Glassy carbon (GC) has superior properties such as high corrosion resistance, heat resistance, and low adhesion to glass materials in a glass molding process (GMP). In addition, the demand for GC molds is increasing in various industries that require high precision of glass parts. However, GC is a difficult-to-machine material with high hardness and brittleness. Electrical discharge machining (EDM) can machine GC regardless of its strength or hardness. In this study, tungsten carbide (WC-Co) electrode was fabricated by wire electrical discharge grinding (WEDG). Characteristics of EDM of micro holes on GC were then analyzed. As capacitance and voltage increased, material removal rate (MRR) increased while machining time tended to decrease. However, at low voltages, short circuit and secondary discharge occurred, which increased the electrode wear rate (EWR). As a result, a D-shaped electrode that could prevent short circuit and debris accumulation was fabricated and a micro hole array was machined.
CNN is one of the deep learning technologies useful for image-based pattern recognition and classification. For machining processes, this technique can be used to predict machining parameters and surface roughness. In electrical discharge machining (EDM), the machined surface is covered with many craters, the shape of which depends on the workpiece material and pulse parameters. In this study, CNN was applied to predict EDM parameters including capacitor, workpiece material, and surface roughness. After machining three metals (brass, stainless steel, and cemented carbide) with different discharge energies, images of machined surfaces were collected using a scanning electron microscope (SEM) and a digital microscope. Surface roughness of each surface was then measured. The CNN model was used to predict machining parameters and surface roughness.
Recently, the demand for micromachining of hard materials has been increasing. Machining microholes, grooves, and structures in hard materials such as tungsten carbide is very difficult. In this study, the machining characteristics of a microdisk tool for microgroove machining of tungsten carbide were studied. Microtools made of polycrystalline diamond (PCD) were fabricated using wire electrical discharge grinding (WEDG) to machine high-hardness tungsten carbide. Rectangular and V-shaped disk tools were fabricated by WEDG with controlled wire paths. In the micro grooving of tungsten carbide, the effects of capacitance and feedrate on the surface roughness of microgrooves and the wear of disk tools were studied. As the capacitance and feed rate decreased, the surface roughness decreased and no significant wear was observed in the PCD tool. However, an increase in tool edge radius of several micrometers was observed.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
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Silicon carbide (SiC) is chemically stable, highly heat-resistant, and resistant to thermal shock. SiC having excellent characteristics in a high temperature and high voltage environment is used in high-power semiconductors, highprecision mechanical devices, optical components, etc. As it is used in various industries, there is a growing demand for processing fine holes or grooves in silicon carbide. In this study, micro holes and grooves were machined on 4HSiC and sintered SiC using electrical discharge machining (EDM). Silicon carbide which has very high hardness can be easily processed by EDM as compared with mechanical processes. As a tool material, a polycrystalline diamond (PCD) which has high wear resistance was used and a micro tool of a diameter of 100 μm was fabricated by wire electrical discharge grinding (WEDG). In the EDM of SiC, the machining characteristics such as surface roughness, discharge gap, and tool wear were investigated.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
Prediction of Machining Conditions from EDMed Surface Using CNN Ji Hyo Lee, Jae Yeon Kim, Dae Bo Sim, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(11): 865. CrossRef
Microchannels machining can be used to make micro molds for microfluidic chips. The fluid flow in the channel can be controlled, by changing the cross sectional shape of the channel. V-shaped channels with a specific angle are not easily made with the etching process. This study presents the mechanical machining of microchannels of V-shaped cross section, on cemented carbide (WC-Co). In this study, to reduce tool wear in the process of machining, the micro conical tool was fabricated using polycrystalline diamond (PCD). The tool wear of the conical tool and form accuracy of channels, were investigated during V-shaped microchannel machining.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
SMEs encounter many difficulties in integrating and operating various information systems introduced to build smart factories. The source of this difficulty comes from integrated management of data interface between information systems. This research proposes a data interface middleware that can operate and manage various data interfaces between information systems in an integrated manner. First, this study identifies the types of information systems and operational information needed to build smart factories and analyzes the ways of data interface and requirements suitable for the manufacturing environment of SMEs. Structure and detailed functions of the data interface middleware are designed based on the analysis results. The proposed data interface middleware consists of the function layer, engine layer, and DB layer. The function layer is a set of functions for operating the middleware, and the engine layer comprises core engines for executing the functions. The DB layer manages all information that gathers when the data interface is executed. We applied the proposed middleware to connect data between the existing ERP and newly introduced smart factory package software in SMEs. Application results show that the associated data types are consistent in the two systems, and accuracy of the data parsing process is reliable.
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Silicon carbide (SiC) has been used as a material for semi-conductor, molds, and micro-electro-mechanical systems (MEMS) because of its superior thermal, electrical, and mechanical properties. However, micro machining of SiC is very challenging due to its hardness and brittleness. This paper presents an experimental study of micro hole drilling of SiC. In this study, polycrystalline diamond (PCD) was used as a tool to overcome the hardness of SiC. The micro PCD tool with a diameter of 110 μm was fabricated by micro electrical discharge machining (EDM). Micro drilling was conducted with varying machining parameters such as tool rotational speed and feed rate. Effects of surface roughness of the tool and lubrication method were also investigated.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
Prediction of Machining Conditions from EDMed Surface Using CNN Ji Hyo Lee, Jae Yeon Kim, Dae Bo Sim, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(11): 865. CrossRef
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
EDM Using Wire Electrical Discharge Milling Electrode Do Kwan Chung Journal of the Korean Society for Precision Engineering.2022; 39(1): 21. CrossRef
Micro tool fabrication is crucial in micro machining. Wire electro-discharge grinding (WEDG) is one of the popular methods applied to fabricate micro tools used for micro electrical discharge machining (EDM), electrochemical machining (ECM), and ultrasonic machining (USM). WEDG can machine micro tools or features regardless of workpiece hardness. In WEDG, however, the machining speed is relatively low and the discharge gap control is not easy. In this study, the micro mechanical machining using the polycrystalline diamond is introduced to fabricate the micro cylindrical tool or micro pin of the tungsten carbide. This method demonstrates the possibility of applying ductile machining of tungsten carbide without brittle fracture or cracks. This paper compared the machining characteristics such as material removal rate and surface roughness with the PCD-mechanical machining and WEDG.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
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High aspect ratio-arrayed micro structures are used in various fields such as semiconductor packaging, biochip, nano composite material and superhydrophobic surface. Micro electric discharge machining (MEDM) has an advantage, in that hard material can be easily removed regardless of mechanical properties of the material. Reverse micro electric discharge machining (REDM) can process various shapes and arrayed features. In this study, REDM was used for fabrication of a micro tool of eccentric shape, and was assisted with vibration to improve machining efficiency. The bored plate made of brass, was prepared as a tool for REDM. Because of the shape of the tool, concentration of debris occurs and increases machining time. The effect of vibration-assisted MEDM on emission of debris and machining time was described for the range of 2 - 6 μm amplitudes and of 100 - 900 Hz frequencies. As a result, vibration applied on machining reduces approximately 55% of machining time.
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Micro Hole Machining Characteristics of Glassy Carbon Using Electrical Discharge Machining (EDM) Jae Yeon Kim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2025; 42(4): 325. CrossRef
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Machining Characteristics of Micro EDM of Silicon Carbide Ju Hyeon Lee, Chan Young Yang, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 131. CrossRef
Micro Drilling of Single Crystal SiC Using Polycrystalline Diamond Tool Ui Seok Lee, Chan Young Yang, Ju Hyeon Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2021; 38(7): 471. CrossRef
Micro Pin Fabrication of Tungsten Carbide Using Polycrystalline Diamond Joo A Park, Ui Seok Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2020; 37(11): 791. CrossRef
Quality management is very important to ensure competitiveness through good quality products. It is performed in all fields of manufacturing. While small and medium-sized manufacturing enterprises have introduced quality management systems for systematic quality control, the effectiveness of such systems has been very low. To overcome this problem, it is necessary to develop and introduce a quality management system that can reflect uality work characteristics of individual SMMEs and support quality work on a company-wide basis. This study constructed a quality management platform for all SMMEs by first gathering common functions essential to perform quality work and then created a customized quality management system for each company by adding optional functions reflecting characteristics and requirements of the individual company. The quality management platform is designed in detail through a series of processes such as deriving functions that users want, redefining them, organizing the information flow, and designing the DB and user interface. It is structured in three steps involving DB layer, functional layer, and service layer. Its effectiveness was demonstrated by constructing and operating the customized quality management system applied to actual companies.
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The fabrication of a micro column array using micro EDM (Electrical Discharge Machining) and eccentric tools was presented. With the eccentric tools, micro columns can be easily machined only by feeding the tool vertically, as is the case in mechanical drilling. Moreover, the tool electrode rotates very fast, which is helpful to flush dielectric fluid in the EDM. In this paper, four eccentric tools were machined, and a micro column was machined in a few minutes. Finally, a hundred micro columns with 200-300 μm in a diameter were machined on a metal plate. In this study, vibration-assisted EDM was introduced to improve the machining rate in the fabrication of eccentric tools. Also, the design parameters of eccentric tools were discussed.
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Study on Micro Grooving of Tungsten Carbide Using Disk Tool Min Ki Kim, Chan Young Yang, Dae Bo Sim, Ji Hyo Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 123. CrossRef
Micro Drilling of Single Crystal SiC Using Polycrystalline Diamond Tool Ui Seok Lee, Chan Young Yang, Ju Hyeon Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2021; 38(7): 471. CrossRef
Rapid manufacturing of large diameter Cu micropillars by micro-electrical discharge machining and focused ion beam Ui Seok Lee, Bo Hyun Kim, Sang-Min Kim, Chung-Seog Oh The International Journal of Advanced Manufacturing Technology.2021; 113(3-4): 1153. CrossRef
Electrochemical micromachining (ECM) processes use anodic dissolution of metals to remove workpiece materials. ECM processes including electrochemical milling and drilling, wire electrochemical machining and electrochemical etching offer a better alternative in manufacturing complex features and nano-pattern surface. Electrochemical discharge machining (ECDM) uses high temperature of electrochemical spark, which is suitable process for micro machining of hard brittle and non-conductive materials such as glass and ceramic. In this paper, the state of the art in electrochemical micro machining technologies was reviewed. Also, some hybrid machining methods are introduced.
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Machining Characteristics of Micro EDM of Silicon Carbide Ju Hyeon Lee, Chan Young Yang, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2024; 41(2): 131. CrossRef
Micro Pin Fabrication of Tungsten Carbide Using Polycrystalline Diamond Joo A Park, Ui Seok Lee, Bo Hyun Kim Journal of the Korean Society for Precision Engineering.2020; 37(11): 791. CrossRef
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In this paper, we propose a simple and low-cost fabrication method of polymer microlens using solvent-vapor-assisted reflow (SVAR). Metal molds for replication of polymer were fabricated using micro milling and the cylindrical shape of polymer was imprinted using hot-embossing process. The cylindrical shape of polymer was changed to hemispherical lens shape by SVAR. The characteristics of fabricated microlens were evaluated according to the condition of SVAR such as temperature and time. The focal length of polymer microlens could be controlled more easily in low-temperature and long-time condition than in high-temperature and short-time condition. That is, the level of concentrated light to focal point could be improved through the control of temperature and time. Also, we confirmed that toluene was more appropriate solvent than acetone in fabrication of PMMA polymer microlens using SVAR.
Today, there are lots of progresses in the field of lens researches, especially in the microlens fabrication. Unlike normal lenses, microlens has been widely used as a role of improving the performance of photonic devices which increase the optical precision, and also used in the fields of the display. In this paper, polymer microlenses with 300 μm diameter were replicated through hot-embossing from nickel mold which was fabricated by micro-EDM. After hot-embossing process, the polymer microlenses have a rough surface due to the crater formed by micro-EDM process, which is projected onto the surface of the lenses. The surface of polymer microlenses was polished using solvent vapor to improve the surface roughness of the microlenses without changing their shape. In the experiment, the surface roughness was improved with the processing time and vapor temperature. Also, the roughness improvement was greatly affected by the solubility difference between polymer and solvent.
Micro cutting of titanium alloy by polycrystalline diamond (PCD) tools was studied. Micro electro discharge machining (MEDM) was used to fabricate customized micro shaping tools from PCD blank. The tool was used to machine micro grooves on Ti alloy and the effects of depth of cut and machining length on tool wear, burr and surface roughness were studied. The shaping tool has cutting edge of a few μm. The crater size of the tool surface was increased with increasing capacitance of EDM machining conditions, which was used to control the surface roughness of the machined micro grooves.
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