Sei-Hwan Kim

Study on the Die Design ＆ Manufacture for Electric motor Terminal of HEV

Environment-friendly vehicles using electricity vary, but electrical motor, battery, BMS, inverter, converter, etc., are the core technologies. This research paper deals with the die design and manufacture of the terminal part, one of the key parts of the electrical motor. This research sought to introduce problems such as assembly defect, correction of the R-part shape, correction of the location between holes, etc., in the process of manufacturing the electrical motor terminal die and to produce final products by correcting the problems that were tackled herein.

A Study on the Automation of Manufacturing and production Process for Press Die

The automation of the machining and manufacturing process of press die is designed to shorten the working time by avoiding unnecessary repetitive works and to obtain subject articles with standard quality. Automation as used in this paper includes 3-D die design, machining center, wire-cut electrical discharge machining, and drawing works. This paper deals with research work on the automation of the machining and manufacturing process of the press die after 3-D die design using the Irp bracket for the control box sensor. The research was conducted under the same setting as that of die design.

A Study on the 3D Die Design and Tryout for the Inverter Shield Shell

This study aims at the design and production of the progressive die of an inverter shield shell that blocks electromagnetic waves when a hybrid or electric automobile generates high frequency. The blank layout includes 11 processes in total and involves a 3D die design. The die produced in the manner above goes through the tryout in the second stage, and then the simplified die that has been imported from Japan is replaced with the progressive die in the mass production of inverter shield shells, which contributes to prime cost reduction and productivity improvement.

A Study on the Production Method Improvement of LED Luminary Fixtures to Substitute for Fluorescent Lamps

This paper is conducted to improve the production method for LED (light-emitting diode) luminary fixtures which are a substitute for fluorescent lamps. LED luminaries have been conventionally manufactured with 6 process stages (laser cutting → bending → plating → signed-pin machining → spring plating → assembly). However, large quantity LED luminaries are required at present, causing cost increases in the existing production method. There is no way of meeting a price affordable for customers, thus dedicated die has been fabricated to achieve productivity and quality improvement as well as cost reduction. In this study, an investigation was performed on production method improvement after fabricating a dedicated die to produce LED luminary fixtures, which are expected to replace fluorescent lamps.

A Study on the Conceptual Design of High Efficiency Induction Motor and the Production of Prototype Motor for Sharing Core (Less than 37kw)

This paper is about the conceptual design and trial production of high efficiency induction motors with a sharing core capacity less than 37kw. For the preparation of a prototype induction motor set, motor design and analysis are required. The methods involved in the design and analysis for the high efficiency induction motor include basic design of motors, design of experiment, equivalent circuit method, and finite element method. Among these, design of experiment can be analyzed by dividing it into optimum design, key parameters, optimum areas, etc. Through the results and analysis of the design, motor characteristics are analyzed and their efficiencies are compared. Based on the analysis results, prototype high efficiency induction motors with a sharing core capacity less than 37kw (5.5kw, 7.5kw, 11kw, four 15kw poles, and six 11kw poles) are produced.

A Study on the 3D Die Design and Tryout of High Pressure Fuel Injection System Parts for Diesel Vehicles

High pressure fuel injection system was originally designed for cold forging as a domestic project, and now its development for the progressive die is in progress as well due to its prime cost and productivity. Accordingly, this study aims to develop a strip layout for the mass production of high pressure fuel injection system parts for diesel vehicles in application to progressive dies, not forged methods, in order to secure satisfactory prime cost and productivity. As a result of carrying out the 3D die design and tryout installation on the press, the production cost for high pressure fuel injection system parts was reduced down to 1/20 of the investment for existing facilities.

A Study on the Die Life Extension and Blank Accuracy Improvement of Progressive Die for Nail Clippers Stamping

This paper is about the technology support necessary to modify the beauty care apparatus from Three Seven Corp., which has received good recognition from foreign markets but not in the domestic market since its nail clipper’s shearing face area was not constant at both sides, its angle of break was large, and its surface was rough, thereby rendering it less than a top level product. For the resolution of the issues, technical support for the tool was performed through the barrel process, performed for 24 hours after the tool received heat treatment. The Tool and Heat Treatment Technology Support Business Unit of Kongju National University helped in improving the tool’s life by 1.3 times and its die maintenance and repair cycle by 2.5 times, increasing sales by 20% and the production volume by more than 20%. Meanwhile, the defect rate has remarkably reduced from 5% to 0.1% as of this period.

A Study on the Strip Layout Design of Ez5

For the progressive notching and forming die, analyzing beforehand according to the interpretation of thin plate molding for massive production is essential. In this study, we dealt with Ez5 particularly its strip layout design based on the exported die as ordered by Japanese S automobile company`s local factory in the USA. We completed the strip layout design consisting of 13 processes by optimizing the blank layout with arrays of a single carrier with wide width drawn in 1 row. This type of die is expected to be ordered in bulk frequently and at the same time via the Internet; any company with die technology will be required to cope with such type of die.

A Study on Development of Small Motor Core Die for High Efficiency Induction Motor

The high-efficiency induction motor reduces the generation loss of conventional induction motors and saves energy with less electricity consumed, enabling the return of initial facilities investments on a shorter-term basis due to its low operation cost and allowing the extension of the life of the motor. Poscore has entered the phase of development of high-efficiency induction motor based on its experiences to date in cooperation with electricity researchers. This paper examines the development of the small motor die for the high-efficiency induction motor.

Study on the Design of Pickup Frame Strip Layout Utilizing PDW of Unigraphics NX4.0

In this thesis, the drawing was prepared for the strip layout of the pickup frame In the press die, the drawing for press layout is a major factor in determining the mass production of the product. The 3D CAD/CAM system was applied to easily correct interference factors with other parts to be mounted. This study improved the material utilization ratio to 28.49% by optimizing the blank layout and strip layout in wide-width arraying. The 3D CAD/CAM software used is Unigraphics NX 4.0, and the strip layout drawing was prepared in 12 processes.