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Highly functional materials and manufacturing technologies for automotive oil seals

June 9, 2016 by Leave a Comment

Technology overview: Automotive oil seals, mechanical elements of sealing the oil used for lubrication and drive, are considered a key part that prevents oil leakage or dust collection, and the life of a machine is largely dependent on sealing.

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In general, oil seals are applied to steering, suspension, engine, transmission, and bearing units of a vehicle, and the technology has improved the range of available temperatures for oil seals and reduced abrasion compared to the existing products, reduced weight of a car and part costs through integration of the oil sealing unit and counterpart, increased durability and life by applying engineering plastic materials to the sealing parts, and provided the oil seal module for sensing revolutions per minute by using hybrid materials of rubber and metal.
In addition, automation specific to oil seal parts and fool proof design ensured low costs and reliable quality. While there is no domestic technology for automotive oil seals, the company has successfully developed proprietary products which are currently supplied to Hyundai, Kia, Mando, ZF, Schaeffler, Chinese and Iranian OEM and parts manufacturers, gradually increasing sales from export and market share.

Industrialization: Previously, most oil seals in the domestic market were produced by joint ventures with Japan or Europe or imported from overseas manufacturers but the company has laid foundation for localization of the parts, first targeting the domestic market, and is gradually increasing exports as well. The company’s major strategy was to reduce royalties by independently developing the rubber materials for oil seals, offer diverse specifications, reduce field claims, and improve product quality.
Initially, the oil seal for steering and suspension units and bearing seal for a drive unit were promoted and supplied to finished automobile manufactures and assembly OEM in the domestic market along with CKD parts suppliers. At present, strategic partnership is under way with major parts manufacturers in the global market.

Problem-solving in industrialization: The oil seal market is dominated by a small number of global companies and it is extremely difficult for a latecomer to enter the market. In these circumstances, the company has first developed an oil seal used for a finished car comparable to the product of a major brand. By developing rubber materials for an oil seal, shapes, and manufacturing technologies, the company could secure proprietary technologies for an automotive oil seal whose performance corresponds to that of a major brand.
Particularly, the part material decides the life and performance of an oil seal, and thus the proprietary composition of the materials was considered to largely influence the future success. An optimized shape was developed through a variety of lab tests and simulation processes as well. In addition to the optimal shape, manufacturing technologies play a critical role in improving performance and life of the product also. Going through these development processes, the company has finally completed technologies related with shape design, adhesion, composition, and forming, and then obtained approval and performance certification for the developed part from finished car and global parts manufacturers.

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High-precision acceleration corrosion test chamber

June 9, 2016 by Leave a Comment

Technology overview: life reliability tests on materials, components, electronics, machinery and equipment have been conducted under various environmental conditions and most tests identify failures modes of components and materials for changes in temperature and humidity and calculate each life span and failure rate. Among life reliability fields, the salt spray test is the most typical for a corrosion test but it has impossible test conditions such as a test of a highly corrosive material, a test under other environments such as high temperature • dampness, a test on other corrosive solutions. Recently, a reliability test set close to an actual life of a component has been required and some companies and laboratories of advanced countries have secured technology that can predict and estimate the corrosive life of a https://korean-machinery.com///inquiryproduct using database by condition. The acceleration corrosion test chamber developed in this research is a device used to evaluate an acceleration corrosion test of precision control and applied as an important test device in the field of each component of automobile, components for ship and electronics components used in a severe environment. The acceleration corrosion test chamber has increased accuracy of test conditions by improving temperature • humidity changing rate of existing foreign devices. Also, by improving high • low temperature test limitations of existing devices, it has replaced foreign devices used in companies and laboratories, which made a highly reliable test possible with excellent performance and price competitiveness.

Industrialization: Since technology development has been successful after research and development for three years from 2010 to 2013, about 70 acceleration corrosion test chambers have been sold to domestic and overseas companies up to now since 2013 and an outstanding result has been produced with consistent improvement and consultation with customers.

Through this project, a large chamber of 2700L class has been developed and technology that can develop larger chamber has been secured. Also, as corrosion resistance of a tester itself has to be excellent in corrosion resistance, a device’s long life technology has been secured. And with end users’ interest in product reliability increasinig, an effort to systematically carry out life tests has been made in various fields such as automobile, ship, electronic • electric products, daily necessities, etc. in Korea. Particularly, with Chinese companies’ increasing interest in reliability tests, exports of this developed product to Chinese companies have been rising.

Problem-solving in industrialization: Existing foreign devices use high-molecular materials to secure corrosion resistance of interior components so the testable temperature range is limited to low temperature (80°) to prevent deformation and dissipation of a relevant component to maintain a component’s life. To solve this problem, interior components have been changed to a metal (titanium) and technology development to secure corrosion resistance has been progressed and applied to industrialization.

The acceleration corrosion test requires air tightness of a chamber to maintain precise temperature and humidity. This problem has been solved by making precise control available by applying door packing technology and banting technology after developing airtight technology.

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Eco-friendly replacement of PVC skin, automotive interior material, to reduce toxic substances

June 9, 2016 by Leave a Comment

Technology overview: PVC Skin has been used on the surface of interior parts such as automotive interior seats, door trims, sun visors, etc. Its application has been gradually expanded as its surface quality is good compared with productivity and production cost.https://korean-machinery.com///inquiry
However, the constant increase in demand for automobiles and interior products has required safety securement of a product and development of an eco-friendly product all over the world. Also, there has been a need for the development of a product that can replace PVC skin vulnerable to ejection of VOCs. Accordingly, to replace PVC, a replaceable product that reduces harmful VOCs and is cost-effective as well has been successfully developed by applying TPO where a manufacturing process and raw material are improved. A database has been established to systematically analyze and improve reasons causing VOCs by dividing a manufacturing process into the calender, surface treatment, embo half-finished product process and shaping stage and sub-dividing these. Raw materials such as a surface treatment agent necessary to manufacture automotive interior materials have been improved and replaced after analysis. The developed TPO product (TPO Sheet-Termoplastic Polyolefin Sheet) has reduced injection of Toluene among VOCs, the problem of PVC skin, by one tenth. It has satisfied domestic and overseas requirements for toxic substances. As eco-friendliness and productivity of the product have improved, the economic effect of export increase in not only Korea but also overseas can be expected and it has set a foundation to increase eco-friendly competitiveness of the domestic automotive industry which has a significant omnidirectional ripple effect. Also, it is expected to contribute to reduction of economic loss and improvement of people’s health as it has strengthened safety of drivers and passengers from ejection of VOCs.
Industrialization: Since it was introduced to Korea in 2014 after a product was developed in August 2013, sales of about 2 billion won have been accomplished. As safety standards of automotive interior air quality have been tightened and interest and demand by domestic/overseas customers for an eco-friendly product have been increasing, it is predicted that sales will continuously increase by expanding automotive interior material applied items and it is judged that the developed product can be replaced on existing automobiles. After supplying in Korea stably, an effort to supply the developed product to global automotive makers (U.S. Europe, Japan and China) has been made. It is expected that the recent global outsourcing policy of GM Global will work as an opportunity to target overseas markets and increase exports.
Untitled-20.jpgProblem-solving in industrialization: A close analysis DB on products and raw materials for each manufacturing process is required to analyze causes of VOC of PVC skin and replacements but it was difficult to establish improvement direction because there was no professional data or accumulated data from the past. To solve this problem, an analysis plan was established and a process product was sampled at the right time. Systematic DB was established and it could be used for development of replacements. Also, to solve a problem of productivity decline and production cost rise due to increase of production lead time after reducing VOCs, the BRX free surface treating solvent exclusive line has been newly created with a developing company’s customer company by benchmarking H company in the USA and the drying process has been optimized. As a result, industrialization has been successful by complementing, verifying and mass-producing the product quality of the developed product.

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High power/small (10W Class) telemetry system for development of aircraft

June 9, 2016 by Leave a Comment

Technology overview: The telemetry system for aircraft, a device displaying, saving, reproducing and analyzing the condition of an aircraft https://korean-machinery.com///inquirywhen testing a developed aircraft in flight by checking an aircraft’s conditions and transmitting them to the ground in real-time and transmission and reception device provides a pilot, and as for a drone, a pilot on the ground, with feedback enabled data as an engineer monitors flight data of an aircraft in real time and judges and responds to an unexpected emergency. The telemetry system for aircraft should secure real-time, continuity of data and robustness of communication link for these functions. Telemetry for aircraft is a major electronic device to develop an aircraft. It is classified as an essential element technology of the aircraft industry along with aircraft manufacturing technology. It is the necessary technology to develop an aircraft autonomously but previously, it depended on the introduction of overseas devices. As this telemetry technology for aircraft has localized every important device used in telemetry for aircraft such as a data collecting device to collect data, a high power (100W class) transmitter to transmit collected data to the ground, a data storing device that saves collected data in an aircraft and compares and analyzes the collected data with wireless data when a test is completed, a ground system that can receive data on the ground, etc., it strengthens the basis to contribute to test evaluation airworthiness certification for the government to export a finished aircraft at this point of time where a domestic aircraft development project is being activated.
Industrialization: By replacing components introduced from overseas, sales of about 4 billion won have been attained to date in 2016, since industrialization of the drone project field was launched in 2012. It is expected that sales will continuously rise as the aircraft development industry is recently growing with the support from the government. It is increasing the domestic market share with strong points such as securement of price competitiveness through developing core technologies in Korea, flexibility of system design, technology support and reduction of time taken until getting A/S. A miniaturized, lightened product has been developed by additionally developing image-processing technology based on telemetry technology for aircraft and composing as a single device through modularization. Also, it increased the possibility of additional industrialization by establishing a system and reducing stabilization time through constantly developing technologies. There is also a high possibility to advance into the fields of bridges, shipbuilding, automobiles, railroads, satellite and bio.

Problem-solving in industrialization: Telemetry for aircraft has the technology-level equivalent to overseas advanced companies by localizing telemetry technology that depended on overseas introduction at this point where the domestic aircraft development industry has been vitalized. However, there was some difficulty in submitting review data for performance and environmental conditions when reviewing applications of other customers and other projects due to changes in shape design according to a customer’s request by applied project. On this, base data that can secure reliability of a product has been complemented by making system composition through changing a module according to a customer’s request available by developing an aircraft telemetry platform model, and preparing a test report after conducting an environmental test on a platform model. As a result, additional industrialization was possible based on a platform model and at present, a project has been constantly promoted based on that platform model.

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Welding technology for 0.5mm-thick metal and development of conveyor belt system

June 7, 2016 by Leave a Comment

https://korean-machinery.com///inquiryTechnology overview: The demand for metal sheet conveyor belts keeps increasing in response to the special demands of the rapidly changing industrial environment (i.e. hygiene, high temperature, chemical resistance, clean environment, etc.). In particular, steel is preferred by the aviation industry and the space industry (NASA), etc. for a power transfer unit with permanent life and by the petrochemical industry for chemicalresisting (e.g. sulfur) conveyor systems. Even the food industry and environmentally friendly products (e.g. Choco Pie, Lotte) prefer steel conveyors for clean and sanitary transport of products. In line with these trends, the import of steel products by developed countries is increasing as well, and this calls for R&D efforts on welding technologies for flexible steel sheets.

In addition, the solar power industry (EVA line) such as LG and JIN HEUNG, using relatively new materials and technologies, is requesting conveyor systems of no-stick tabber belt for solar cells, especially for processes of EVA sheet production, IPO film production, and high-temperature forming. However, there is no welding technology needed for such conveyor belt systems and the entire plant or welded belts are being imported without any other option. Therefore, development of the welding technology is crucial to the supply of the metal sheet conveyor systems. In these circumstances, the company has successfully developed the welded parts and surface processing technologies, which allow ultra-thin metal to be made into conveyor systems.

Industrialization: A top priority is to develop stainless steel materials for demonstration of steel processing technologies, optimized for each intended use, and to localize imported belts to be supplied to a local company (JUST IN TIME) through massproduction systems. The company has developed technologies of joining stainless steel belts with metal sheets by welding to make conveyor systems and also a processing machine to sell the product in the form of part materials or plant. The patents for the technologies have been obtained as well. Currently, total inspection is applied to the products. Taking into consideration a rotation test (a nondestructive inspection), the company has conducted a life test under the same conditions as those of the customer’s site and reflected the results in product development.

Problem-solving in industrialization: Due to the nature of small quantity batch production, the belt system needs to be customized and this requires manufacture of a mold, causing increasing costs of a jig. In the initial stage, a customized jig was outsourced and this led to high costs, but now the company uses its own tools and equipment (lathe and milling) to lower the costs.

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125℃ (exhaust temperature) heat recovery hot-air drying unit that saves energy with a heat pump

June 7, 2016 by Leave a Comment

Technology overview: The company has designed a refrigerant system and heat https://korean-machinery.com///inquiryexchanger in order to increase the maximum hot blast temperature up to 125℃ and also designed/realized a waste heat recovery cycle and independent hot blast system, applied to 125℃ refrigerant (R22, R407c) and four cycles. Their design and development include 125℃ evaporator and condenser as well as a pressure backup and control system to prevent high
pressure above 32kgf/㎠.
The company has developed an optimized compressor and expansion valve in addition to multi-step control and proportional control technologies depending on inlet-air temperatures. The newly developed automatic control system can save energy by 40% compared to a regular electric heater (95kWh capacity). The company’s automatic distribution control technology can control hot blast according to inlet-air temperatures. Furthermore, they have optimized a heat pump and auxiliary heater distribution control and improved the range of temperatures control and accuracy.
Also, their air volume control technology significantly enhances accuracy of air volume measurements across the range of temperatures. Air volume is controlled based on the average air volume measurement, taking into account air volume, wind velocity, temperatures, and specific gravity of air. The company has tested a 125℃ waste heat recovery hot-air drying unit and established a measurement platform (supported by KTL). Energy saving has been tested across the range of the highest heat blast temperatures and measurement platform has been designed. They have established measuring systems for waste heat recovery rates, auxiliary heater operation rates, and power consumption. The basic performance test and environmental test for the 125℃ waste heat recovery hot-air drying unit have been done and assessed (KTL) as well.

Industrialization: According to regular printing processes, eight or nine-color printing is applied to gravure while 4-color printing is applied to dry laminate printing, and the final drying process is applied to both. In this case, 10 units are needed for one production line of gravure and five units for dry laminate printing. Each dryer can control temperatures, air volume, and cooling cycle automatically. For gravure 10 units can be controlled in an integrated manner for batch operation of one production line.

In addition, a duct for exhaust gas, containing organic solvent, and a dust collector has been developed. Supplying heat blast optimized for the site by controlling temperatures and air volume could save energy by 70% in case of 200M/MIN gravure printing. ROI (return on investment) is estimated at 1.6 years, which proves high energy-saving effects.

Problem-solving in industrialization: Initially, there was a lack of data on energy saving rates, which can provide assurance to overseas buyers, but the results of tests on residual solvents and adhesive strength and energy-saving test by Armco Thailand proved 70% reduction for gravure printing and met the requirements of the internal standards and international environmental standards on residual solvents and adhesive strength. The data have been sent to the head office and the U.S. branch office of Armco with high prospects for being selected by the company to meet its energy reduction targets, and installation of an e-Saver has been under discussion since March 2015 with the U.S. branch office.
Armco is running over 40 printing factories worldwide, and replacing the existing 4,000 units with e-Saver is worth approximately KRW 80 billion. Armco Beijing, a joint stock company, has decided on the installation of e-Saver in April 2015 and shipment is under way as well.

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Mobile core component production based process platform technology

June 7, 2016 by Leave a Comment

Technology overview: Production base process platform technology was https://korean-machinery.com///inquirydeveloped for each mobile core component module (substrate module, display module, external module), where production based process platform technology for mobile core component is a portal technology that can develop and supply from materials to common production base process technologies including cast, mold, metal forming, heat treatment, surface treatment, and welded connection to produce mobile core components. Of display modules, technology development for ultra-thin light guide panel that is a core component in LCD BLU is described in this volume. Guide panel, a core component in LCD BLU, is an optical part to transform point light source from LED into uniform surface light source, and its size has been bigger and its thickness has been thinner according to the smartphone market trend of light weight, slim, and large screen. Flagship models that are currently being produced by all the global major companies average about 5 inches in size and 0.3mm in thickness for light guide panels. When 5-inch size and 0.3mm thick light guide panel is produced using high speed injection, it was hard to secure mass productivity. In order to produce ultra-thin light guide panel, it is necessary to solve critical problems created from high speed injection production such as uncompleted molding, bending, and residual stress. Injection compression molding method was developed to solve such problems, which improves the resin flow in injection molding, enhances formability and allows ultra-thin light guide panel production through advantages like residual stress improvement. The mass-production of ultrathin light guide panel manufactured based on this development technology can be performed by U-tech only among domestic companies in the same line of business, which is expected to enhance U-tech’s competitiveness in the Chinese smartphone market that will have bigger growth rate in future.

Industrialization: Now in 2015, 0.28mm thick ultra-thin light guide panel developed through injection compression molding technology is a component of a global top maker’s product, and that can be produced by U-tech only domestically and by only two companies in the world including U-tech.
Consequently, since 2011 when sales were started in full-scale through injection compression molding technology, sales amount has been increased gradually, and in 2014 especially, over 10 billion won of sales was achieved with the success of 0.28mm ultra-thin light guide panel development. Because not just thickness but also optical properties were improved compared with existing film type high speed injection products base on form compression molding technology developed by U-tech, great outcome could be achieved in terms of quality. Accordingly, because demand for ultra-thin light guide panel is expected to be increased worldwide, U-tech’s slim technology will have great competitiveness in the market, and the company would advance to become a leading company of ultra-thin display technology in the global market based on constant improvement in form compressing technology.

Problem-solving in industrialization: Injection compression molding technology has been considered as almost the only solution for injection molding method to produce ultra-thin light guide panel in previous years. Therefore, not only U-tech but also competitors have been working on the development, but keep failing because they cannot secure mass productivity. Major mass production issues include defects in product reproducibility, dimension, and appearance. U-tech also had difficulties in mass production due to such problems in injection compression molding technology, but the company succeeded in mass production with benefits of accumulated precision mold manufacturing technology, close cooperation with injection molding companies, it molding technique improvement, and could be recognized as a manufacturer of ultra-thin light guide panel in global markets.

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Particle control and corrosion resistance enhancement process for reaction sintering silicon carbide ring

June 7, 2016 by Leave a Comment

Technology overview: reaction sintering silicon carbide is compact https://korean-machinery.com///inquirysintered body manufactured by mixing silicon carbide powder and carbon and then impregnating metal Si at high temperature. Penetrated metal Si reacts to carbon and creates new reaction sintering silicon carbide, while the rest fills the remaining pores, so that almost 0% porosity product can be produced. This method is applied to large tube, boat or ring type products in semiconductor process. Reaction sintering SiC fixture has such high resistance against plasma that more usage time can be expected compared with existing silicon ring, thus it is applied to the etching process, one of the critical processes in semiconductor manufacturing. Functions required for silicon carbide ring in this application include long life cycle in plasma environment containing fluorine, substandard particle generation, and low surface impurity concentration. To solve this, development including consideration on etching tool was performed for raw material high purification, optimized final product cleaning method, and longer life cycle in fluorine constraining plasma environment. Studies were performed on drug types, cleaning methods, and degreasing methods to be used in developing product cleaning method. Also, high density can be achieved through silicon carbide powder composition adjustment by observing the etching trend of plasma in reaction sintering silicon carbide, and reducing usage time can be resulted from testing in an environment similar to actual environment. This was proven from actual final consumer environment, and the capability on silicon carbide material and quality was recognized. The application scope of developed silicon carbide ring becomes wider, the demand keeps increasing, and application to different shape of products other than rings is consistently increasing, so great economic benefits are expected.

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Industrialization: Si ring consistently used in semiconductor processes is gradually substituted by reaction sintering silicon carbide rink. As a result of consistently contacting to the world’s number 1 semiconductor chip maker who has business transaction with Inocera and concentrating on new product promotion, now Inocera has about 600~800 million won of annual sales and gets favorable technical comments on product durability, therefore its sales are expected to be increasing accordingly. Now the company is widening its technical application to different shapes of fixtures other than ring shape. Also, being recognized with its technical skills, the company concluded a product supply contract with a global semiconductor equipment company, and is trying to enter the global market based on that.
Problem-solving in industrialization: Optimized cleaning method, particle measuring technique, and plasma resistance measuring techniques in the material are product element technologies required for industrialization. But entering the market was difficult in the early stage, because cleaning methods or particle measuring techniques are not commonly shared, but rather treated as companies’ know-how. Also, etching tool in the plasma environment for reaction sintering silicon carbide was an unknown field, because nobody had tried it before. But, as the company developed appropriate particle measuring method first, they can understand impact on many cleaning processes. Based on that, the company developed a nearly optimized cleaning method. Also, as the company established test etching equipment with the support of this task and observed the etching ratio of silicon carbide materials and etching tool, the company can understand optimal silicon carbide composition and solve issues through existing silicon carbide composition adjustment techniques.

Micro structure_before etching  /  Micro structure_after etching

 

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Combined vibration controlling mount industrializing technology

June 7, 2016 by Leave a Comment

https://korean-machinery.com///inquiryTechnology overview: The goal is to develop a vibration controlling system essential to operate semiconductor and display manufacturing devices and other extremely sensitive manufacturing/ inspection devices. The combined controlling system has been developed, which operates vibration proof and controls transient vibration and micro-vibration at the same time. It has been industrialized by applying vibration criteria of a device considered structural dynamic characteristics and excitation force of superfine production line. It can survey and monitor the status of a PC interface device. It meets with the BBN Criteria Class D level. A combined mount combining a MR damper vibration controller and an electro-magnetic shaker with an air spring vibration proof device has been designed and manufactured.
Vibration controlling algorithm considering excitation force, dynamic characteristics of a building structure and vibration guides of a device has been developed. Controlling system technology has been developed. The combined vibration controlling system using a MR damper, electro-magnetic and intelligence control type module to synthetically control environmental vibration, transient response vibration, etc., occurring when operating an extremely sensitive device has been industrialized.

Product Outline                                                          Controller

It is the specialized diagnosis system including a control system of 4~24 controllable mounts and monitoring, as the six-degrees of freedom combined vibration proof system. It has input and output by vibration controlling algorithm, this algorithm-realized embedded controller and CAN communications. The combined mount is the active control system that combines a vibration proof device blocking excitation force, a semi-active vibration controller controlling power and an active type shaker. The controlling algorithm calculates the controlling power using a vibration status measured by a vibration sensor and vibration is removed by sending the calculated controlling power to an operator as a controlling order.

Industrialization: Sales of MRAM, a combined type of Air Spring and MR Damper, have risen upon completion of development, once commercialized while conducting a research and after its industrialization applied to the production lines of Samsung Electronics Co., Ltd, MEMC, LG Electronics, etc. Since domestic technology is applied, it can significantly lower time and engineering fees. After development, we received many inquiries from companies requiring precise vibration control such as semiconductor devices, coater devices, thickness gauges, nanoprocessing, high-sensitive devices, etc. and applied the combined vibration controlling mount system.
Personnel from SK Hynix participated in research so that it can be applied in the actual field. SK Hynix is actively involved in R&D and industrialization so that it can applied to a field right away. Despite high prices in Japan, the USA, etc., performance is dissatisfactory
and getting AS is difficult. However, there is no proper alternative.
It seems promising since development of the combined vibration controlling mount system has been accepted as a good alternative to consumers of domestic displays and precision devices.

Problem-solving in industrialization: The key of the device is credibility of performance. When carrying out a task, a leveling location, controlled frequency area, noise level, control freedom, etc., are evaluated using various measurement evaluation methods by stating controlling performance in the quantitative performance evaluation item and the product credibility is evaluated by KTL. Vibration environment and characteristics of an applied field are analyzed, an installation planned superfine device is produced and dynamic characteristics of a testing device are analyzed and evaluated. The optimal smart-VS considering vibration tolerance criteria and dynamic characteristics of a device is selected. A professional engineer of RMS Technology Co., Ltd. precisely adjusts vibration proof and vibration control performance suitable for a selected field and device. After confirming targeted performance of vibration control and vibration proof by measuring and evaluating vibration, an optimized product is installed with setting tuning work. After
installation is completed, whether vibration performance is satisfactory or not is confirmed. A product is marketed to existing customers through actual results in the vibration controlling area of displays and semiconductor devices and provision of various vibration controlling total solutions. The product is drawing positive responses based on level of satisfaction after use.

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Design of precise forming method that can implement highly advanced and accurate forging

June 7, 2016 by Leave a Comment

Sindo High Tech Co.,Ltd. (Ho-gwon Seo, CEO)
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Sindo High Tech Co., Ltd., a company specialized in the forging of automobile components such as inner pipe and inner sleeve, has maintained its existence as a front-runner for cold forging products in Daegu region by concentrating on cold forging over the past 30 years. Sindo High Tech, now focusing on higher value-added components and hybrid automobile components, has 60~80% of domestic market share with dominant cost-competitiveness and superior quality using cold multi-former, and is trying to strengthen its technical competitiveness to pioneer overseas routes.

Securing fabrication process technology for highly

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competitive superior components The suspension, connecting the axle and body of a car, prevents damage to the body and the load and improves the impression of riding by enabling the axle not to deliver the impact from the road directly to the car body. Currently developed products include bushing that can be assembled with RR MBR Knuckle and other parts in the suspension and it is mainly used as a component that can influence wheel alignment as well as reduce vibration generated during operation. It is being used in GM global automobile, and its demand is expected to be increasing as the application will be extended to newly developed models. Thus, in compliance with consistent needs for high reliability, Sindo High Tech carried forward component development showing high reliability.
Existing fabrication processes are composed of a total of three steps where all components are made individually and then welded, which is very wasteful for materials, requires much energy-use in the manufacturing, and there is great concern about defective forming in welding or damage in the neck area. In order to improve such flaws, parts fabrication processes were developed through this research task; making precise forming with cold multi-former and forming the shape after removing stress from the materials and surface treatment, which consequently reduced the processes dramatically. Moreover, developing technology that can manufacture parts economically having not just high yield but also superiority in terms of characteristics allows securing competitiveness.
In this regard, Ho-gwon Seo, CEO of Sindo High Tech Co.,Ltd explained, “After designing dies for each process based on developed process blueprint, we had to undergo many trials and errors because we could not have expected results in the course of manufacturing actual dies through feasibility study and testing trial produces due to many causes. We made steady and persistent efforts to improve program interpretation and mold design technique based on the results from such trial and error, and finally could solve the problems by the aid of cooperative organizations.”

Development of integral ROD-A by securing four core element technologies

In existing production processes for ROD-A, hole unit and circular unit were produced separately and passed through thewelding process before being supplied as a component.
However, that process was so wasteful for materials that there was a problem that reduces productivity and durability significantly in the welding process of making separated parts into one integral component. In order to solve this problem, Sindo High Tech developed integral ROD-A for final shape forming using primary product forming and high load press through cold multiformer. The first core technology is cold extrusion multi-forging method and mold design technology. It is possible to design a method that considers forming volume and forming energy for each step and molds for which dimension changes caused by elastic recovery in the molds and the materials are considered. The second core technology is forming interpreting technique based on the finite element method. Based on the finite element method, it is possible to have techniques for breaking prediction and coupled analysis, considering flow stress in materials interpreting the forming and using damage models. The third core technology is the optimization of forming process parameters and micro-structure control in raw material. Forming features for raw materials can be secured through the optimization of load-deformation, metal flow characteristics, stress & distortion, and energy distribution, and spheroidized annealing process optimization. The fourth is technology of securing mold durability.

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It can lubricate the mold, extend the service life with heat and surface treatment, and minimize damage through stress interpretation. Trial products were manufactured based on such core element technologies, and final improvement could be made through characteristic evaluation. Also, mass- production technique could be secured through standardization, and industrialization could succeed.
CEO Mr. Seo who suggested that competitiveness, highdefinition, and high-quality is required for current core components in the world’s automobile industry explained that ”
Especially, demands for weight- reduction and cost-reduction keep on increasing to overcome resources, energy-saving, and environment issues in automobile industry. In accordance with such needs of the times, Sindo High Tech has developed new fabrication processes that allow more cost savings than existing processes and new markets, which result in increase in annual sales. Because processes that can reduce CO2 generation from
production processes are required according to strengthened international environmental regulations, the business is very promising in future.”

The world’s first acquisition of a patent regarding precise forming method in Korea and abroad

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In this country, trailing arm bush used in Hyundai-Kia Motors relies on welding by press forging, and automation facility is insufficient due to high-priced facility investment. In addition, studies for optimal forming conditions are so insufficient that our technical power is more than 10 years behind compared to Japan. For the overseas forging industry in advanced countries (specifically, the USA, Japan, and Germany), forging simulation is commonly used in process design. Even China, that has more outdated technology now than our country, would catch up the technology 4~5 years later and become a considerable threat to us. However, material utilization and performance improvement and studies on cost saving are consistently being progressed now mainly by local small and medium-sized cold forging companies. Most of all, automobile component business is developed in Daegu, and the former cold forging field is specialized in the new forging industry. In this regard, Sindo High Tech possesses many patents for new cold forging processes, and especially it is expected to acquire a patent for its precise forming method for the first time worldwide as a part of performance from this research task.

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Representative patents related to such technical development include the automobile mounting pipe manufacturing method (Sindo High Tech Co.,Ltd., registration no. 1009089190000). This is about mounting pipe manufacturing that plays a supportive role to install other parts, and characterized by strong and efficient manufacturing even with simpler process than existing process.

In addition to this, the cylindrical bushing manufacturing method (Sindo High Tech Co.,Ltd., registration no. 1007811420000) can produce completed product of cylindrical bushing having fringe in both sides using multi-former, which allows remarkably improved production speed and saves manufacturing costs.

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