• Journal of the Korean Crystal Growth and Crystal Technology
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• v.33 no.6
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• pp.216-225
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• 2023

This paper describes the finite element analysis and die design change of cold heading punching process to increase the cold forging tool life and reduce the tool wear and stress concentration. Through this study, the optimization of punch tool design has been studied by an analysis of tool stress and wear distribution to improve the tool life. Plastic deformation analysis was carried out in order to understand the cold heading process between tool and workpiece stress distribution. Cold heading punch die design was set up to each process with different four types analysis progressing, the cold heading punch dies shapes with combination of point angle and punch edge corner radius shapes of cold forging dies, punch die material properties and frictional coefficient. The design parameters of point angle and corner radius of punch die geometry, die material properties and frictional coefficient were selected to apply optimization with the DoE (design of experiment) and Taguchi method. DoE and Taguchi method was performed to optimize the cold heading punch die design parameters optimization for bolt head cold forging process, it was possible to expect an reduce the cold heading punch die wear to the 37 % compared with current using cold heading punch in the shop floor.

• Proceedings of the KSR Conference
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• 2007.11a
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• pp.480-493
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• 2007

Many railway-advanced countries are using the various types of track to reduce the track maintenance and repair cost according to the improvement of velocity. It spends on much maintenance and repair cost for ballast track due to abrasion of ballast, track irregularity and unisotropical ballast-support stiffness. The ballast track on railway bridge is accelerating the deterioration of ballast according to interaction of railway bridge and track. As continuing the deterioration, it is caused dynamic loads. Due to these effects, it increases negative loads of track and bridge. However, when designing the railway bridge, the effect of ballast track was applicate only dead load, so elastic behavior effect of ballast track is not influenced. Therefore, this paper presumes the stiffness of ballast track on railway bridge considering dynamic behavior of railway bridge, it was evaluated that effect on dynamic behaviors of railway bridge according to ballast track stiffness.

• Journal of the Korean Geosynthetics Society
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• v.15 no.4
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• pp.71-78
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• 2016

In this study, execution costs of the foundation system are compared with PHC and steel pile in the same soil layers and load condition. Steel piles installed on the thin weathered rock are reduced as 12.5% in comparison with the number of PHC piles. Steel piles installed on the soft rock through weathered rock with 1.7m of thickness reduce the number of piles as 35.7% (STK 400) and 46.4% (STK 490), respectively, in comparison with PHC piles installed on the weathered rock. Also, they reduce the number of piles as 26.5% (STK 400) and 38.8% (STK 490), respectively, in comparison with steel piles (STK 400) installed on the weathered rock. When the thickness of footings is constant, steel piles installed on the soft rock may reduce the area of footings up to 12.2% (STK 400) and 45.4% (STK 490), respectively, in comparison with PHC piles installed on the weathered rock. Total cost of foundation system installed on the soft rock with steel piles (STK 400) increases as 12%, whereas in case of replaced with steel piles (STK 490), it reduces as 16% in comparison with PHC piles installed on the weathered rock. This is because the cost reduction due to the number of piles and footing area is more effective despite high cost of steel piles (STK 490). When the thickness of weathered rock is less than 5m, installing steel piles (STK 490) on the soft rock through it is more economic in comparison with installing PHC piles on the weathered rock.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.30 no.3A
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• pp.201-209
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• 2010

Generally, PSC girder bridge uses total gross cross section to resist applied loads unlike reinforced concrete member. Also, it is used as short and middle span (less than 30 m) bridges due to advantages such as ease of design and construction, reduction of cost, and convenience of maintenance. But, due to recent increased public interests for environmental friendly and appearance appealing bridges all over the world, the demands for longer span bridges have been continuously increasing. This trend is shown not only in ordinary long span bridge types such as cable supported bridges but also in PSC girder bridges. In order to meet the increasing demands for new type of long span bridges, PSC hollow box girder with H-type steel as compression reinforcements is developed for bridge with a single span of more than 50 m. The developed PSC girder applies compressive prestressing at H-type compression reinforcements using unbonded PS tendon. The purpose of compressive prestressing is to recover plastic displacement of PSC girder after long term service by releasing the prestressing. The static test composed of 4 different stages in 3-point bending test is performed to verify safety of the bridge. First stage loading is applied until tensile cracks form. Then in second stage, the load is removed and the girder is unloaded. In third stage, after removal of loading, recovery of remaining plastic deformation is verified as the compressive prestressing is removed at H-type reinforcements. Then, in fourth stage, loading is continued until the girder fails. The experimental results showed that the first crack occurs at 1,615 kN with a corresponding displacement of 187.0 mm. The introduction of the additional compressive stress in the lower part of the girder from the removal of unbonded compressive prestressing of the H-type steel showed a capacity improvement of about 60% (7.7 mm) recovery of the residual deformation (18.7 mm) that occurred from load increase. By using prestressed H-type steel as compression reinforcements in the upper part of cross section, repair and rehabilitation of PSC girders are relatively easy, and the cost of maintenance is expected to decrease.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.36 no.4
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• pp.705-713
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• 2016

For the soft ground construction, the factors not considered in the design stage occurs in the construction stage so that they cause the increase of the construction cost due to the structural stability and the design change. The subject of the study is the construction section of the industrial complex access road made in the Ochang region of Chungcheongbuk-do. The study is concerned with selecting the soft ground handling method such as the replacement method using rock debris and the surcharge reflecting the service load as the soft ground handling measure and analyzing the effect of reducing the construction cost with the stability of structures and the reduction of the construction period. The soft ground in the study section consists of sandy and cohesive soil and is 2.4m to 5.5m deep. It is distributed unevenly between the 1.5m to 5.9m stratums under the ground surface. Settlement is not serious, but the future uneven settlement and difference are expected so that the future settlement behavior is estimated by analyzing the site measurement results after the soft ground treatment. Moreover, in consideration of the regional characteristics and economic efficiency, soil with good quality is replaced with rock debris as the replacement material so that 29% of the construction cost is reduced due to the increase of stability and the reduction of duration. If the estimation of the dispersion of the pore water pressure within the dam body and the change of the underground water level and the relation of the actually measured soft ground with consolidation is studied further on the basis of the study, it is expected that the behavior of the soft ground will be correctly estimated in various site conditions.

• Journal of Korean Society of Steel Construction
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• v.25 no.5
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• pp.555-567
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• 2013

Slim floor system using deep decks has been developed and employed in Europe to reduce the floor height of steel structures. Although long span buildings involving the issue of reducing floor height are being increasingly built in Korea, employing deep decks in more than 7m long span structures is likely to cause problems associated with excessive deflection. This study is applied to the long-span concrete casting of the deep deck plate usability of deflection due to bending and torsional instability of open cross-section, as a way to improve the problem of cap plates are suggested, and the optimum length of reinforcement and location are derived from theoretic estimation. The cap plates are placed on the deep decks with regular intervals to overcome the instability of open sections, improve the stiffness of the sections and control the deflection at the centers. The improvement in flexural capacity associated with the location of the cap plates and the length of reinforcement are verified through analysis and test.

• Proceedings of the Korea Concrete Institute Conference
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• 2010.05a
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• pp.39-40
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• 2010

The demands for longer span and reduction of story height have greatly increased as building structures become much larger and higher in recent years. Although the development of flexural members for reducing story height or making long span has been studied by many researchers and engineers, there is still a lack of efficient systems that meet these two demands simultaneously. This study aimed at developing a new composite beam system suitable for long span and reduction of story height, and proposed a prestressed composite beam with corrugated web. It has great resistance against non-symmetric construction load due to its strong out-of-plane shear strength with relatively small member height as well as good constructability and economic efficiency by removing/minimizing form work. The corrugated webs also make accordion effect introducing larger effective prestressing force to top and bottom flanges, which causes larger upward camber reducing the member deflection. Five full-scale specimens with key test parameters, which are web sectional shapes and number of drape points, were tested to understand their flexural behavior and to verify the performance of the proposed method. The experimental test results showed that the proposed prestressed composite beam had greater flexural strength and stiffness than the ordinary non-prestressed composite beam.

• KSCE Journal of Civil and Environmental Engineering Research
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• v.31 no.3A
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• pp.215-225
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• 2011

In general, the precast columns can obtain its homogeneous quality as they are produced in a factory with a hollow concrete block type by using high strength concrete, so that they can generate the reduction of dead load. Such a method of precast hollow concrete columns is already implemented in USA and Japan and used for connecting between blocks which use PC tendons. However, it is inevitable to have uneconomical construction with excessive cost in early stage when PC tendons are used. This study aims to develop an economical precast column with high quality and constructability which consists of only splice sleeve and general reinforcing bar without using PC tendons in order to reduce the construction period and cost. To achieve this goal, this study tested the performance of total 5 minimized models in the experiment with the variables such as hollowness, diameter of main reinforcement bar and cross-sectional size for the cross section of precast column by using grouting type splice sleeve which is a new type joint rebar. And it also verified the performance of column in the experiment for a large-sized model in order to overview its applicability by excluding large scale effect.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2017.05a
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• pp.130-130
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• 2017

Au 합금 도금층은 내마모성 및 내식성이 우수하고 접촉저항이 낮기 때문에, 커넥터, 인쇄회로기판 등과 같은 전자부품의 접속단자부에 널리 적용되고 있다. 각 부품들을 효과적으로 전기적 신호를 통해 연결하기 위해서는 낮은 접촉저항이 요구되며, 이러한 Au 합금 도금층의 접촉저항은 합금 원소의 종류 및 함량, 용융 솔더와 전자부품을 고정시키는 표면실장공정에서 받는 theremal aging의 온도와 시간에 따라 변화된다. 현재 전자부품용 커넥터에 실시되고 있는 금 합금도금은 Au-0.3wt%Co합금, Au-0.2wt%Ni합금도금이 대부분 적용되고 있으며, 높은 순도(금 함유량 99.7wt%이상)로 인하여 금 사용량을 절감하기 어려운 실정이다. Sn은 Au와 높은 고용률을 갖는 합금을 형성하는 장점을 갖고 있기에 금 사용량 절감에 큰 기여를 할 수 있을 것으로 예상된다. 따라서 본 연구에서는 Sn을 합금 원소로 사용하여 높은 Sn함량을 갖는 Au 합금 도금층을 제작하고, 무연솔더의 융점보다 더 높은 온도인 533K에서 thermal aging을 실시하여, Sn함량별로 thermal aging에 따른 접촉저항과 솔더퍼짐성의 변화를 기존의 Co, Ni합금과 비교 조사하였다. 또한, 표면분석을 통하여 Au-Sn합금 도금층의 접촉저항이 변화하는 요인에 대해서도 고찰하였다. 표면적 $0.2dm^2$의 순수 동 시편 위에 약 $2{\mu}m$두께의 Ni도금을 실시한 후 Sn 함량을 다르게 준비한 도금 용액(Au 6g/L, Sn 1~8g/L)을 사용하여 Au-Sn합금 도금을 실시하였다. Au-Sn합금 도금층은 전류밀도 0.5ASD, 온도 $40^{\circ}C$에서 약 $0.1{\mu}m$두께가 되도록 도금하였으며, 두께는 형광X선 도금두께측정기로 측정하였다. 금 합금 도금층 내의 Sn함량은 Ti시편 위에 도금한 Au-Sn합금층을 왕수에 용해시킨 다음, ICP를 사용하여 분석하였다. Au-Sn합금 도금층의 접촉저항은 준비된 시편을 533K에서 1분 30초, 3분, 6분 간 열처리한 후, 5회 접촉저항을 측정하여 그 평균값으로 하중에 따른 금 합금 도금층의 접촉저항을 비교하였다. 솔더링성은 솔더볼을 합금 표면에 솔더페이스트를 이용하여 붙인 뒤 533K에서 30초간 열처리하고, 열처리 후 솔더볼의 높이 변화를 측정해 열처리 전 솔더볼의 높이에 비해 퍼진정도를 측정하였다. 또한, 도금층 내의 Sn함량에 따라서 접촉저항이 변화하는 요인을 분석하기 위해서 X선 광전자 분광기를 이용하여 도금층 표면의 정량 분석 및 화학적 결합상태를 분석하였다. ICP분석결과 Au-Sn합금층 내의 Sn함량은 도금용액의 조성별로 9~12wt% Sn 합금층이 형성된 것을 알 수 있었고 기존의 Au-Ni, Au-Co 합금층과 비교해 합금함량이 크게 증가된 것을 알 수 있었다. 또한 접촉저항 측정 결과, 기존의 Au-Ni, Au-Co합금층의 접촉저항과 비교했을 때 Au-Sn합금층의 접촉저항이 더 낮은 것을 알 수 있었다. 또한, 솔더퍼짐성 측정 결과 기존의 Au-Ni, Au-Co합금층과 비교해 솔더퍼짐성이 우수한 것을 확인할 수 있었다. 따라서 전자부품용 접점재료에 합금함량이 높은 Au-Sn합금층을 적용시키면 더 우수한 커넥터의 성능을 얻을 수 있을 뿐 아니라 경제적으로 큰 절약 효과를 기대할 수 있을 것으로 판단된다.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.3
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• pp.269-275
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• 2019

As the national industry is developing gradually due to the expansion of the economic scale, the construction of large and super high-rise structures for building social infrastructure has been increasing, and studies have been conducted actively to transmit the large loads at the upper portion to the lower bedrock. In this study, the PHC was extended to an ultra-high strength PHC, which increased the concrete compressive strength of the PHC from the conventional 80 MPa to 110 MPa, and the PHC, which extended the tip of the pile. After construction with the driving method and injected pile method, the tendency of the bearing capacity was tested through a load test. Measurements of the bearing capacity of the extended PHC using the pile driving method revealed the main surface friction force to be smaller than that of the general PHC, and the stet-up effect was also insignificant. On the other hand, the effect of the friction force on the ground surface when the injected pile method was applied is expected to increase the bearing capacity when the gap between the main surface and the ground is wide and the cement paste is filled tightly. In addition, the ultrahigh strength PHC showed higher bearing capacity than the conventional PHC, and the permissible pile stress was less than 60%. Therefore, it is possible to reduce the number of piles and reduce the construction cost and effect of shortening the length of the pile by designing the tip of the pile on the ground with the intensity of soft rock as a method for utilizing the increased strength of the ultra-high strength PHC.