본 연구에서는 3차원 솔리드 모델러로부터 Modeling한 후 제작된 model 에 사용자가 원하는 측정 위치를 지정함으로써 자동적으로 측정용 NC Data를 얻을 수 있는 알고리즘을 설계하고 이를 Program화하였다. 3-D Modeler로서 Unigraphics를 사용하였으며, 공작기계는 FANUC Controller를 장착한 Machining Center이다. 측정용 센서는 접촉식 Probe를 사용하였다. 본 연구를 통하여 CAD시스템에서 구축된 Geomaatric Model로부터 직접 측정을 위한 NC data를 얻고 이 data를 가공후의 측정 Data와 비교하여 봄으로써 제품의 가공정밀도를 확인해 볼 수 있으며, 가공시의 간섭 check, 잔삭가공여유, 과절삭등 다양한 정보를 얻을 수 있을 것이다. 향수 지속적인 연구개발을 통하여 data의 통계처리 및 공작기계의 오차 보정등을 고려하여 줌으로써 기계상에서의 측정 data에 대한 신뢰도를 구축할 수 있을 것으로 사료된다.

The effect of press warm forming in cylindrical deep drawing of stainless-aluminum clad sheet metals are examined . The temperature of die and blank holder is varied from room temperature to 20$0^{\circ}C$, while the punch is kept cooled during test to increase the fracture strength of workpiece on the punch corner area. Test materials chosen for experiments are STS304-Al050-STS304, STS304-A1050-STS430-, STS304 and Al050 metals and teflon film as a lubricant is used on both sides of a workpiece. The limit drawing ration as well as quality of drawn cups (distribution of thickness and hardness)are investigated and discussed.

박판금속성형공정을 통하여 컴퓨터를 이용한 계산방법으로 효율적이고 정확하게 해석할 수 있는 박판성형해석시스템인 SAIT_STAMP를 개발하였다. 또한 이를 현업문제에 적용하여 금형의 개발기간과 비용을 줄이고 성형품 품질저하 문제들을 해결하는데 이용하였다. SAIT_STAMP 는 성형해석, 성형후해석 프로그램과 전·후 처리기로 구성이 되어있다. 금형과 재료의 접촉 및 마찰을 고려한 새로운 접촉처리방법을 성형해석에 적용하여 해석속도와 해석정확도를 향상하였고 다단계성형 및 유압성형 등 박판성형에 필요한 대부분의 기능을 개발하여 적용하였다. 성형후해석은 성형해석의 결과를 토대로 스프링백해석을 수행한다. Visual C++을 사용하여 개발된 전·후 처리기는 window 95N/T 환경의 PC에서 수행된다. 개발된 프로그램을 이용하여 현업 문제에 적용 해석하였으며 상용S/W 대비 우수한 결과를 얻었다. 현재 삼성내 9개 관계사에서 설치되어 사용중이며 프로그램의 대외신뢰성확보를 위해 대학과 비경쟁업체에 프로그램을 설치하여 프로그램을 설치하여 프로그램의 시험과 성능향상을 하고 있다.

Spinning is one of the incremental forming process by the rotating mandrel and forming roller, and has been applied to manufacturing the wheel disc of automobile to simplify the manufacturing process and to improve the mechanical properties of product. In the proesent study the process variables have been extracted and considered to decide the specification of the spinning machine. The maximum values of working load and power have been evaluated and the blank size has been disigned. The shape and dimensionof forming roller have been designed and the process condition such a s rotational velocity of mandrel and the feedrate of roller have been decided.

Heat - affected zones degenerated in cold forging die have been investigated to improve the tool life. There are many cases of heat-affected zone which are degenerated in manufacturing die and using the cold forging process. In order to define amounts of grinding inmanufacturing the toolfor cold forging, we have investigated the hardness and microstructure of surface layer after EDM. Considering the results of T.R.S. and compression test, it is likely that mechanical properties of tool have been decreased sharply if the heat-affected zones degenerated by EDM were not machined properly. also analyzed the tool surfac which is fractured during the cold forging. According to the microstructures and hardness distribution, surface of many tools have been degenerated in cold forging and fractured due to the heat-affected zone.

In this study, two kinds of life prediction method for hot forming die are developed . One is empirical method requiring some experiment that evaluate thermal softening of die material accoring to operating conditions. The other is analyticl method that calcuate wear quantity of die occuring during the forming process. Wear is a predominant factor as well as plastic deformation and heat checking . And, these methods are applied to prodict tool life real die producting part for automobile. Thus , the applicability and the accuracy of the presented methods are investigated. Using the verified life prediction method above , optimal blocker die design minimizing the finisher die is done.

The horizontal cold chamber pressure die casting produces a variety of net shape, complicate-geometry castings with desired mechanical properties. dimensional tolerance, and surface finish. However, top quality castings can be achieved only when optimal performance of thecold chamber (shot sleeve )and plunger is maintained druing the molten metla injection phase of the process. Unforturately, inreality , shot sleeves deteriorate fast and sometimes fail catastrophically due to incorrect design. These early and unexpected failures of shot sleeves cost die casters money and productiivity. To prevent promature failures of shoe sleeves major faulure mechanisms were investigated. with the aid of analyticla solutions robust design criteria for shot sleeves have been developed. The data directly obtained from failed shot sleeves in the die casting industry for automotive parts, support a strong correlation between design and filures. by applying these design criterial we expected premature faulures of shot sleeves can be avoided in die casting industry.