In this research, a new piston pinhole boring machine for simultaneous 3-axis machining using linear motor and tilting unit is developed. We propose a new method that combines the linear motor and tilting unit to overcome the limitations of existing techniques. By using the linear motor, we suggest oval machining of piston pin holes. The horizontal reciprocating motion of the linear motor allows for oval machining, creating horizontal or vertical ovals on the pin holes based on the spindle tool's rotation angle. For profile machining of piston pin holes, we propose the use of a tilting unit that converts servo motor motion into linear motion. The vertical motion of the tilting unit enables profile machining, allowing the spindle tool connected to it to translate vertically during spindle rotation and shape the pin holes. To ensure simultaneous oval and profile machining, we suggest channel synchronization, separating the oval and profile machining channels. Synchronizing these channels enables both oval and profile machining to be performed simultaneously on the pin holes. In summary, this research aims to develop a piston pinhole boring machine that effectively utilizes the linear motor and tilting unit for accurate and productive pin hole machining, achieving simultaneous 3-axis machining.

In this research, a new structure of an asymmetric piston dedicated machining center is developed. By applying 2 linear motors in this machine, the slide unit structure could be simplified by comparing to the ball screw method, resulting in easier maintenance of the machine and enabling simultaneous machining in 2 axes and high-speed precision machining. In addition, a dedicated HMI for the asymmetric piston is developed to support efficient operation by workers, allowing them to verify product quality and take necessary actions. It is confirmed that by fully utilizing control libraries and productive programming languages, immediate response to future demands could be achieved. Through speed control loop performance testing, it is confirmed that applying feedforward function could improve the response speed, control accuracy, and stability of the speed control loop. The application of polynomial interpolation and Newton interpolation in the actual machining of asymmetric pistons confirmed the achievement of dynamic machining precision at high speeds. The developed machine and HMI are expected to contribute significantly to the efficiency, productivity, and improvement of product quality in the machining of asymmetric pistons.

This study was to develop a piston rod made of SiC by applying a sintering treatment after press molding in order to replace the imported piston rod used in the past. As a result of evaluating the mechanical properties of the developed piston rod, the following conclusions were obtained. The surface roughness value of the piston rod made of silicon carbide was 0.950Ra, and the surface Vickers hardness value was 19.94GPa. As a result of XRD analysis of the surface of the prototype piston rod, the main crystalline phase was 6H-SiC, and the crystalline phases of 4H-SiC and α-SiC were existed. In addition, a trace amount of SiC was detected. As a result of SEM observation of the piston rod surface of the prototype, a number of large porosity were observed. As a result of measuring the surface hardness of the piston rod made of SiC, it showed 70% of the physical properties compared to imported products.

In the automotive industry, the platinum titanium anodes (Pt/Ti anode) play a significant role in electroplating of chromium coating on the vehicle’s shock absorber piston rod. In this paper, the structure of Pt/Ti anode was designed to obtain high quality and save time for the electroplating process. The structure of anode was designed in 2D & 3D modeling and analyzed by CATIA and ABAQUS program, respectively. The structural modeling of the anode was analyzed and carried out using a finite element method (FEM) by applied various loads. The manufacture anodes were installed in an electroplating bath in order to test the efficiency of chromium coating on shock absorber piston rod and safety of anode structure. The results presented indicate that the structural analysis is safe after applied loads due to the allowable stress is higher than the maximum equivalent stress about 4 times, and the chromium coating test obtained high-efficiency results.

In this analysis, the analytical model was verified through the normal mode analysis of the piston for the 2.9 liter IDI (indirect injection) engine. Heat transfer analysis was carried out by selecting two cases of applied temperature using the validated model. The first case was a condition of 350℃ on the piston upper surface and 100℃ on the piston body and inner wall. In the second case, the conditions were set to give a temperature of 400℃ on the upper surface of the piston and 100℃ on the piston body and the inner wall. In addition, the temperature distribution due to heat transfer was obtained for the pistons with boundary conditions of two cases, and then the thermal stress distribution due to thermal expansion was obtained using the input. Using this analysis result, the thermal stress caused by thermal expansion due to the thermal conduction of the piston is examined and used as the basic data for design.

This study is a study on the cracking of the main piston surface which is generated in the injection molding machine to generate mold force. The main piston machining process consists of high frequency heat treatment, grinding and super finishing after lathe turning. Scale, defect size, and fracture texture were observed for four cracks on the surface of the piston during the tempering process after high frequency heat treatment using a metallurgical microscope. In this study, it was confirmed that the cracked structure of the piston structure was ferrite and pearlite structure. It was confirmed that cracks progressed to 480 ㎛ and scale layer of 3 ㎛ or less. Surface hardening layer and hardness were min 2.0mm/HRc 58±2 spec 1.6 mm/HRc 56.5~57.5 In addition, cracks on the surface of the piston appear perpendicular to the rolling process. Therefore, it can be assumed that the crack occurred in the low temperature tempering process at 200°C or less after the high frequency heat treatment, not the material defect. Therefore, the temperature should be maintained at 200°C or higher during tempering after high-frequency heat treatment, and the cracking defect on the surface of the piston can be prevented by setting the feed rate to 1.3 mm/s or less during heat treatment.

왕복동식 압축기에서 피스톤과 커넥팅로드는 중요한 부분이다. 이러한 주요부에 기계적 부하가 과도하게 가해지면 해당 기부 속이 손상될 수 있으며, 교체하기도 쉽지 않고 비용도 많이 든다. 따라서 내구성과 수명에 영향을 미치는 요인을 분석할 필요가 있다. 본 연구의 주요 목적은 피스톤과 커넥팅로드의 최대 응력 집중 위치를 확인하는 것이다. 이를 위해 설계된 공기압축기의 작업 공정의 동적 계산을 기반으로 피스톤 및 커넥팅로드의 응력 분석을 수행하였다. 공기압축기의 피스톤과 커넥팅로드의 3 차원 모델을 따로 설계하고, 이러한 부품들의 유한요소 해석은 수치해석적인 근사해법을 사용하였다. 피스톤은 열 경계 조건 없이 크랭크 샤프트의 각도에 따라 압 력 부하를 받는다. 시뮬레이션 결과는 피스톤과 커넥팅로드의 응력 집중 위치와 그 값을 예측하고 추정할 수 있다. 그 결과 크랭크 각도 135°와 225°에서 피스톤은 190MPa, 커넥팅로드는 123MPa 이상의 최대 등가응력이 나타났으며 이는 인장 항복강도 이하의 값이다. 또한, 커넥팅로드와 피스톤에 계산 된 안전 계수는 1보다 높게 나타났다. 더욱이, 이러한 결과는 왕복동 공기압축기 제작사에 피스톤 및 커넥 팅로드를 설계함에 있어서 최적화를 위한 참고 자료로 활용 될 수 있다.

In this study, factors analysis is performed for reducing friction in elevation motion of a large television stand over 50 inch. The first study is for specification decision and volume compensation experiment as an apparatus for compensating of the volume of the cylinder is compressed as the volume of piston rod. The second study is for optimized piston structure development by comparison pipe orifice and labyrinth orifice. Consequently, the result of total consideration in stability problem and performance of volume compensation for specification decision and volume compensation experiment is determined the final speculation of hollow rod ∅8 x ∅4 and riveting system. and the labyrinth orifice is not founded that of the Ø0.4~0.6 orifice both tests on 300 mm intervals.

In this study, The first study attempted to reduce the frictional force the gas seal lip technology. The second study is for specification decision and volume compensation experiment as an apparatus for compensating of the volume of the cylinder is compressed as the volume of piston rod. Consequently, in the gas seal lip technology, the outer-in diameter of ∅20 x ∅8 in the test result of hollow rod is revealed more proper if the weight of 50 inch television assumed as 30 kg. and the result of total consideration in stability problem and performance of volume compensation for specification decision and volume compensation experiment is determined the final speculation of hollow rod ∅8 x ∅4 and riveting system. The spring constant(K) showed an excellent value above the target value of 0.01 to 0.015 N/mm.

The study for reducing friction in elevation motion of a large television stand using over 50 inches is performed in this paper. The first study attempted to reduce the frictional force the gas seal lip technology. The second study is for optimized piston structure development by comparison pipe orifice and labyrinth orifice. As the result of the first study, in the gas seal lip technology, the outer-inner diameter of Ø20 × Ø8 in the test result of hollow rod is revealed more proper if the weight of 50 inch television assumed as 30. As the result of the second study, the optimized piston structure development through experiment is fixed orifice specification as labyrinth orifice because pipe orifice is founded slip up/down phenomenon of the Ø0.4~1.0 orifice and the labyrinth orifice is not founded that of the Ø0.4~0.6 orifice both tests on 300 mm intervals.

In this study, factors analysis is performed for reducing friction in elevation motion of a large television stand over 50-inch. The first is a pipe type cross-section control for accurate position control of the piston rod. Here it was compared with the pipe type and labyrinth type orifice cross-section. The second study is for specification decision and volume compensation experiment as an apparatus for compensating of the volume of the cylinder is compressed as the volume of piston rod. Consequently, in the orifice cross section study between pipe type and labyrinth type through CAE and experimental consideration, cross section of labyrinth type orifice is preferred for reducing of friction. The result of total consideration in stability problem and performance of volume compensation for specification decision and volume compensation experiment is determined the final speculation of hollow rod φ8×φ4 and riveting system.

The suspension system of special tracked vehicle is using hydraulic piston pump to adjust track tension and control vehicle position change. During operation of vehicle on rough field, failure of suspension control was occurred due to the piston pump failure. In this study, investigation was performed to analyze the cause of hydraulic piston pump failure. Main reason of piston pump failure is strong peak pressure and insufficient structural safety of shoe. The static stress analysis considering peak pressure was performed to find the weak point of the shoe. From the result, it is confirmed that pass hole of lubrication is the weakest point. Improved piston shoe shows 27% decrease in maximum stress and satisfies the design target which is less than 40% of stress margin.

ㅊBy controlling the piston speed of the gas spring applying to the digital television stand application of the gas spring, a user can operate the elevation when the gas spring is working under long stroke(200～300 mm, the TV elevation displacement). According to stroke, by some devices with the problem rising from between the difference of external forces, the emotional quality in television elevational function is realized. The piston speed control technique is investigated to perform this experiment piston flow analysis and flow rate control for precise tubular cross section and propose a piston structure for elevation action. This study is for the development of the gas spring of the large size television stand with 50 inch over. In the gas spring development of elevation working, a device to compensate for the volume of the cylinder is generated as much the volume of the piston rod. As this study result, at the development of working gas spring, the hollow shaft is more favorable than the solid one in the apparatus to compensate for the cylinder volume generated.

The mechanical properties and microstructures of Aluminum 6056 alloys were investigated for their use in the fabrication of a piton block. The EN-AW6056 alloys exhibited a tensile strength of 375 MPa for a solution treatment temperature of 550 oC for 2 h followed by an aging treatment at 190 oC for 4 h. The microstructures of the heat treated specimen showed that the Mg2Si phase with a size of 3~5 um was dispersed throughout the aluminum matrix when the heat treatment was done. Moreover, in order to identify the forgeability of the specimen, upsetting tests were done. For up to 80 % of the upsetting ratio, the specimen maintained its original shape, and at above 80 % of the upsetting ratio, the specimen underwent crack development. The specimen was successfully forged without any defects with the examined material conditions. The material conditions together with the forging conditions are discussed in terms of the microstructures and mechanical properties.