이 중, 수처리 분리막의 경우 m-phenylene diamine과 Trimesoyl chloride를 반응물로 사용하고 있다. 분리 막의 성능은 다양한 중합 성능에 의해 영향을 받고 있으며, 본 연구에서는 유기 용액의 퍼짐 속도가 어떻게 분리막 표면 및 구조에 영향을 주는지를 주사전자현미경을 통해 고찰하였다. 퍼짐 속도는 7.6과 25 mm/sec로 조절하였으며, 유기상 용액은 1~3방울까지 조절하였다. 관찰된 결과는 퍼짐 속도가 7.6 mm/sec에서는 한 방울 떨어트릴 경우, 25 mm/sec에서는 두 방울 떨어트릴 경우 폴리아마이드 막에 균열을 발견할 수 없었다. 반면 나머지 경우에 모두 균열이 발생하였다. 따라서, 초기 유기 용액의 퍼짐 속도는 폴리아마이드 분리막의 성능에 영향을 줄 것으로 관찰되었다.

The purpose of this research isto make improve productivity through process improvement without expensive capital investment in a small scale mold manufacturer. The target company which is selling sand mold casting products employs many foreigners, and 50% of factory workers worked by the periphery of a specific manufacturing sector were difficult to communicate smoothly on site. Also, the company has the customized production method which production and delivery time are constant each month. However, the company's situation is getting harder since the order volume of existing suppliers has decreased and profit has reduced. So, we decided that the company needs new customers and overseas markets in the long run but to improve the process without facility investment in the short term is important task. We improved the process, created the standard of work for foreign workers, and improved the working environment by eliminating the on-site risk factors that the staff could not perceive. The results were as follows. The productivity has improved by 1.5 times. Training by work standards has shortened the OJT time of new workers and efficient working methods have become standard. Improvement of the work environment has improved the job satisfaction of workers and enabled long-term service of workers in the mold industry where labor shortage is serious.

In this study we manufacture a Ni-Cr-B-Si +WC/12Co composite coating layer on a Cu base material using a laser cladding (LC) process, and investigate the microstructural and mechanical properties of the LC coating and Ni electroplating layers (reference material). The initial powder used for the LC coating layer is a powder feedstock with an average particle size of 125 μm. To identify the microstructural and mechanical properties, OM, SEM, XRD, room and high temperature hardness, and wear tests are implemented. Microstructural observation of the initial powder and LC coating layer confirm the layer is composed mainly of γ-Ni phases and WC and Cr23C6 carbides. The measured hardness of the LC coating and Ni electroplating layers are 653 and 154 Hv, respectively. The hardness measurement from room up to high temperatures of 700°C result in a hardness decrease as the temperature increases, but the hardness of the LC coating layer is higher for all temperature conditions. Room temperature wear results show that the wear loss of the LC coating layer is 1/12 of the wear level of the Ni electroplating layer. The measured bond strength is also greater in the LC coating than the Ni electroplating.

Properties of coatings produced by warm spray were investigated in order to utilize this technique as a repair method for Al tire molds. Al-(0-10 %)Al2O3 composite powder was sprayed on Al substrate by warm spraying, and the microstructure and mechanical properties of the composite coating layer were investigated. For comparative study, the properties of the coating produced by plasma spray, which is a relatively high-temperature spraying process, were also investigated. The composite coating layers produced by the two spray techniques exhibited significantly different morphology, perhaps due to their different process temperatures and velocities of particles. Whereas the Al2O3 particles in the warm sprayed coating layer maintained their initial shape before the spray, flattened and irregular shape Al2O3 particles were distributed in the plasma sprayed coating layer. The coating layer produced by warm spray showed significantly higher adhesive strength compared to that produced by plasma spray. Hardness was also higher in the warm sprayed coating layer compared to the plasma sprayed one. Moreover, with increasing the fraction of Al2O3, hardness gradually increased in both spray coating processes. In conclusion, an Al-Al2O3 composite coating layer with good mechanical properties was successfully produced by warm spray.

There is a considerable amount of research on metal material product worker’s hearing loss caused by noise that comes from manufacturing process. A further investigation that characterizes the sound that comes from manufacturing process of metal material products. however. To do this, a noise management plan is needed. It should include a generated sound process from the main sources of disturbance at manufacturing process areas. And a soundproof measurement will identify the amount of noise reduction needed for a hearing-safe working environment. Finally, researchers in this study measured tests on the noise and the vibration process, and the noise caused by operations allowed for an investigation on the suitability of certain environmental conditions. Noise-related programs can be used to predict the noise distribution of the noise level characteristic. This can help identify and reduce the presence of sound interference through sound proofing measures.

Soybean peptide (SP) exhibited low intestinal absorption at oral administration due to its fragile structure under gastric digestion. Therefore, we have attempted to encapsulate peptide by cross-linkage interaction between positive charged chitosan (CS) or chitosan oligosaccharide (CSO) and negative charged peptide. The CS (or CSO) with SP nanoparticles were prepared by using ultrasonification technique. The objective of this study was to find the optimal processing method by changing concentration, pH, and homogenizing conditions. We measured physicochemical properties such as particle size, zeta-potential, encapsulation efficiency (EE%), release rate (RR) and antioxidant ability of samples. The results showed that the optimal processing method was using 0.5% (w/v) CSO (diluted by pH 3 Acetic acid buffer) mixed with 0.5% (w/v) SP (diluted by pH 6 buffer) by 9:1 ratio. Afterwards, using high-speed mixer at 12,000 rpm for 3 min, and then passed 2 times through an ultrasonicator (50% power, 3 min). In this way for processing, the particle sizes of CSO/SP nanoparticles were approximately 300 nm, zeta-potential were approximately 45 mV. In addition, the EE% and RR of CS/SP nanoparticles was higher than the CSO/SP nanoparticles. The increase in antioxidant ability of SP was attributed to the affected by CS/CSO microcapsules. In conclusion, this research can befoundation for the manufacturing process of CS/SP nanoparticles, and it was expected that the future application of this nanoparticle in food matrix.

This study was performed to evaluate changes of microbiological and hygienic quality characteristics of dry-cured ham during manufacturing process. The water activity(Aw) of dry-cured ham decreased significantly during the period(P<0.05). The salt contents increased from at 0 day to 60 days and decreased slightly at 60 days of post-curing(P<0.05). The contents increased after 120 days again. As the curing, drying and aging progressed, the VBN and TBA of dry-cured ham increased(P<0.05). The dry-cured ham samples showed significantly higher VBN at 120 and 180 days and higher TBA at 180 days. Regarding microbiological analysis, the total aerobic counts and lactic acid bacteria counts increased significantly during the stage(P<0.05). The total aerobic counts closely paralleled the lactic acid bacteria counts. In general, this research can be used as fundamental information for the mass production of a hygienic dry-cured ham.

The purpose of this study is to improve a process of the automatic manufacturing system for producing a phosphor bronze wire developed the previous study. For this purpose, the authors have improved the manufacturing process, such as wire tension control, discoloration, winding and the control appears as a problem when the automatic manufacturing system applied to the field. Also, performance tests for the developed system such as the straightness, tensile strength, hardness, diameter deviation, discoloration have been performed. As a result, we could product the 0.35mm of phosphor bronze wire with continuous processes. The performance of the prototype system satisfies all the objects of this study.

The aim of experimental evaluation is to investigate the effect of wear resistance on 3D printing FDM(Fused Deposition Modeling). For this purpose, ABS(Acrylonitrile Buadiene Styrene) material was applied to test of wear-resistance. Ball-on-disk wear test has been performed using steel balls to determine the variation of tribological characteristics. Friction coefficient, wear loss and friction force showed a difference in the respective test conditions.

Assessment of noise exposed population is to check the environment noise level and social influence in order to reduce the risks such as annoyance and disturbance that are generated by environmental noise. Also, this method suggests the preferential noise abatement policy and action plan by accurately finding the area that the noise causes harmful effect to human health. Recently, a noise map, which can predict noise in comprehensive area, is used for the assessment of noise exposed population, breaking from the methods using existing measures. In particular, countermeasure for noise can be considered more effectively by using assessment methods of noise exposed population for specific noise level, area, and building types which are the main input factors in noise maps. In this study, we propose noise reduction ranking decision at manufacturing process of metal material products due to noise map.

The purpose of this paper is to analyze the problems and the sources of defective products and draw improvement plans in a small plastic boat manufacturing process using TOC (Theory Of Constraints) and statistical analysis. TOC is a methodology to present a scheme for optimization of production process by finding the CCR (Capacity Constraints Resource) in the organization or the all production process through the concentration improvement activity. In this paper, we found and reformed constraints and bottlenecks in plastic boat manufacturing process in the target company for less defect ratio and production cost by applying DBR (Drum, Buffer, Rope) scheduling. And we set the threshold values for the critical process variables using statistical analysis. The result can be summarized as follows. First, CCRs in inventory control, material mix, and oven setting were found and solutions were suggested by applying DBR method. Second, the logical thinking process was utilized to find core conflict factors and draw solutions. Third, to specify the solution plan, experiment data were statistically analyzed. Data were collected from the daily journal addressing the details of 96 products such as temperature, humidity, duration and temperature of heating process, rotation speed, duration time of cooling, and the temperature of removal process. Basic statistics and logistic regression analysis were conducted with the defection as the dependent variable. Finally, critical values for major processes were proposed based on the analysis. This paper has a practical importance in contribution to the quality level of the target company through theoretical approach, TOC, and statistical analysis. However, limited number of data might depreciate the significance of the analysis and therefore it will be interesting further research direction to specify the significant manufacturing conditions across different products and processes.

에폭시 수지는 기계적 물성, 내약품성, 치수 안정성 등이 우수하기 때문에 고기능 소재로서 수요가 증가하고 있다. 이에 따라 에폭시 수지 제조공정에서 발생하는 부산물의 양도 증가하여 부산물 내의 원료 물질 회수에 대한 관심이 높아지고 있다. 본 연구에서는 원료물질을 회수하는 증류/분리막 복합 공정에 적용할 수 있는 탈수용 복합막을 연구하였다. 실리카-지르코니아 졸에 α-알루미나를 분산시킨 코팅용액과 실리카 졸을 이용하여 Dip-coating법으로 실리카 복합막을 제조하였다. 에폭시 공정 부산물인 Epichlorohydrin/IPA/H2O을 이용하여 투과증발 실험한 결과 복합막은 총투과도 0.1∼0.7 kg/m²⋅h, 물의 선택도 50∼110를 나타내었다.

This paper deals with the production plan for the foaming process, the core part of the refrigerator manufacturing process. In accordance with this change, the refrigerator manufacturing process has also been converted into the mixed-model production system and it is necessary to optimize the production release pattern for the foaming process. The pattern optimization is to create a mixed-model combination which can minimize the number of setup operations and maintain mixed-model production. The existing method is a simple heuristic that depends on the demand priority. Its disadvantages are low mixed-model configuration rate and high setup frequency. Therefore, demand partitioning occurs frequently. In this study, we introduce the tolerance concept and propose a new pattern optimization algorithm based the large neighborhood search (LNS). The proposed algorithm was applied to a refrigerator plant and it was found that mixed-model configuration rate can be improved without demand partitioning.

Graphite can be classified into natural graphite from mines and artificial graphite. Due to its outstanding properties such as light weight, thermal resistance, electrical conductivity, thermal conductivity, chemical stability, and high-temperature strength, artificial graphite is used across various industries in powder form and bulk form. Artificial graphite of powder form is usually used as anode materials for secondary cells, while artificial graphite of bulk form is used in steelmaking electrode bars, nuclear reactor moderators, silicon ingots for semiconductors, and manufacturing equipment. This study defines artificial graphite as bulk graphite, and provides an overview of bulk graphite manufacturing, including isotropic and anisotropic materials, molding methods, and heat treatment.

This study provides a comparison and analysis of the predicted damages related to hazardous chemical substances used in “A” solar cell manufacturing process. In order to predict potential damages, different accident scenarios were established using the ALOHA model and the KOSHA guideline. This study evaluates chemical spills and leaks from cylinder and pipeline. Maximum distance of chemical movement, based on an initial concentration of 150 ppm, was estimated as up to 258 m in summer and 251 m in winter. The impacts of the leakage of chemicals such as ammonia, were dependent on the initial concentration of the chemical leaked, the atmospheric stability and temperature, and the wind speed. All of those however, were affected by air humidity.

The object of this paper is to examine the noise generating mechanism at manufacturing process of metal material products. To accomplish the object; A noise generating mechanism of high noise machine, which is mounted in the small and medium size enterprise, was investigated. The measurement method of the noise for the machine by manufacturers were investigated. The noise at the 250 point of the manufacturing procrss machine in the 40 processes of the 3 factories, 3 business fields was measured. The database of the noise was built from the measurement data. The major sound sources and frequency range for the manufacturing processes of metal product machine was investigated.

Optimum lot size calculation for real world manufacturing environment has been focused since last few decades. Several extensions have been made to the basic economic order and production order quantity models to realize the possible practical situations in industry. However, focus on work-in-process inventory has been ignored relatively. This paper provides a comprehensive review of the models developed for group technology based manufacturing environment focusing on work-in-process inventory. Models have been extended from a perfect manufacturing conditions to an imperfect manufacturing situation considering rework, rejection and inspection. Optimum lot size has been evaluated using a simple algebraic optimization approach. Significant parameters are highlighted using sensitivity analysis for the developed models. Numerical example is used to illustrate the utilization of such models in day-to-day production setups and the impact of significant factors’ variation on total cost and optimum lot size.

Super air heater devices have some advantages such as compact structure, energy-saving, long service life and convenient installation. In this paper, an automatic production process for air heaters is proposed to compensate some disadvantages of the manual process. The enhancement of production efficiency and productivity is confirmed through the heat treatment performance test decreasing defectiveness rate of 0.23% compared with the previous device.

This study is a basic research for repair material production which manufactured a Cu repair coating layer on the base material of a Cu plate using kinetic spray process. Furthermore, the manufactured material underwent an annealing heat treatment, and the changes of microstructure and macroscopic properties in the Cu repair coating layer and base material were examined. The powder feedstocks were sphere-shaped pure Cu powders with an average size of 27.7μm. The produced repair coating material featured 600μm thickness and 0.8% porosity, and it had an identical α-Cu single phase as the early powder. The produced Cu repair coating material and base material displayed extremely high adhesion characteristics that produced a boundary difficult to identify. Composition analysis confirmed that the impurities in the base material and repair coating material had no significant differences. Microstructure observation after a 500℃/1hr. heat treatment (vacuum condition) identified recovery, recrystallization and grain growth in the repair coating material and featured a more homogeneous microstructure. The hardness difference (δHv) between the repair coating material and base material significantly reduced from 87 to 34 after undergoing heat treatment.