• Transactions of Materials Processing
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• v.32 no.3
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• pp.122-128
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• 2023

As electric vehicles (EV) have increasingly replaced the conventional vehicles with internal combustion engines (ICE), most of automotive makers are actively devoting to the technology development of EV parts. Accordingly, the manufacturing process for power source has been also shifting from engine/transmission to EV motor/reducer system. However, lack of experience in developing the EV motor still remains as a technical challenge. In this paper, we employed the forming simulation based on finite element modeling to solve this problem. In particular, in order to increase the accuracy of the forming simulation, we introduced the elastic-plastic constitutive model parameters for polymer-copper hybrid wire by investigating the individual strain-stress curves, and elastic modulus of polymer and copper. Then, the reliability of modeling procedure was confirmed by comparing the simulated results with experiments. Finally, the identified mechanical properties and finite element modeling were applied to a hairpin forming process, which involves multiple deformation paths such as bending, pressing, widening, and twisting. The proposed numerical approach can replace common experience or experiment based trials by reducing production time and cost in the future.

• Journal of the Society of Naval Architects of Korea
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• v.56 no.2
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• pp.128-134
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• 2019

In shipbuilding, accurate fabrication of curved hull plates is one of the most important steps, since the shape of ship hull, which is very critical in the overall performance of a ship, is a collection of such plates. The curved hull plates forming process requires a significant amount of time by skilled workers in shipbuilding. In general, the workers cause thermal distortion in the plate and forming initial shape using gas heat source. So shipbuilding companies need skilled workers who have long experience. To solve the problem, a lot of researchers tried to develop automation system for curved hull plates. In this paper, we propose automatic heating system with gantry robot, high frequency induction heater to replace the gas heat source and automatic measurement system. We apply the system to forming concave type plate that is actually used in ship manufacturing. In addition, a system was developed to automatically generate heating information, such as the heating location and the heating speed, for actual heating process. Then the system was applied to the actual heating material. It is shown that the proposed triangle heating pattern makes desired concave shape successfully. The induction heating system showed that it can be used for automation system of curved hull plates forming process replacing gas heat source.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.10
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• pp.1748-1753
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• 2003

This paper describes the forming of fine gear housing using RP system. In order to apply 3D model formed through CAD software to RP system, it is necessary of transforming 3D model into STL file format. Besides, when the same shape is formed repetitively, we must solve the program that the shape accuracy of prototype is irregular. Therefore, we will make an experiment on influence of 3D model, file transformation and prototype on facetres, AutoCAD system value. On the basis of experimental result, we will develop an automatic file transformation program for RP. In the final process, we will manufacture on a better prototype according to the experiment result of fine gear housing.

• Korean Journal of Computational Design and Engineering
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• v.17 no.3
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• pp.188-197
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• 2012

Recently, aluminum ships are constructed more than ever because of the environmental pollution generated by FRP (Fiber Reinforced Plastic) ships. In particular, FRP ships have been replaced by the Aluminum ships. The forming process of the curved aluminum plate has been performed only by labor works without systematic technique. Therefore, it is difficult to construct the aluminum ship that the design satisfies both required propulsion performance and hull design. Present study introduces a MPSF (Multi Point Stretching Forming) that is a flexible manufacturing technique to form large sheet panels of doubly curvature. The hull pieces are stretch-formed over the MPSD (multi-point stretching die) generated by the punch element matrix. In this study, MPSF is applied to deform the doubly curved surfaces of aluminum ship. The forming system including FEA (finite element analysis) of the processes for stretching the plate were carried out by static implicit analysis is suggested. Residual deformation of the surface is modeled by an elasto-plastic contact phenomena while the forming process is simulated by FEA. Finally, the proposed system is also validated, comparing the deformed shape by MPSF with that of object surfaces.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.10
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• pp.1853-1860
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• 1992

The plane-strain stamping process is analyzed by a forming energy minimization method in order to obtain forming load, slip length and strain distribution in each step of punch stroke. All the developed programs are integrated into total CAD/CAE SYSTEM for the purpose of the practical usage in die design. The computed strain distribution and the amount of draw-in are compared with those of the actually developed panel It is found that there is a good agreement between theoretical and experimental results.

• Journal of the Optical Society of Korea
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• v.16 no.2
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• pp.127-132
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• 2012

This study discusses photoresist forming using a composite grayscale to fabricate a Fresnel lens. Grayscale lithography is a common production method used to facilitate the forming of lenses with different curvatures and depths. However, this approach is time consuming and expensive. This study proposes a method for overcoming these obstacles by integrating a digital micromirror device and microscope to supplant the traditional physical grayscale mask. This approach provides a simple and practical maskless optical lithography system. According to the results, the two adjacent grayscales displayed substantial differences between the high grayscale and influence the low grayscale that ultimately affected photoresist formation. Furthermore, we show that change of up to 150% in the slope can be achieved by changing the grayscale gradient in the central zone and the ring profile. The results of the optical experiment show a focus change with different gray gradients.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.1
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• pp.79-84
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• 2004

A light-guide is one of several important components of backlight unit in TFT-LCD. The manufacturing technology and optical system design of the light guide is very sensitive to quality and cost of the TFT-LCD module. In the present study a new manufacturing method which is called as direct surface forming(DSF) has been tested under various conditions. DSF is very similar to the well-known hot embossing except for partial contact between mold and substrate. The final V-groove pattern shows different shapes depend on the temperature of mold surface, contact time of mold and depth of V-groove.

• Journal of Ocean Engineering and Technology
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• v.13 no.1 s.31
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• pp.79-87
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• 1999

As it is well appreciated plate forming by line heating takes an important role in ship production process. The paper deals with the development of line heating simulator which can produce the resultant deformation due to line heating in a few minute adn with which user can see the result graphically. For the present purpose mechanical modelling is adopted which can explicitly represent the physical resultant of line heating. In developing the present line heating simulator several program modules are integrated by adopting GUI concept such that the simulator can produce resultant deformation with keeping high accuracy. Application example is illustrated for the twisted shape surface which can be frequently seen in ship and offshore structures.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2006.06a
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• pp.325-326
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• 2006

In this study, in order to develop piezoelectric device for multilayer piezoelectric ultrasonic motor, low temperature sintering $Pb(Mn_{1/3}Nb_{2/3})_{0.02}(Ni_{1/3}Nb_{2/3})_{0.12}(Zr_{0.48}Ti_{0.52})_{0.86}O_3$ system ceramics were fabricated according to the variations of forming pressure of casting sheet. At the 300[$kgf/cm^2$] forming pressure, the maximum density of 7.8[$g/cm^3$] was obtained. At the 350[$kgf/cm^2$] forming pressure, the maximum values of effective electromechanical coupling factor $k_{cff}\;=\;0.24$ and mechanical quality factor Qm=628 were obtained.

• Journal of Korea Foundry Society
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• v.34 no.3
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• pp.94-99
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• 2014

A commercially used Zr-based amorphous alloy was recycled and the effects of introducing carbon during recycling on the glass forming ability and mechanical properties of the alloy were investigated. The initial carbon content used in this study was 229ppm. The carbon content was gradually increased as the number of recycling iterations was increased and after the $4^{th}$ recycling it rapidly increased. As return scrap was recycled, polygonal particles precipitated, and they were identified as ZrC. The amount of the precipitates also increased with recycling. Tg, Tx and ${\Delta}T$ of the base alloy were 615 K, 696 K and 81 Kr respectively and they changed to 634 K, 706 K and 72 K after the $10^{th}$ recycling. The decrease of the ${\Delta}T$ value indicates deterioration of the glass forming ability. Hardness was not changed during three iterations of recycling but after the $4^{th}$ recycling it significantly increased. This is ascribed to an increase of amount of the hard particles, namely ZrC.