• Design & Manufacturing
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• 제2권1호
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• pp.11-14
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• 2008

we can save a development cost and time as computer was used in tool and die design of car fields in die manufacture process. Dimension accuracy errors such as springback, springgo, overcrown and twist were reduced product accuracy and caused trouble to assembly each parts of car. In this paper, CADCEUS was used to modify and optimize results of deflection for a tail gate panel of car parts in order to reduce dimension accuracy errors by springback in sheet metal forming. As CADCEUS was used to apply for a tail gate panel, the time for quality to improve was reduced to 30%.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 추계학술대회 논문집
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• pp.233-235
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• 2001

Residual stress in the forged parts affects the resistance to mechanical failure, dimensional uniformity, and the service life of the parts. In order to elucidate the development of residual stress in open-die forging process, elasto-plastic finite element analysis was implemented to radial forging process. Super duplex stainless steel SAF 2507 was selected as workpiece material and a series of mechanical tests followed by numerical compensation to deformation heating was conducted to obtain necessary flow data. The residual stress distributions were calculated using commercial 3-D FEM code and the effects of process design were evaluated from selected results.

• International Journal of Precision Engineering and Manufacturing
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• 제3권4호
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• pp.43-53
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• 2002

Polishing a die that has free-form surfaces is a time-consuming and tedious job, and requires a considerable amount of high-precision skill. In order to reduce the polishing time and cope with the shortage of skilled workers, a user-friendly automatic polishing system was developed. The polishing system is composed of two subsystems, a three-axis machining center and a two-axis polishing robot. The system has five degrees of freedom and is able to keep the polishing tool in a position normal to the die surface during operation. A sliding mode control algorithm with velocity compensation was proposed to reduce tracking errors. Trajectory tracking experiments showed that the tracking error can be reduced prominently by the proposed sliding mode control compared to a PD (proportional derivative) control. To evaluate the polishing performance of the polishing system and to and the optimal polishing conditions, the polishing experiments were conducted.

• 한국기계가공학회지
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• 제12권1호
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• pp.117-125
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• 2013

Variations of springback in stamped parts are induced by the uncontrollable noises including the variation of incoming material properties, lubrication and other forming process parameters. Reduction of springback variation is very important during springback compensation processes on stamping dies and assembly processes. To reduce the variation of springback, a robust optimization methodology which uses complex method combined with orthogonal array is proposed. The proposed method is applied to the robust design of U-channel die for the reduction of side wall curl. It is shown that the drawbead and die radius of U-channel draw die can be effectively optimized by the proposed method.

• 열처리공학회지
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• 제35권2호
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• pp.66-73
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• 2022

Partial-hardened hot stamping has been well known to be very effective to absorb more energy in automotive lateral crash. Hardness distribution and dimensional change after partial-hardened hot stamping have been studied to find out effect of thermal deformation of the heated hot stamping die on dimensional accuracy of automotive center pillar. Soft zone of commercial center pillar showed 275~345 in Vickers hardness, indicating bigger non-uniformity which resulted from thermal deformation of heated die. Dimensional changes in soft zone of the commercial center pillar measured by three dimensional scanner were much bigger than that in hard zone. It has been found that hot stamping die compensation considering thermal deformation in soft zone causes a significant decrease in hardness deviation in the soft zone, corresponding to 20 percent of commercial center pillar and subsequently leads to much higher dimensional accuracy.

• 소성∙가공
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• 제21권7호
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• pp.397-402
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• 2012

The flange hub is a main component in an automotive steering system. In general, the flange hub are fabricated by mechanical machining, which is a process where material waste is inevitable. It is well-known that a net-shape cold forging cannot only reduce material waste but can also improve the mechanical strength of the final product. Thus, a forging process design was conducted for production of a flange hub. Significant spring-back occurs around the flange due to its small thickness in conjunction with the residual stresses after forging. In order to achieve the required dimensional accuracy, a process design with appropriate spring-back control is needed. In this study, a modification of the forging die was designed based on FE analysis with the purpose of spring-back compensation. Four kinds of different die designs were evaluated and the optimum design has two times less spring-back than the initial design. The compensation angle of the optimum design is 0.5 degrees. The results have been experimentally confirmed by cold forging of a flange hub and comparing the amount of spring-back between the actual component and the FE analysis.

• 대한산업공학회지
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• 제39권3호
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• pp.149-155
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• 2013

Electric discharging machining (EDM) is commonly adopted to machine the precise and tiny part when it is difficult to meet the productivity and the tolerance by the conventional cutting method. The die-sinking EDM method works well to machine the micro-parts and the perpendicular wall of die and mould, whereas EDM drilling, called super drill, is excellent to machine the deep and narrow hole regardless the material hardness and the hole location. However, the electrode wear is rapid compared to the conventional cutting tool and makes it difficult to control the electrode feeding and to machine precisely. This paper presents an efficient method to estimate the electrode wear using hole pass-through experiment while the stochastic method is used to compensate for the estimation model. To validate the proposed method, the commercial EDM drill machine is used. The experiment result shows that the electrode wear amount can be predicted very precisely.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 추계학술대회 논문집
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• pp.277-280
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• 2000

Reverse Engineering is a procedure where the results of engineering decisions in manufacturing is feedback to the design phase and the knowledge-base is generated from the process know-how to reduce the errors. Since it used to take lots of time and efforts to finalize the machining of dies out of the original CAD design especially for die spotting and try-outs, reverse engineering is important to improve the productivity and quality of the die manufacturing process. In this regard, we developed system to support reverse engineering in machining of stamping dies for auto-body production. They automatically generate the relevant MC programs for a CMM simply with the input of measuring points in CAD environments, and show the CAD model and the results of inspection simultaneously for the ease of comparison. They also help reduce the overall clearance between the lower and upper dies. Applying these systems to the machining process of stamping dies, we could improve the reliability of measuring and get the optimal compensation distance between the two dies. We also analyzed the expected benefits of the system in terms of savings in time and costs.

• 소성∙가공
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• 제13권7호
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• pp.594-599
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• 2004

In the sheet metal forming operations, the strain measurement of sheet panel is an essential work which provides the formability information needed in die design, process design, and product inspection. To measure efficiently complex geometry strains, the 3-dimensional automative strain measurement system, which theoretically has a high accuracy but practically has about 3～5％ strain error, is often used. For eliminating the strain error resulted in measuring the strains of formed panels using an automated strain measurement system, the position error calibration method is suggested, which computes accurate strains using the grids with accurate nodal coordinates. The accurate nodal coordinates are calculated by adding the nodal coordinates measured by the measurement system and the position error found using the multiple regression method as a function of the main error parameters obtained from the analysis of strain error in a standard cube. For the verification, the strain distributions of square and dome cups obtained from the position error calibration method are compared with those provided by the finite element analysis and ASAME.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 춘계학술대회논문집
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• pp.270-273
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• 2003

The strain measurement of the panel in the sheet metal forming is essential work which provides experimental data needed to die design, process design, and product inspection. To measure efficiently the complex geometry strain, the 3-dimensional automative strain measurement system, which has high accuracy in theory, but has some 3∼5% errors in practice, is often used. The object of this study is to develop the error compensation technology to eliminate the strain, errors resulted when formed panels are measured using an automated strain measurement system. To achieve the study object, the position error calibration method correcting coordinates of the grid node recognized by a camera using error functions is suggested. Then the position errors were found by calculating the difference in the position of the cube node between real coordinates and measured coordinates in toms of node coordinates and the error calibration equations were derived by regressing the position errors. In order to show the validation of the suggested position error calibration method, finite element analysis and current calibration method was performed for the initial-blankformed.