• 소성∙가공
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• 제32권6호
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• pp.303-310
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• 2023

Electrohydraulic forming(EHF), one of the high-speed forming method, can supplement the weak point of previous forming process such as deep-drawing and electromagnetic forming. Indeed, EHF is time-consuming process during installing wire before experiment that hard to apply to industry. In this research, applying wireless electrode, the formability of SUS430 sheet was compared through EHF experiments using wire-installed electrode and the other, wireless. Although the power was a little lacking, the advantages of the experiment using wireless electrode could be confirmed with checking the optimal location of electrodes where the plasma is generated and comparing free-bulging height depending on former and later condition of electrodes with performing several single and multistage experiments for same voltage, 6 kV.

• 한국산학기술학회논문지
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• 제18권3호
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• pp.320-326
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• 2017

다단 딥드로잉 기술은 제품의 생산성 향상과 비용 절감을 위해 휴대폰 배터리 케이스 제품의 생산 공정으로 많이 사용하고 있다. 휴대폰 배터리 케이스는 용량과 강성을 목적으로 세장비가 큰 사각 컵 형상으로 제조된다. 사각 컵 형상의 다단 딥드로잉은 세장비가 크고, 복잡한 변형 형태 메커니즘으로 인한 제품의 좌우 높이 차이가 발생한다. 이로 인해 제품 조립과 표면 품질에 문제가 발생한다. 본 연구에서는 이러한 문제를 개선하기 위해 제품의 높이 차이가 최소가 되는 블랭크 형상에 대해 연구했다. 제품 좌우 높이 차이가 최소가 되는 블랭크 형상을 찾기 위해 최적 설계와 해석을 수행했다. 타원형 블랭크의 장변과 단변을 설계 변수로 설정하고, 목적 함수는 높이 차이가 최소가 되도록, 제품의 두께 감소율이 목표 범위에 도달하도록 설정했다. 또한 최종 제품 형상의 높이를 구속 조건으로 설정하였다. 그 결과 최적 설계를 통한 초기 블랭크 설계로 높이 차이가 최소가 되었으며, 원하는 공정을 지정하여 높이 차이가 최소화 되도록 수행 가능하다. 향후 개발된 자동화 프로세스로 인해 모든 각형 타입의 초기 소재 설계가 가능할 것으로 판단된다.

• 한국산학기술학회논문지
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• 제16권9호
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• pp.5789-5794
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• 2015

최근 스마트 폰, 모바일 PC 제품의 외관에 필요한 가벼운 금속제품으로 제조를 하기 위하여 알루미늄 압출 공정과 CNC 가공기법을 적용한 생산방식이 널리 사용되고 있다. 하지만, 알루미늄 압출법은 외관 디자인의 제약이 있으며, 특히 CNC 가공 프로세스가 상대적으로 높은 생산 비용 및 낮은 생산성으로 생산단가가 많이 높은 단점이 있다. 본 연구에서, 새로운 처리 방법을 순서 재료비를 대폭 감소시키고, 제조 속도를 향상시키기 위해 판재성형과 부피성형의 두가지 공정을 섞어 새로운 판단조 공정을 개발하였다. 새로운 판단조 공법(hybrid plate forging)이란 우선 일반적인 딥드로잉으로 중간 모양을 만든 후 원하는 벽 부위만 증육을 하는 방법을 의미한다. 이러한 판단조 공법을 활용하여 재료의 낭비와 제조 시간을 최소화하는 것이 가능하게 된다. 본 연구에서는 상용 유한 요소 프로그램 AFDEX-2D를 통해 판단조공정을 설계하였고 최적의 사용 가능한 소재의 두께와 초기 폭을 설계하였다. 최종적으로 실제 노트북 케이스 금형을 제작하여 제안한 방법의 타당성을 검증하였다.

• 한국정밀공학회지
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• 제11권4호
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• pp.77-87
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• 1994

This paper deals with an automated forming sequence design system by which designers can determine desirable operation sequences even if they have little experience in the design of cold forging process. The forming sequence design in the cold forging is very important and requires many kinds of technical and empirical knowledge. They system isproposed, which generates forming sequence plans for the multistage cold forging of axisymmtrical solid products. Since the process of metal forming can be considered as a transformation of geometry, treatment of the geometry of the product is a key in planning process. To recognize the geometry of the product section, section entity representation and primitive geometries were used. Section entity representation can be used for the calculation of maximum diameter, maximum height, and volume. Forming sequence for the part can be determined by means of primitive geometries such as cylinder, cone, convex, and concave. By utilizing this geometrical characteristics (diameter, height, and radius), the product geometry is expressed by a list of the priitive geometries. Accordingly the forming sequence design is formulated as the search problem which starts with a billet geometry and finishes with a given product one. Using the developed system, the sequence drawing with all dimensions, which includes the proper sequence of operations for the part, is generated under the environment of AutoCAD. Based on the results of forming sequence, process variables(strain, punch pressure, die inner pressure, and forming load) are determined.

• 대한기계학회논문집A
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• 제35권9호
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• pp.1027-1033
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• 2011

VCM 강판은 용융아연도금강판 위에 PET/PVC 코팅하여 가전제품의 외판 소재로 사용되고 있다. 본 연구에서는 VCM 강판의 프레스 성형 중 발생하는 PET 코팅층의 찢김을 저감하기 위해 프레스 성형공정변수를 재설계하였다. 프레스 공정변수들이 PET 코팅층의 찢김에 미치는 영향을 분석하기 위해 유한요소해석을 수행하였다. PET 코팅의 찢김 현상은 드로잉 성형시 제품의 코너부 소재두께의 증가로 인해 금형과 소재 사이의 과도한 마찰에 의해 발생한다. 이를 해결하기 위해 블랭크 형상의 변경을 통해 드로잉성형시 코너부의 소재두께 증가를 저감하였으며, 트리밍 공정시 플랜지부의 과도한 두께 증가부분을 제거하여 플랜지 성형시 소재두께가 금형간극 이하로 분포하도록 하였다. 또한 성형실험과 유한요소해석을 통해 재설계된 공정변수들을 검증하였다. 이를 통해 PET 코팅의 찢김이 없는 양호한 최종제품의 성형이 가능함을 확인하였다.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회B
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• pp.2609-2614
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• 2007

Shell & Tube type Oil Cooler is widely used for hydraulic presses, die casting machines, generation equipments, machine tools and construction heavy machinery. Temperature of oil in the hydraulic system changes viscosity and thickness of oil film. They have a bad effect to performance and lubrication of hydraulic machinery, so it is important to know exactly the heat exchanging efficiency of oil cooler for controlling oil temperature. But most Korean manufacturers do not have test equipment for oil cooler, so they cannot carry out the efficiency test of oil cooler and it is impossible to verify its performance. This paper includes information of construction of necessary utilities for oil cooler test and design and manufacture of test equipment. One can select the optimum product by obtaining performance data through tests of various kinds of oil coolers. And also the paper developed a program which can be easily used for design of 2D and 3D drawings of oil cooler.

• Journal of Mechanical Science and Technology
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• 제16권12호
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• pp.1687-1692
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• 2002

The problem analyzed here is a sheet metal forming process which requires a drawbead. The drawbead provides the sheet metal enough tension to be deformed plastically along the punch face and consequently, ensures a proper shape of final products by fixing the sheet to the die. Therefore, the optimum design of drawbead is indispensable in obtaining the desired formability. A static-explicit finite element analysis is carried out to provide a perspective tool for designing the drawbead. The finite element formulation is constructed from static equilibrium equation and takes into account the boundary condition that involves a proper contact condition. The deformation behavior of sheet material is formulated by the elastic-plastic constitutive equation. The finite element formulation has been solved based on an existing method that is called the static-explicit method. The main features of the static-explicit method are first that there is no convergence problem. Second, the problem of contact and friction is easily solved by application of very small time interval. During the analysis of drawbead processes, the strain distribution and the drawing force on drawbead can be analyzed. And the effects of bead shape and number of beads on sheet forming processes were investigated. The results of the static explicit analysis of drawbead processes show no convergence problem and comparatively accurate results even though severe high geometric and contact-friction nonlinearity. Moreover, the computational results of a static-explicit finite element analysis can supply very valuable information for designing the drawbead process in which the defects of final sheet product can be removed.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2001년도 춘계학술대회 논문집
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• pp.735-739
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• 2001

This paper describes a research work of developing computer-aided design of a product with bending and piercing for progressive working. An approach to the system for progressive working os based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theorise, experimental results and the empirical knowledge of field experts. the system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of three main modules, which are input and shape treatment, flat pattern layout and strip layout modules. Strip layout of the system is designed by using fuzzy set theory. Process planning is determinated by fuzzy value according to several rules. Strip layout drawing generated in strip layout module is presented in 3-D graphic forms, including bending sequences and piercing processes with punch profiles divided into for external area. Results obtained using the modules enable the manufacturer for progressive working of electric products to be more efficient in this field.

• 한국정밀공학회지
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• 제18권2호
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• pp.177-185
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• 2001

This study shows the process design and forming analysis of permalloy shielding can that support the automobile multi-display parts to indicate the accurate information of car. This study is particularly important, since the strain and thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite sensitively. The objective functions are strain and thickness deviation. The punch radius, die radius and blank holding force are considered as design parameters. Orthogonal array (OA) table and characteristics are applied to neural network (NN) as train data. After training, the optimal and robust condition of design parameters is selected. This study shows the correlation between the design methodology of NN and the statistical design of experiments (DOE) approach.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.86-91
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• 2005

The stack, the core unit of the MCFC system, is composed of the three main parts which are the electrodes, the matrix keeping the electrolyte and the separator. Among these, the separator made of low carbon steel is manufactured by some sheet metal forming processes. The flatness of flange of the mask plate of the separator is crucial not only to enhance the stack performance but also to reduce the production cost. This study has focused on the enhancement of flatness of the mask plate flange by controlling some process parameters like the punch and die comer radii, the blank holding force, the friction coefficient and so on. The springback phenomenon occurring in the flange drawing process has been studied first using the finite element method (FEM) in order to understand what causes the springback. The distribution pattern of local longitudinal stress in the flanged part has been revealed very important in predicting the final shape of the flange. This fact has been backed up by the experimental results carried out with the developed test dies.