This study focuses on optimizing the uniform pressing process in precision manufacturing, addressing challenges posed by surface roughness and height differences between components. In real-world conditions, such irregularities can lead to non-uniform pressure distribution during pressing, negatively affecting product quality. To mitigate these issues, a buffer protection layer was introduced between the press and components. The optimization process was conducted through finite element analysis (FEA) to determine the ideal material properties, including elastic modulus, Poisson's ratio, and thickness of the buffer layer. Two surface roughness scenarios were examined to assess the impact of surface conditions on pressing uniformity. The results indicate that a higher elastic modulus, Poisson’s ratio, and thicker buffer layers are more effective in achieving uniform pressing, particularly under rougher surface conditions. This study provides a practical solution for improving the precision and reliability of pressing processes, ensuring better product consistency and enhancing overall manufacturing efficiency.

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.

The cutting process, which is a key processing technology in various industrial fields is achieving continuous growth, and the demand for high-quality cutting surfaces is continuously demanded. Plasma cutting continues to be studied for its excellent workability and productivity, but problems with cutting surface quality such as dross formation occur, so research to secure excellent cutting surface quality through appropriate control of process variables is essential. In this study, we propose a method for predicting surface roughness using real-time current and cutting speed data obtained while performing plasma cutting on A106 B steel pipe. Surface roughness was predicted based on the RBF algorithm applicable to prediction and control models. It was shown that the surface roughness of the plasma cutting surface can be predicted with the arc current waveform and process speed data. This study can be used as a basic study to control the surface roughness of the cut surface in real time.

Carbon steel pipes, which are essentially used in the manufacturing industry, are used in various fields due to the advancement of the industry, and a cutting process is essentially applied to pipes manufactured in a nominal size. The cutting process is the most basic and first process used to obtain a material in a desired shape, and it can affect the quality of subsequent processes such as welding or painting, so high-quality cutting surfaces are essential. Therefore, due to the advantage of improving productivity, it is essential to study to secure the appropriate quality of the cutting surface of the plasma cutting process, which is widely used in the industrial field. In this study, the effect of cut surface quality according to process parameters in the plasma cutting process for carbon steel pipe materials was analyzed. The surface roughness was measured to determine the quality of the cut surface, and the relationship between the surface roughness and the process variables was confirmed by selecting the arc current and cutting speed, which are identified as the main factors forming the surface roughness, as process variables.

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

The function of coolant in machining is to reduce the frictional force in the contact area in between the tool and the material, and to increase the precision by cooling the work-piece and the tool, to make the machining surface uniform, and to extend the tool life. However, cutting oil is harmful to the human body because it uses chlorine-based extreme pressure additives to cause environmental pollutants. In this study, the effect of cutting temperature and surface roughness of titanium alloy for medical purpose (Ti-6Al-7Nb) in eco-friendly ADL slot shape machining was investigated using the response surface analysis method. As the design of the experiment, three levels of cutting speed, feed rate, and depth of cut were designed and the experiment was conducted using the central composite planning method. The regression expressions of cutting temperature and surface roughness were respectively obtained as quadratic functions to obtain the minimum value and optimal cutting conditions. The values from this formula and the experimental values were compared. As a result, this study makes and establishes the basis to prevent environmental pollution caused by the use of coolant and to replace it with ADL (Aerosol Dry Lubricant) machining that uses a very small amount of vegetable oil with high pressure.

생체용 마그네슘 합금은 전연성 부족과 열에 의한 팽창률 변화가 심하여 2mm 이하의 판재를 만드는 것이 매우 어려움 문제이다. 이를 해결하기 위해 압연 방식, 세이퍼 방식, 밀링 방식 등의 다양한 방법이 존재할 수 있다. 압연 방식을 적용하여 실험을 진행하였으나 Mg 합금은 전연성, 취성의 문제로 인해 파괴되는 현상이 발생하였다. 그리고 세이퍼 방식은 가공시 충격이 발생하는 단속절삭이기 때문에 표면에 자국이 남게 되고 시험편이 휘어지는 현상이 발생하는 문제가 발생하였다. 최종적으로 밀링 방식으로 전환하여 가공실험을 수행해 본 결과 매우 만족할 만한 결과값을 얻게 되었고, 이 결과는 절삭조건을 절삭회전수 1000rpm, 이송속도 127mm/rev, 절삭깊이 0.5mm로 엔드밀 사용하여 가공하였을 때 Ra = 0.44㎛의 표면거칠기값을 얻게 되었다. 본 논문에서는 생체 마그네슘 합금재료로 미소판재를 가공하였을 때 매우 좋은 표면을 유지하며 2mm 이하의 미소 두께를 지속적으로 가공이 가능하도록 하였으며, 다양한 절삭조건, 2날과 4날 엔드밀 날수 변화 등을 통해 최적의 가공조건을 알아보는 실험을 진행하였다.

Intertidal mud crab (Macrophthalmus japonicus) is an organism with a hard chitinous exoskeleton and has function for an osmotic control in response to the salinity gradient of seawater. Crustacean exoskeletons change in their natural state in response to environmental factors, such as changes in the pH and water temperature, and the presence of pollutant substances and pathogen infection. In this study, the ecotoxicological effects of irgarol exposure and heavy metal distribution were presented by analyzing the surface roughness of the crab exoskeleton. The exoskeleton surface roughness and variation reduced in M. japonicus exposed to irgarol. In addition, it was confirmed that the surface roughness and variation were changed in the field M. japonicus crab according to the distribution of toxic heavy metals (Cd, Pb, Hg) in marine sediments. This change in the surface roughness of the exoskeleton represents a new end-point of the biological response of the crab according to external environmental stressors. This suggests that it may affect the functional aspects of exoskeleton protection, support, and transport. This approach can be utilized as a useful method for monitoring the aquatic environment as an integrated technology of mechanical engineering and biology.

In the field of length, a gauge block is one of the representative gauges used as a standard for length. The main management items of the gauge block are central length, flatness, parallelism, hardness, and surface by visual inspection. The surface of the gauge block may wear over time due to repeated wringing. This phenomenon may deteriorate the precision accuracy and affect the reliability of the measurement results. In this study, the parameters of the surface roughness of the gauge blocks used repeatedly for about 10,000 hours were analyzed. The paired t-test of population mean difference was compared by using the gauge block that has changed over the years as a preliminary experiment and the gauge block with little frequency of use for less than 1 year as the reference value.

Ti-6Al-4V alloy has a wide range of applications, ranging from turbine blades that require smooth surfaces for aerodynamic purposes to biomedical implants, where a certain surface roughness promotes biomedical compatibility. Therefore, it would be advantageous if the high volumetric density is maintained while controlling the surface roughness during the LPBF of Ti-6Al-4V. In this study, the volumetric energy density is varied by independently changing the laser power and scan speed to document the changes in the relative sample density and surface roughness. The results where the energy density is similar but the process parameters are different are compared. For comparable energy density but higher laser power and scan speed, the relative density remained similar at approximately 99%. However, the surface roughness varies, and the maximum increase rate is approximately 172%. To investigate the cause of the increased surface roughness, a nonlinear finite element heat transfer analysis is performed to compare the maximum temperature, cooling rate, and lifetime of the melt pool with different process parameters.

The development of IOT technology and artificial intelligence technology is promoting the smartization of manufacturing system. In this study, data extracted from acceleration sensor and current sensor were obtained through experiments in the cutting process of SKD11, which is widely used as a material for special mold steel, and the amount of tool wear and product surface roughness were measured. SVR (Support Vector Regression) is applied to predict the roughness of the product surface in real time using the obtained data. SVR, a machine learning technique, is widely used for linear and non-linear prediction using the concept of kernel. In particular, by applying GSVQR (Generalized Support Vector Quantile Regression), overestimation, underestimation, and neutral estimation of product surface roughness are performed and compared. Furthermore, surface roughness is predicted using the linear kernel and the RBF kernel. In terms of accuracy, the results of the RBF kernel are better than those of the linear kernel. Since it is difficult to predict the amount of tool wear in real time, the product surface roughness is predicted with acceleration and current data excluding the amount of tool wear. In terms of accuracy, the results of excluding the amount of tool wear were not significantly different from those including the amount of tool wear.

CFRP materials are one of the excellent lightweight materials of the next generation. Also, the CFRP materials are attracting materials form the global automotive industry. However, CFRP material is made at a high cost of carbon fiber as raw material, so research of production cost reduction into the development of molding equipment and molding process technology related to mass production for the automotive industry is actively administered. Generally, CFRP is known as a high corrosion-resistant material in which no corrosion occurs. However, the investigation of the relationship with corrosion behavior on the roughness of CFRP's conditions according to is rarely studied. In this paper, the surface roughness has conducted three surface roughness conditions given arbitrarily, and the electrochemical evaluation has performed under the electrolysis conditions of 5 wt.% NaCl, which is the salt-water test condition of vehicle parts in automotive industries. Moreover, the samples were analyzed with changes of microstructures by FE-SEM and chemical composition's variation by EDS before and after electrochemical evaluation.

As product diversity increases and product life cycle gets shorter, lead time reduction and manufacturing cost saving of die & mold are getting important in machinery, automotive, and electronics industries. To develop a novel free-machining die & mold steel, we try to modify the chemical compositions of AISI P20 mold steel by adding boron, nitride, and sulfur. After making three types of mold steels which are base metal of AISI P20 mod., boron and nitrogen added, and boron, nitrogen, and sulfur added to the base metal. Milling tests are carried out using TiN, TiCN, and TiAlN coated WC end-mills under various cutting conditions. Boron and nitrogen added steel machined by TiN coated tool shows the most excellent tool wear and surface roughness characteristics. The results might come from BN inclusions in base metal acting as a stress concentration source and lowering strain resistance during cutting process. The relationship between tool wear and surface roughness are also discussed including feed rate effects.

Because of the economy and construction simplicity, Jacketing method has been widely used in strengthening RC columns in Korea. Although some studies on the compressive performance of jacketed elements have been conducted by experimental or analytical methods, the correlation between the axial performance and the surface roughness of the jacketed element has not been performed. In this study, the surface roughness of chipped surface of old element was measured and the compressive strength test was performed to evaluate the surface roughness and jacketed effects. The test results are as follows; (1) Compressive strength was improved by 1.8%∼3.1% by chipping, (2) Compressive performance of the jacketed elements reduced to 85%∼93% of theoretical values, (3) As a result of analysis of correlation between surface roughness index and axial strength, surface roughness index based on the wave length was more effective than existing methodology for evaluation surface roughness.