The development of the lightweight sandwich plate with periodically repeated cores is one of hot issues to reduce the weight of the part. The behavior of the sandwich plate under static and dynamic loads is greatly influenced by the design of the cores. The aim of this paper is to investigate the effects of the corrugated angle on low velocity impact characteristics of the lightweight sandwich plate with corrugated cores. The corrugated core with the fold surface is designed to improve the joining characteristics between cores and skin sheets. The corrugated angle of the corrugated cores ranges from 45o to 90o. Specimens are manufactured from the fused deposition modeling (FDM) process. The characteristics of the fabricated specimen are investigated. Impact experiments are performed using a drop impact tester with a stretching type of fixture and the hemispherical nose of the impact head. From the results of the experiments, the influence of the impact energy and corrugated angle on the failure pattern of the lightweight sandwich plate is examined. The effects of the corrugated angle on critical impact energies for different failure patterns are investigated. Finally, the failure map of the lightweight sandwich plate with corrugated cores is estimated.

In this work, casting processes, such as filling and solidification, were simulated in order to accurately predict volume shrinkage defects in large-sized sand gravity casting. Turbulent flow of melted materials and a difference of solidification speed can cause volume shrinkage defects. In order to solve this problem and to understand the phenomenon, a porous filter application was studied. Two different porosities of 10 and 20 p.p.i filters were introduced into the gating system, and in view of the results so far achieved, the defect was dramatically reduced by 22%, compared to that without the use of the filter.

The solenoid valve is used widely across various industries; however, solenoid valves for use in high-temperature environments have to be highly specified, such as those used in thermal power plants and steel mills. As such, we have developed a solenoid valve, using an already developed solenoid, to allow for more specific use. In this type of development method, use of 3D printing is very effective, allowing for a reduction in errors in design and production. This study includes a mathematical model of the solenoid valve. Then, the simulation from the mathematical model was performed using the AMESim (Advanced Modeling Environment for Simulation of Engineering Systems). We made a prototype valve using the simulation results and also measured the flow rate and dynamic performance.

Recently micro-nano structures has widely been reported to improve the performance of waterproof, heat isolation, sound and light absorption in various fields of electric devices such as mobiles, battery, display and solar panels. A lot of micro-sized holes on the surface of thin film provide excellent sound, or heat, or light transmission efficiency more than solid film and simultaneously nano-sized protrusions around micro hole increase the hydrophobicity of the surface of thin film because of lotus leaf effects as generally known previously. In this paper new rapid fabrication process with 355 ㎚ UV laser ablation was proposed to get micro-nano structures on the surface of thin film, which have only been observed at higher laser fluence. Developed thin micro-nano structured film was also investigated the hydrophobic property by measuring the contact angle and demonstrated the possibility to apply to water droplet separation.

Recently porous polymer has widely been applied to packaging, heat isolation, and sound absorption in various fields from the electrics to the automobiles industry. A lot of micro porosities inside foamed polymer provide lower heat conduction and lighter weight than non-porous polymer, because they involve gas or air during foaming process. In this paper experimental approaches of the UV laser micro machining behavior for Expanded Polypropylene (EPP) foamed polymer materials, which have different expansion rates, were investigated. From these results, the ablation phenomena were finally observed that the ablation is depended upon stronger photochemical than photo-thermal effect. This study will also help us to understand interaction between UV laser beam and porous polymer.

This paper presents an evaluation of efficiency on glass precision machining by using abrasive water-jet machine. In this study, problems of conventional water-jet machining are examined experimentally and are analysized numerically. Especially, the reason of whitening on the machined surface of biochip glass is determined. It is found that the mass flow rate of abrasive input and transverse speed of water-jet are key parameters to control the direct machining of micro hole and channel on a glass substrate. Based on results of experimental analysis, possibility of direct fabrication of micro holes and channels on a glass substrate is successfully confirmed.

High-pressured jetting is now widely used in the advanced cutting processes of polymers, metals, glass, ceramics and composite materials because of some advantages such as heatless and non-contacting cutting. Similarly to the focused laser beam machining, it is well known as a type of high-density energy processes. High-pressured jetting is going to be developed not only to minimize the cutting line width but also to achieve the short cutting time as soon as possible. However, the interaction behavior between a work piece and high-velocity abrasive particles during the high-pressured jet cutting makes the impact mechanism even more complicated. Conventional high-pressured jetting is still difficult to apply to precision cutting of micro-scaled thin work piece such as thin metal sheets, thin ceramic substrates, thin glass plates and TMM (Thin multi-layered materials). In this paper, we proposed the advanced high-pressured jetting technology by introducing a new abrasives supplying method and investigated the optimal process conditions of the cutting pressure, the cutting velocity and SOD (Standoff distance).

UV laser ablation of polyimide is a combination of photochemical and photothermal mechanism. Photochemical mechanism is that molecular bonds are broken by photon energy and photothermal is evaporation and melt expulsion. When the laser processing, the etching depth needs to be calculated for prediction of processing result. In this paper, in order to predict the laser etching depth of poly imide by UV laser with the wavelength of355nm, the theoretical model which includes both the photothermal and the photochemical effect was introduced. The model parameters were obtained by comparing with experimental results. The 3rd harmonic Nd:YVO₄ laser system was used in the experiment. From these experimental and theoretical results, the laser ablation of a polyimide was verified to achieve the highest quality microstructure.

Usually nanosecond pulsed laser processing of metal is mainly affected by the thermal ablation. Many studies of the theoretical analysis and modeling to predict the laser ablation of metal are suggested on the basis of the photothermal mechanism at higher laser fluence. In this paper, we investigate the etching depth and laser fluence of laser ablation of copper foils and propose the simplified SSB Model(Srinivasan-Smrtic-Babu model) to study the photothermal effect of nanosecond pulsed laser ablation. The experimental results show that the photothermal ablation of the 355㎚ DPSS Nd:YV04 laser is useful to process the copper thin foils.

High-speed machining (HSM) with excellent quality and dimensional accuracy has been widely used to create 3D structures of metal and plastics. However, the high-speed machining process is not suitable for the rapid realization of 3D thin-walled product because it consumes considerably long time in fixturing process of a work piece. In this paper, an effective rapid manufacturing process is proposed to fabricate 3D thin-walled products directly using HSM, phase change filling and ultrasonic welding. The filling process is useful to hold the thin-walled product during the machining step. The ultrasonic welding process is introduced to make one piece product from two piece parts that are machined by HSM and filling process. The proposed rapid manufacturing (RM) process has been shown that the RM process enables to fabricate the 3D thin-walled products using ABS plastics and aluminum metals from 3D CAD data to functional parts.

To provide the various machining materials with excellent quality and dimensional accuracy, high -speed machining is very useful tool as one of the most effective rapid manufacturing processes. However, high-speed machining is not suitable for micro scale thin-walled structures because of the lack of the structure stiffness to resist the cutting force.
A new method which is able to make a very thin-walled structure rapidly will be proposed in this paper. This method is composed two processes, high-speed machining and filling process. Strong workholding force comes out of the solidification of filling materials. Low-melting point metal alloys are used in order to minimize the thermal effect during phase change and to hold arbitrary shape thin-walled structures quickly during high-speed machining. To verify the usefulness of this method, we will show some applications, for examples thin-wall cylinders and hemispherical shells, and compare the experimental results to analyze the dimensional accuracy of typical parts of the structures.