• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.6
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• pp.89-97
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• 2022

Ultrasonic metal welding has been widely used for joining lithium-ion battery tabs. Weld quality monitoring has been an important issue in lithium-ion battery manufacturing. This study focuses on the weld quality monitoring in ultrasonic metal welding with the longitudinal-torsional vibration mode horn developed newly. As the quality of ultrasonic welding depends on welding parameters like pressure, time, and amplitude, the suitable values of these parameters were selected for experimentation. The welds were tested via tensile testing machine and weld strengths were investigated. The dataset collected for performance test was used to train the multi-layer perceptron neural network. The three layer neural network was used for the study and the optimum number of neurons in the first and second hidden layers were selected based on performances of each models. The best models were selected for the horn and then tested to see their performances on an unseen dataset. The neural network models for the longitudinal-torsional mode horn attained test accuracy of 90%. This result implies that proposed models has potential for the weld quality monitoring.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.10
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• pp.1204-1209
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• 2011

In this study, fatigue life is evaluated by comparing with lighter car body through the experiment on SPR joints. An experimental activity on sheet metal samples of Aluminum 5J32 and Steel SPRC440 has been conducted to achieve better understanding of the process. In addition, SPR joint used less than the existing Spot Welding improves joint strength and fatigue life is evaluated by using SPR and adhesive joining Hybrid. Joining(bonding) strength and fatigue life on SPR and Hybrid (SPR + adhesive) are evaluated throughout the experiment. With joining strength than 20 % of the aluminum material, dissimilar materials has improved over 2 times as large as the strength In case of dissimilar materials, the fatigue life of aluminum is increased by 1.6 to 2.5 times as large as the life.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.314-319
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• 2002

The Automation and Control Group at the University of Brasilia is developing an automatic welding station based on an industrial robot and a controllable welding machine. Several techniques were applied in order to improve the quality of the welding joints. This paper deals with the implementation of a laser-based computer vision system to guide the robotic manipulator during the welding process. Currently the robot is taught to follow a prescribed trajectory which is recorded a repeated over and over relying on the repeatability specification from the robot manufacturer. The objective of the computer vision system is monitoring the actual trajectory followed by the welding torch and to evaluate deviations from the desired trajectory. The position errors then being transfer to a control algorithm in order to actuate the robotic manipulator and cancel the trajectory errors. The computer vision systems consists of a CCD camera attached to the welding torch, a laser emitting diode circuit, a PC computer-based frame grabber card, and a computer vision algorithm. The laser circuit establishes a sharp luminous reference line which images are captured through the video camera. The raw image data is then digitized and stored in the frame grabber card for further processing using specifically written algorithms. These image-processing algorithms give the actual welding path, the relative position between the pieces and the required corrections. Two case studies are considered: the first is the joining of two flat metal pieces; and the second is concerned with joining a cylindrical-shape piece to a flat surface. An implementation of this computer vision system using parallel computer processing is being studied.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.4
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• pp.85-96
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• 2001

In this paper, part features are classified and then its coding system is constructed by the considered characteristics of features in assemble process. Analyzing the characteristics of features, code values about part features are determined. Assembly process is divided into five functions such as transporting, handing, approaching, alignment and joining, and then the detail parameters of each functions such as determined. Code values about assembly process are determined according to detail parameters. The detail parameters are kinds of available working method and assembly tools when each assembly function is going on. By the coding system, available assembly process can be grasped and perceived for the part that it is difficult to assemble.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.9
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• pp.1-10
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• 2021

Recently, the repair and recycling of damaged mechanical parts via metal additive manufacturing processes have been industrial points of interest. This is because the repair and recycling of damaged mechanical parts can reduce energy and resource consumption. The directed energy deposition(DED) process has various advantages such as the possibility of selective deposition, large building space, and a small heat-affected zone. Hence, it is a suitable process for repairing damaged mechanical parts. The shaft is a core component of various mechanical systems. Although there is a high demand for the repair of the shaft, it is difficult to repair with traditional welding processes because of the thermal deformation problem. The objective of this study is to propose a repair procedure for a damaged shaft using the DED process and discuss its applications. Three types of cases, including a small shaft with a damaged surface, a medium-size shaft with a worn bearing joint, and a large shaft with serious damage, were repaired using the proposed procedure. The microstructure and hardness were examined to discuss the characteristics of the repaired component. The efficiency of the repair of the damaged shaft is also discussed.

• Proceedings of the KWS Conference
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• 1995.10a
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• pp.101-104
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• 1995

This paper deals with the development of fundamental design and manufacturing technique of hydraulic valve spool by optimizing of friction welding, the development of in-process real-time weld quality evaluation technique by acoustic emission and the evaluation of the mechanical properties and the fatigue life about the bar-to-bar dissimilar friction welded hydraulic valve spool steels.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.255-259
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• 2002

VIRGO 104 is a low carbon martensitic stainless steel that is applied to the famous Three Gorges Project. By using VOD melting process VIRGO 104 has low carbon and [H] [O] contents, and shows excellent mechanical properties and weldability. The best solution to guarantee welding quality is PWHT by 600 Cx8h.

• Proceedings of the KWS Conference
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• 2005.11a
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• pp.55-57
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• 2005

In this study, modeling of the CD stud welding system was conducted considering mechanical and electrical components. The electrical components such as arc resistance, cable resistance, capacitance, internal resistance and cable inductance were found to affect the output waveform significantly. The calculated results showed food agreements with the experiment results within 20% error. The main defect of CD stud welding with 1010 steel stud and SS400 steel plate was the void trapped between stud and base metal. The effect of the spring force and stud tip size on void formation was investigated.

• Journal of Welding and Joining
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• v.30 no.6
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• pp.113-119
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• 2012

Ultrasonic bonding is the novel packaging method for flip-chip with high yield and low-temperature bonding. The bonding module is a core part of the bonding machine, which can transfer the ultrasonic energy into the bonding spot. In this paper, we propose topology optimization technique which can make new design of boding modules due to the constraints on resonance frequency and mode shapes. The designed bonding module using topology optimization was fabricated in order to evaluate the bonding performance and reliable operation during the continuous bonding process. The actual production models based on the proposed design satisfied the target frequency range and ultrasonic power. The bonding test was performed using flip-chip with lead-free Sn-based bumps, the results confirmed that the bonding strength was sufficient with the designed bonding modules. Also the performance degradation of the bonding module was not observed after the 300-hour continuous process with bonding conditions.

• Journal of Welding and Joining
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• v.14 no.5
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• pp.95-105
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• 1996

Korea Gas Corporation has operated high pressure gas transmission line of about 600 kilometers and, therefore, a series of repair welding processes are required in order to cope with external defects such as dent, gouge, cracking usually due to mechanical attacks. Most of gas pipelines repair processes are performed after completely venting remaining gas. However, in some case, though it is very unusual, repairs require without venting gas. For instance, this case is that damaged pipeline is remedied with split sleeve by welding. In this paper, in an effort to confirm a safe application of the split sleeve welding, residual stress, strain and temperature distributions are evaluated by computer simulation and experiments. The results obtained are as follows : 1) Computer modelling is supposed to be reasonable because microstructure changes due to welding is simulated coincidently as compare to that of real condition. 2) The maximal temperature on inside surface of pipeline is 50$0^{\circ}C$ for the repair welding process. 3) The amount of residual stress is estimated as the stress corresponding to 0.8% strain. 4) The repair process employed is determined to be technically preferable because of its avoiding cracks and fractures in the course of welding.