• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2002.05a
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• pp.39-39
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• 2002

In order to improve wear and fatigue resistance of the structural materials, especially cold work roller for 304 stainless steel, an eco-super-finishing and surface hardening treatment using ultrasonic vibration energy was developed and applied to the SKD-ll roller. The eco-super-finishing machine was designed and fabricated by DesignMecha Co, by its own technology. It was observed that the surface roughness, hardness and residual stress were changed from $Ra{\;}={\;}O.25\mu\textrm{m}$, Hv=710 and ${\sigma}$={\;}+400{\;}MPa{\;}to{\;}Ra{\;}={\;}0.165\mu\textrm{m}$, Hv = 1200 and ${\sigma}=-610$ MPa after 20 KHz micro-cold forging, which means almost equal to the 300 % improvement of life-time.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.12 no.1
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• pp.115-125
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• 2016

The prototype SFR has currently been under design by KAERI. The size of its major components is much larger than that of APR1400 and high temperature materials are applied for it. The increased size of components and those specific materials effect on material procurement, manufacturing process and fabrication facilities. The manufacturing methods are studied for Reactor Vessel/Guard Vessel, Control Rod Drive Mechanism, Heat Exchanger, Primary Pump, Reactor Vessel Internals, Steam Generator and In-Vessel Transfer Machine. The proper manufacturing methods are suggested for each component including side forging technology for ultra large forgings of Reactor Vessel to minimize the weld seams on which In-service Inspection should be conducted.

• Transactions of Materials Processing
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• v.22 no.6
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• pp.317-322
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• 2013

A radio frequency(R/F) switch connector is widely used in wireless devices such as mobile phone and navigator to check defects of the circuit board of product. The R/F switch connector shell plays a role in protecting the switch connector. Previously, this part was machined using a turning, which is time-consuming and has poor material utilization. Furthermore, the workpiece material of brass containing lead that has excellent machinability has environmentally regulated during recent years. The purpose of the current study was to develop the connector shell by forming through progressive dies including embossing, burring and forging process in order to achieve higher productivity and dimensional accuracy without tool failure. To accomplish this objective, a strip layout was designed and finite element (FE) analysis was performed for each step in the process. Try-out for the connector shell was conducted using progressive die design based on FE-analysis results. Dimensional accuracy of developed part was investigated by scanning electron microscopy. The result of the investigation for the dimensions of the formed connector shell showed that the required dimensional accuracy was satisfied. Moreover, productivity using the progressive die increased four times compared to previous machining process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.173-176
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). In this study, process design for closed-die forging of a Lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of Lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.4
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• pp.1290-1300
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• 1996

The finite element method, based on rigid-plastic formulation, is widely used to simulate metal forming processes. In order to improve the computational efficiency of the rigid-plastic FEM, one-point integration is used to evaluate the stiffness matrix with four-node rectangular elements and eight-node brick elements. In order to control the hourglass modes, hourglass strain rate components were introduced and included in the effective strain rate definition, Numerical tests have shown that the proposed one-point integration scheme reduces the stiffness matrix evaluation time without deteriorating the convergence behavior of Newton-Raphson method. Simulations of a ring compression, a plane-strain closed-die forging and the three-dimensional spike forging processes were carried out by using the proposed integration method. The simulation results are compared to those obtained by applying the conventional integraiton method in terms of the solution accuracy and computational efficiency.

• Transactions of Materials Processing
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• v.30 no.4
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• pp.165-171
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• 2021

This study was conducted on the manufacturing method of high-strength aluminum bolts. We obtained the displacement-load information by tensile test of the Al 6056 raw material and the T6 heat-treated material and calculated the precise flow stress and fracture limit using repetitive finite element analysis for before and after heat treatment. We designed a multi-stage forging process for T6 heat-treated material, and calculated that the accumulated damage value does not exceed fracture limits by finite element method. We produced the prototype forgings without any harmful defects such as cracks and folding occurring. Bolts made of T6 heat treated material show 9.6%higher tensile strength than T6 heat treated material after wire drawing.

• Korean Journal of Computational Design and Engineering
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• v.9 no.2
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• pp.133-142
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• 2004

CAMPfonn2D is a Finite Element Method (FEM) based process simulation system designed to analyze two dimensional (2D) flow of various metal forming processes. It enables designers to analyze metal forming processes on the computer rather than the shop floor using trial and error and provides vital information about material and thermal flow during the forming process to facilitate the design of products. CAMPfonn2D can be used by companies, research institutes and industrial applications to analyze forging, extrusion, drawing, heading, upsetting and many other metal forming processes. Also, process simulation using CAMPfonn2D can be instrumental in cost, quality and delivery improvements at leading companies. Today's competitive pressures require companies to take advantage of every tool for rapid manufacturing of well-designed product. So, the preprocessor of simulation program must be easy to use to speed-up design. In this paper, we introduce new version of Preprocessor and show how easy to use it. And, Preprocessor will prove itself to be easy and extremely effective.

• Korean Institute of Interior Design Journal
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• no.6
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• pp.28-37
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• 1995

As we approach the end of the twentieth century, it seems we need a new way to express the thoughts, needs, and values that are undergoing a drastic change and a new strategy to create diverse cultural forms that would reflect and incorporate such changes. In this study, I am introducing the chaos theory as a new way of thinking that would help counterbalancing the deter-ministic world-view and forging a harmonious unity of man and his environment. As a creative principle, the theory seems to offer an unlimited number of structural possibilities for art and design. In fine, this study discuss-es the reductive nature of modernist approach and offer instead the chaos theory that is more probabilistic and capable of greater diversity.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.226-231
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• 2006

The fuel injector is a pa.1 that controls the fuel supply of automotive engine. The housing of the fuel injector supports the rod, the needle valve and the solenoid. In this study, the rigid-plastic FE-analysis by using the design of experiments (DOE) and the response surface methodology (RSM) has been performed to produce the product reducing the under-fill and the maximum effective strain. From the results of DOE, the stem of counter punch and the face angle of punch at the $1^{st}$ process, and the stem of punch at the $2^{nd}$ process were determined as the significant design variables far each response such as the upper under-fill, lower under-fill and the maximum effective strain. From the results of RSM, the optimal values of the design variables have been also determined by simultaneously considering the responses.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2007.06a
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• pp.527-528
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• 2007