• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.27 no.10
• /
• pp.1793-1799
• /
• 2003

An optimal design of a multi-layered plate structure to endure high-velocity impact has been suggested by using size optimization after numerical simulations. The NET2D, a Lagrangian explicit time-integration finite element code for analyzing high-velocity impact, was used to find the parameters for the optimization. Three different materials such as mild steel, aluminum for a multi-layered plate structure and die steel for the pellet, were assumed. In order to consider the effects of strain rate hardening, strain hardening and thermal softening, Johnson-Cook model and Phenomenological Material Model were used as constitutive models for the simulation. It was carried out with several different gaps and thickness of layers to figure out the trend in terms of those parameters' changes under the constraint, which is against complete penetration. Also, the measuring domain has been shrunk with several elements to reduce the analyzing time. The response surface method based on the design of experiments was used as optimization algorithms. The optimized thickness of each layer in which perforation does not occur has been obtained at a constant velocity and a designated total thickness. The result is quite acceptable satisfying both the minimized deformation energy and the weight criteria. Furthermore, a conceptual idea for topology optimization was suggested for the future work.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.5
• /
• pp.131-136
• /
• 2016

Currently, an EDM tapping procedure has comprised some parts of the engraving discharge process for the press die. Usually, tapping has been used in cases where we are unable to mechanically machine using steelwork processes due to an increase in the hardness of a material after heat treatment in relation to a design change or missing process. Here, we analyze the influence of discharge tap shape on discharge time, discharge current, and the number of repetition conditions when a cold-work tool steel (STD11) has been treated with a discharge tapped by a screw-shaped cu electrode. The most important influence on processing condition has been determined to be the number of discharge repetitions. As this number increases, the angle reduction of a thread closes to an angle of the electrode via a power generation reduction. The optimal combination of conditions has been determined to be three discharge repetitions, $180{\mu}s$ of discharge time (same as existing regulations), and 25.4A of peak current. A 0.2749db advantage has emerged after comparing between this combination of optimal conditions and the SN rate of existing regulations.

• Elastomers and Composites
• /
• v.43 no.3
• /
• pp.173-182
• /
• 2008

Rubber-pad forming process for materials such as metal in which portions of the die which act upon the material is composed of a natural or synthetic rubber or elastomer material. This makes the rubber pad forming process relatively cheap and flexible, high accuracy for small product series in particular. In this study, we carried out the physical test and finite element analysis of elastomer such as natural rubber and urethane for steel rack rube forming. The non-linear property of elastomer which are described as strain energy function are important parameter to design and evaluate of elastomer component. These are determined by material tests which are uni-axial tension and bi-axial tension. This study is concerned with simulation and investigation of the significant parameters associated with this process.

• The Journal of Korean Academy of Prosthodontics
• /
• v.35 no.2
• /
• pp.417-430
• /
• 1997

The purpose of this study was to compare the fracture resistance of copy-milled and conventional In-Ceram crown. Four groups of ten uniform sized all-ceramic crowns were fabricated. In-Ceram Spinell and In-Ceram Alumina crowns were fabricated as control group, Celay In-Ceram Spinell and Celay In-Ceram Alumina crowns were fabricated as test group. All specimen were cemented on stainless steel master die with resin cement, and stored in $37^{\circ}C$ water for 1 day prior to loading in Instron testing machine. Using a steel ball at a crosshead surfed of 0.5mm/min, the crowns were loaded at $30^{\circ}C$ angle until catastrophic failure occurred. The results obtained were as follows : 1. With the value of $984.8N{\pm}103.67N$, the strength of Celay In-Ceram Alumina crowns had a significantly higher fracture strength than conventional In-Ceram Alumina crowns ($876.2N{\pm}92.20N$) (P<0.05) 2. The fracture strength of Celay In-Ceram Spinell crowns($706.3{\pm}70.59N$) was greater than that of conventional In-Ceram Spinell crowns($687.4{\pm}90.26N$), but there was no significant difference(P>0.05). 3. The In-Ceram Alumina crowns had a significantly higher fracture strength than In-Ceram Spinell crowns in both methods(P<0.05). 4. Ther order of fracture strength was as followed : Celay In-Ceram Alumina, In-Ceram Alumina, Celay In-Ceram Spinell and In-Ceram Spinell crowns

• Tribology and Lubricants
• /
• v.31 no.4
• /
• pp.157-162
• /
• 2015

In this study, an ultrasonic nanocrystalline surface modification (UNSM) technique is applied to tungsten carbide-cobalt (WC-Co) to extend the service life of carbide parts used in press mold. The UNSM technique modifies the structure, reduces the surface roughness, increases the surface hardness, induces the compressive residual stress, and increases the wear resistance of materials by introducing severe plastic deformation. The surface roughness, hardness, and compressive residual stress of WC after UNSM treatment improve by about 42, 10, and 71%, respectively. A wear test under dry conditions is used to assess the effectiveness of the UNSM technique on the friction and wear behavior of WC. The UNSM technique is found to reduce the WC friction coefficient by approximately 21% and enhance the wear resistance by approximately 85%. The improved friction and wear behavior of WC may be mainly attributed to the increased hardness and compressive residual stress. Moreover, the WC specimen is treated by UNSM technique using three different WC, silicon nitride (Si₃N₄) and stainless steel (STS304) balls. The surface treated by WC balls shows the highest hardness when compared with treatment by stainless steel and silicon nitride balls. According to the obtained results, the UNSM technique is believed to increase the durability of the carbide component by improving the friction and wear behavior.

• Journal of Powder Materials
• /
• v.15 no.5
• /
• pp.359-364
• /
• 2008

To satisfy the demand of higher cutting performance, mechanical properties with tungsten carbide (WC-Co) tool materials were investigated. Hardness and transverse rupture strength with WC grain size, Co content and density were measured. Compared to H, K, and S manufacture maker as tungsten carbide (WC-Co) tool materials were used for high-speed machining of end-milling operation. The three tungsten carbide (WC-Co) tool materials were evaluated by cutting of STD 11 cold-worked die steel (HRC25) under high-speed cutting condition. Also, tool life was obtained from measuring flank wear by CCD wear measuring system. Tool dynamometer was used to measure cutting force. The cutting force and tool wear are discussed along with tool material characteristics. Consequently, the end-mill of K, H manufacture maker showed higher wear-resistance due to its higher hardness, while the S maker endmill tool showed better performance for high metal removal.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.19 no.9
• /
• pp.93-99
• /
• 2020

Recently, as the weight reduction of vehicles has been actively progressed, parts developed using aluminum 60XX series from existing steel materials are increasing. In this paper, the bushing used for the front frame rail, which is one of the parts for fixing engines and other parts in automobiles, was changed to an aluminum material of the Al60XX series, and it was intended to be produced by applying of cold forging method. The bushing is a part that secures the engine frame, and in order to produce it by cold forging, the molding limit is predicted through process design, and a multi-stage process is designed through finite element analysis. In addition, in order to verify the feasibility of the designed forging process, the limits of the multi-step process were verified based on the Cockcroft Latham theory, and the crack and overlap of the actual forging work were predicted and improved.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.22 no.1
• /
• pp.173-177
• /
• 2013

The purpose of this paper is to investigate the influences on mechanical properties of two-stroke cycle motor pistons manufactured by casting, conventional forging and powder forging, through the comparison of characteristics, merits and disadvantages of each forming technology. For each forming technology, the optimal process parameters were determined through the experiments for several conditions, and microstructure, hardness, tensile strength and elongation of pistons are compared and analyzed. In conventional forging process, material temperature was $460^{\circ}C$ and the die temperature was $210^{\circ}C$ for the Al 4032. The optimal condition was found as solution treatment under $520^{\circ}C$ for 5 hours, quenching with $23^{\circ}C$ water, and aging under $190^{\circ}C$ for 5 hours. In powder forging process, the proper composition of material was determined and optimal sintering conditions were examined. From the experiment, 1.5% of Si contents on the total weight, $580^{\circ}C$ of sintering temperature, and 25 minutes of sintering time were determined as the optimal process condition. For the optimal condition, the pistons had 76.4~78.3 [HRB] of hardness, and 500 [MPa] of tensile strength after T6 heat treatment.

• Journal of the Korean Society for Precision Engineering
• /
• v.2 no.2
• /
• pp.31-42
• /
• 1985

The metal flow and the strain distribution is investigated for the steady state and non-steady state bulk deformation processes by using an improved visioplasticity method which includes the effective smoothing scheme. The comparison of various smoothing schemes leads to the selection of the five- point least square smoothing method which is employed to reduce the measurement errors. As a steady state forming process experiments are carried out for axisy- mmetric forward extrusion through conical and curved dies of various area reduc- tions using Aluminum and steel billets. Axisymmetric backward extrusion is chosen for a nonsteady state forming process. In axisymmetric forward extrusion the results from visioplasticity show that the curved die of a fourth-order polynomial renders more uniform distribution of strain rates and strains. Higher reduction leads to greater strain rates at the outer side of the billet. The visioplastic observation for axisymmetric backward extrusion as a non-steady state deformation process shows the concentration of higher strain at the inner wall of the extruded product. The visioplastic results in forward extrusion are in agreement with the computed results by the finite element method. It is thus shown that the visio- plasticity combined with a smoothing technique is an effective method to determine the pattern and the distribution of strain rates and strains.

• Journal of the Korean Society for Precision Engineering
• /
• v.16 no.12
• /
• pp.168-173
• /
• 1999

It is investigated that internal defect of planetary gear which consists of two gears with different number of teeth on both side. The internal defect, central burst, begin to form at the place of adiabatic shear band which usually has maximum ductile fracture value during the forming operation, forward and backward extrusion. It makes the plastic forming of planetary gear difficult. The prediction of defect to minimize the cost to produce the planetary gear. The finite element simulation code DEFORM is applied to analyze the defects. In the analysis, the toothed gears are assumed as axisymmetric cylinders whose diameters are equal to those of pitch circles of the each gears. Experiments were carried out with the SCM415 alloy steel as billet material and AIDA 630-ton knuckle-joint press. The calculated results and experimental inspections are compared to design a die and blank without defects and the results are useful to predict the internal defect.