• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.4
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• pp.118-125
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• 2015

The roll-forming process is a highly productive incremental forming process and is suitable for manufacturing thin, high-strength steel products. Recently, this process has been considered one of the most productive processes in manufacturing high-strength steel automotive structural parts. However, it is very difficult to develop the roll-forming process when the cross-sectional shape of the product changes in the longitudinal direction. In this study, a roll-forming process for manufacturing high-strength steel automotive parts with a linearly variable symmetric hat-type cross-section was developed. The forming rolls were designed by the 3D CAD system, CATIA. Additionally, the designed forming rolls were modified by the simulation through the 3D elastic-plastic finite element analysis software, MARC. The results of the finite element analysis show that the final roll-forming roll can successfully produce the desired high-strength steel automotive part with a variable cross-section.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.5
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• pp.84-89
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• 2001

The alignment of the rollers carrying the web is found to be one of important factors to the lateral behavior of the moving web and to the quality of the final web products. But, the perfect alignment of the rollers is not always possible and the web itself can be cambered. Thus the control of lateral behavior of the moving web is critical in the most of web handling systems. The web guiding system that adjusts the angle of the alignment between two adjacent rollers is commonly used in industry. But, in this paper a new web guiding system is proposed by using the lateral dynamics of the moving web induced by a tilted roller in normal direction of a web. The computer simulation study was carried out to verify the steering performance of the suggested guiding system. Computer simulation study shows that the performance of the new guiding mechanism is better than that of an existing guiding mechanism.

• Journal of the Society of Naval Architects of Korea
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• v.44 no.5
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• pp.517-525
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• 2007

This paper presents how to approximate an optimal shape of roll bending process in the fabrication of a curved shell plate. The roll bending process usually makes the cylindrical or conic shape from an initial flat plate. It means that the final shape is developable or its surface representation has zero Gaussian curvature. The fabrication shape is important in order to find process parameters of roil bending. An optimal concept is used to determine the developable fabrication shape which is in the closest proximity to the design surface or the given shell plate and is subject to developability. The results and the efficiency of this algorithm are evaluated by applying to some shell plates. Furthermore, the fabrication shape will be fundamental information for other process parameters of roll bending such as the vertical displacement of the center roller and the rolling directions.

• Journal of the Korean institute of surface engineering
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• v.55 no.3
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• pp.173-179
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• 2022

This study presents a roll-to-roll process which is capable of Ag nanowire (AgNW) transfer from polyethylene terephthalate (PET) film to polycarbonate (PC) film. We developed a roll-to-roll machine that consists of two film suppliers, a coater of photo-curable resin, a film laminator, an ultraviolet (UV) exposure unit, and a film winder to facilitate large-area electrode transfer between different flexible substates. Using the process, optimal fabrication condition was investigated by parametric experiments in terms of the UV exposure time, number of thermal cycling, and exposure time of high temperature and humidity. A fabricated AgNW on PC film showed sheet resistance of 52 Ω/sq and optical transmittance of approximately 80 % over a range of visible light.

• Journal of Power System Engineering
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• v.16 no.6
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• pp.52-58
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• 2012

Roll forming process is one of the most widely used processes in the world for forming metals such as a furniture drawer guide or an up and down slide guide. It can manufacture goods of the uniform cross section on a large scale throughout the continuous processing. In the domestic design and manufacture, roll forming process for production is taking most of the method of 2-point under rail slide. However, this method is vulnerable to the structural strength and stiffness is not suitable for high load conditions. Therefore, through systematic study of high load, low noise 3-point ball type of under rail slide its own design and manufacturing technology is the need to build. In this paper, to make center member of 3-point ball-type under rail slide for the refrigerator doors, the roll forming modeling and simulation are performed. Tensile test is performed about SCP-1 1/2H for determine the mechanical properties of materials. Modeling and simulation of roll forming is used MSC.MARC software of a dedicated analysis program used by rigid plastic finite element method. Interference between the roll and the final shape are predicted from the results of the simulation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.2
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• pp.173-178
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• 2012

Currently, active research is being performed on printing of electronic devices such as RFID devices, flexible displays, solar cells, and e-paper. This technique has several advantages over existing technologies such as lithography and etching. In particular, RFID devices, flexible displays, solar cells, and e-paper require flexibility and a mass production system. Thus, attention is being focused on the roll-to-roll process. High quality should be guaranteed in the roll-to-roll printed electronics systems, and good thickness and roughness qualities must be ensured. Experimental design was applied to this problem to analyze the main effects and interaction effects of various factors. Matching technology between the nip roll characteristics and the quality of the print pattern in roll-to-roll printed electronics systems was proposed to improve the printing quality.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.5
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• pp.45-51
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• 2018

Roll forming refers to the production of long plate-molded products, such as panels, pipes, tubes, channels, and frames, by continuously causing the bending deformation to thin plates using rotating rolls. As the roll forming method has advantages in terms of mass production because of its excellent productivity, the size of the roll forming industry has been continuously increasing and the roll forming method is increasingly being used in diverse industrial fields as a very important processing method. Furthermore, as the roll forming method mainly depends on the continuous bending deformation of the plate materials, the time and the cost of the heterogeneous materials developed in the process are relatively large when considered from the viewpoint of plastic working because many processes are continuously implemented. The existing studies on roll forming manufacturing have reported the loss of large amounts of time and materials when the raw materials or product types were changed; further, they have stated that the use of this method can hardly guarantee the uniformity of the formed shapes and the consistency in terms of size and cannot detect all the defects occurring during the mass production and related to the dimensions. Therefore, in this research, a real-time process data-based smart roll forming method that can be applied to multiple products was studied. As a result, a roll forming system was implemented that remembers and automatically sets the changes in the finely adjusted values of the supplied quantities of individual heterogeneous materials so that the equipment setting changing time for heterogeneous material replacements or changes in the products being produced can be shortened. It also secures the uniformity of the products so that more competitive and precise slide-rail products can be mass-produced with improvements in the quality, price, and productivity of the products.

• Proceedings of the Korea Technical Association of the Pulp and Paper Industry Conference
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• 2001.11a
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• pp.128-128
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• 2001

제지기술의 변화속도가 빨라지고 제품의 고품질화가 요구가 많아지면서 finishing 공정 에 대한 관심과 중요성이 점점 더 높아지고 있다. 소비자의 요구에 부합되는 제품의 품 질을 얻기 위해서 여러 가지 방법들이 개발되고 있으며, 그 중에서 calender 설비 및 처리 기술이 계속적으로 발전하고 있는 추세이다. 특히 coated paper 제조 공정에서의 s supercalender 처 리 기 술은 매 우 중요하다. F Finishing 공정은 종이의 품질을 결정하는 제지 공정의 마지막 단계로서 calendering 처리 방법에 따라 제품의 품질을 크게 변화시킬 수 있다. 따라서 본 연구에서는 기존의 s supercalendering 처리 조건을 변경시켜 도공지의 품질 특성을 관찰하였으며 실험실용 s supercalender와 현장 적용을 통하여 supercalender 처리 조건이 도공지 품질에 미치는 영향에 대하여 검토하고 이를 이용하여 제품 품질을 개선시키기 위해서 수행하였다. 안료 배합비를 달리하여 다양한 온도와 압력 조건을 적용하여 보았으며 동일한 백지광 택을 갖는 여러 조건들에 대해서 각각의 품질 특성을 살펴보았다. 동일 백지광택에서 온도가 높을수록 macro-roughness, micro-roughness는 더 우수하게 나타났으며 이는 printability의 차이로 이어 졌다. 실험실용 supercalender를 이용한 실험에서 경도가 다른 두 가지 탄성롤로 cotton roll 과 polymer roll을 사용하였으며 통일한 온도와 압력 조건에서 calendering 특성은 서 로 다르게 나타났다. Calendering 조건이 가혹할수록 두 roll간의 특성은 더욱 두드러지 게 나타났으며 macro-roughness 보다는 micro-roughness에서 차이가 더 큰 것으로 확인되었다. 이러한 두 roll간의 특성 차이로 인하여 실제 인쇄 결과는 다르게 나타날 것으로 예상된다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.4
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• pp.121-126
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• 2011

An accumulator placed on the refrigerant cycle pipe lines is a part to relax fluctuations of pressure within the pipe lines and stabilize refrigerants flowed into pipe. The accumulator has been mainly manufactured by the process of tube spinning using CNC(Computer Numerical Control) lathe. However, this process has the defects which are low productivity per hour and high cost. For that reason, tube end-forming using roll die is actively being developed, recently. The purpose of this study is to develope the tube end-forming process using roll die in order to manufacture the accumulator for the refrigeration pipe lines. First, the process design of tube end-forming was performed based on specification of product, and then was verified with FE analysis. Also, the effects of friction coefficient and revolution speed of roll die on forming load were investigated. The analytical results were applied in the final process design of tube end-forming. Finally, tube end-forming test was carried out to verify the validity of the FE analysis and the process design.

• Proceedings of the KAIS Fall Conference
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• 2011.12b
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• pp.646-648
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• 2011

본 논문에서는 쌍롤 박판주조(Twin Roll Casting, TRC)법을 이용하여 AA4343 합금을 제작하였다. 주조시 롤 간격을 조절하여 냉각속도를 달리하였으며 인고트 주조(Ingot Casting, IC)법을 이용하여 제조된 합금과의 미세조직학적 차이와 이에 따른 물성 변화를 고찰하였다. TRC 및 IC로 제조된 합금을 냉간압연하였으며 압연 건전성을 평가하였다. 한편, 냉각속도별로 상이한 미세조직을 구현할 수 있는 스텝몰드(Step Mold Casting, SMC)법을 이용하여 제조된 합금의 냉각속도에 따른 미세조직 및 경도 차이를 조사하여 상대 비교하였다. 냉각속도가 빠를수록 주조 셀조직의 크기 및 공정 Si 입자의 크기가 감소하였으며 이로 인하여 경도가 증가되는 효과를 나타내었다. 주조시 생성된 공정 Si 입자의 크기는 압연에 의하여 그 크기의 변화가 거의 없었으며 열분석 결과 액상선 온도의 변화가 일부 발생하나 큰 차이가 없었다.