• 한국정밀공학회지
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• 제25권1호
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• pp.72-78
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• 2008

Metal stamping is widely used in the mass-production process of the automobile. During the stamping process, air may be trapped between the draw die and the panel and/or between the punch and the panel. Air pocket rapidly not only increases forming load in the final stage, but also deforms the product just formed by compressive air inside the air pocket in knockout process. To prevent these problems air bent holes are drilled in the die to exhaust the trapped air but all processes associated with air bent holes are performed by empirical know-how of workers in the field due to lack of researches. Therefore this study developed an automated design system for predicting the shape and position, and volume of air pocket on the draw die by using the AutoLISP language under AutoCAD circumstance. The system is able to display the shape of air pocket occurred in the draw die and to calculate automatically its volume by strokes. So it makes a stepping stone to calculate theoretical size of an air bent hole and numbers according to it by predicting and analyzing the position and volume of air pocket. Results obtained from the system enable the designers or manufacturers of the stamping die to be more efficient in this field.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.73-77
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• 2005

In this work, the influences of tool temperature on the formability of AZ31 sheet material in warm deep drawing processes of square cup were investigated. Deep drawing tests under different tool temperatures for magnesium alloy sheet at elevated temperature $250^{\circ}C$, where AZ31 sheet shows a good formability, and FE analyses were carried out. The successfully formed part without any defects was obtained when temperature of tool was over $100^{\circ}C$ while the fracture was occurred at the corner of the square cup below $100^{\circ}C$. It is shown that lower temperature of tool than that of magnesium sheet causes the temperature drop of the material by heat transfer and thus Interrupts the dynamic recrystallization of it. Therefore, in order to obtain successful part of magnesium alloys, it is necessary that the tool temperature is limited to the same or slightly lower temperature than sheet material.

• 소성∙가공
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• 제12권5호
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• pp.440-448
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• 2003

Sheet or plate bending is one of the most important industrial metal forming processes. Considerable attention has been focused on gaining a better understanding of bending characteristics. One of defaults in bending process is the springback. In this study, the springback characteristics of tailor-welded strips in U-bending process was investigated. Furthermore, effect of the process variables such as the geometry of the tools, thickness combination of workpiece, and welding prcoessing on springback were experimentally clarified. First, tailor-welded strips are joined by the laser welding process and consisted of two types of thickness combinations of the SCPl sheet, $0.8t{\times}1.2t$ and $0.8t{\times}1.6t$ to investigate the effect of different thickness combination on the springback. Secondly, two different directionly welded strips, one was welded along the centerline of the strip-width and the other was along the centerline of strip-length, were adopted to compare the effects of the location of weld line on the springback. Some cases of the experimental results were compared to the results simulated by using a commercial FEM code, PAM-STAMP and the theoretical results using the springback formula as well.

• 대한기계학회논문집A
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• 제28권5호
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• pp.654-661
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• 2004

In deep drawing of sheet metal, there are many cases in which the uniform and thin wall thickness of the drawn products is more important than the bottom thickness. In this case, we can not easily get the deep drawn products with the uniform and precise wall thickness by only drawing process. Therefore in general the manufacturing processes which both the drawing and the ironing process are proceeded sequentially are used. But this method has the disadvantages of a cost-up, decrease of productivity and degradation of quality, because the ironing process is added after the drawing process. In this study, in order to improve those problems and to enhance the effect of deep drawing, the combined process of redrawing and ironing fur multistep drawing of cylindrical cups is used. In this experiment, we considered the characteristics of the combined process such as the relation between the drawing and ironing rates, the drawing limits and the forces needed for operations. The suggested force prediction shows that it can successfully represent experimental results.

• 한국정밀공학회지
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• 제18권1호
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• pp.44-55
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• 2001

The flow behavior of semi-solid materials (SSM) is required to assist the industrial application of thixoforming technology. Particularly, to reduce many lead times, many numerical analysis packages have been developed to simulate required metal forming processes. The objectives of the development of SEMI-FORM for thixoforming process design are to predict the effect of various process variables such as pressing force, die temperature, and die velocity. However, there have not been any reports which adapt these packages to the specific characteristics of SSM. SO, this paper presents an overview of the development of thixoforming simulator of SEMI-FORM. The solver and post-processor of SEMI-FORM S/W for an automated thixoforming process design with arbitrarily shaped die are composed of FORTRAN Power Station 4.0 and Visual Basic 5.0, respectively. This developing SEMI-FORM S/W would be very useful for thixoforming practitioners and engineers to select the optimal process conditions to produce automotive parts with high quality.

• 한국분말재료학회지
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• 제26권1호
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• pp.16-21
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• 2019

In aluminum brazing processes, corrosive flux, which is used in preventing oxidation, is currently raising environmental concerns because it generates many pollutants such as dioxin. The brazing process involving non-corrosive flux is known to encounter difficulties because the melting temperature of the flux is similar to that of the base material. In this study, a new brazing filler material is developed based on aluminum and non-corrosive flux composite powder. To minimize the interference of consolidation aluminum alloy powder by the flux, the flux is intentionally embedded in the aluminum alloy powder using a mechanical milling process. This study demonstrates that the morphology of the composite powder can be varied according to the mixing process, and this significantly affects the relative density and mechanical properties of the final filler samples.

• Design & Manufacturing
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• 제15권4호
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• pp.37-42
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• 2021

The tube necking process increases the thickness of the material, and some of the tube necking products require cutting on the inside of the formed product as a post-process. In order to prevent over-cutting or un-cutting due to increased thickness during cutting, it is necessary to know in advance the increase in thickness after forming. Therefore, in this study, the thickness change according to the tube necking was observed. Aluminum 3003-F and 6061-O were used for the materials used in the experiment, and necking was carried out up to 50% of the outer diameter of the tube through five processes. The two materials were formed under the same conditions, and the thickness of three points was observed in each process. In addition, the thickness increase of the two materials was compared, and the trend of thickness increase according to the cumulative necking ratio was observed. As a result of the experiment, both materials had the smallest thickness at the end of the formed product. In addition, as a result of comparing the thickness measurement values of the two materials, the maximum difference was 0.1mm, indicating that there was no difference in thickness between the two materials.

• 대한기계학회논문집
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• 제17권1호
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• pp.101-111
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• 1993

본 연구에서는 제안된 뉴로-퍼지 제어기를 사용하여 유압 서보 시스템을 제어 하고 학습하기 위한 구조로써 유압 서보 시스템의 모델링을 위한 추가적인 노력이 필 요없는 feedback error learning 구조물 채택하였다. 학습 과정에서 필요한 유압 서 보 시스템의 입-출력 사이의 감도(sensitivity)의 효과는 학습 계수에 포함된다. 이 러한 형태의 제어기가 유압 서보 시스템 제어에 유용하게 적용될 수 있다는 것을 보이 기 위해서 불확실성과 높은 비선형성 뿐만아니라 외란의 영향을 받는 유압 서보 시스 템을 대상으로 시뮬레이션을 수행했다. 시뮬레이션 결과에 의하면 제안된 뉴로-퍼지 제어기는 수학적인 모델을 기초로한 기존의 제어 알고리즘에 비해 쉽게 구성할 수 있 고 높은 정밀도, 빠른 학습 속도를 얻을 수 있는 장점을 가지고 있음을 알 수 있다.

• 한국소음진동공학회논문집
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• 제25권1호
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• pp.5-12
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• 2015

According to the analysis of special medical examination and work environment monitoring data, the rate of C1 and D1 on noise hazard exceeded 90 % among those of total hazardous factors. The rate of company exceeding noise exposure limit was also more than 90 %. The analysis result shows that main ages diagnosed with C1 and D1 was age of 50s. The majority scale company having workers diagnosed with C1 and D1 was the companies employing 5~49 workers. Types of industries which have a large number of companies exceeding noise exposure limit were automobile and trailer manufacturing, metal processing industry and primary metal manufacturing. A large number of work processes exceeding noise exposure limit were forming and processing work, cutting and bending work and grinding. To reduce the number of company exceeding noise exposure limit, the reduction counterplan should be focused on the type of industry and the work process which exceeded noise exposure limit frequently. However, the reduction counterplan is preemptively necessary to the type of industry and the work process which exceeded noise exposure limit consecutively if the purpose of reduction counterplan is not to merely reduce the number of company exceeding noise exposure limit but to abate workers' suffering from noise.

• 한국대기환경학회지
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• 제17권2호
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• pp.213-222
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• 2001

Cylindrical type ceramic filers, that is 60 O.D$\times$10t$\times$600L and 60 O.D$\times$10t$\times$1,000L were manufactured by vacuum forming processes using ceramic ray materials. For cylindrical type ceramic filters, porosity and bulk density were measured for, 80 to 90% and 0.3 to 0.4 g/㎤, respectively at uniform pore size of 41 to 45${\mu}{\textrm}{m}$. Bench scale candle filters (60$\psi$ $\times$10t$\times$600L) were tested using different dusts collected from many industries including chemical processing, glass processing and metal manufacturing pants. Collection efficiencies found out to range from 99.87% to 99.90%, while resistance coefficients from 1.1$\times$10(sup)11/$m^2$ to 1.7$\times$10(sup)11/$m^2$ . Full scale low density ceramic filters (60$\psi$ $\times$10t$\times$1,000L) were also tested at 1 atm, $600^{\circ}C$ to reveal the filtration efficiency, conditioning, and resistance coefficients using two different types of dust as chemical processing and metal refined processing. Darcys law resistance coefficients were measured to range 1.44$\times$10(sup)11/$m^2$ to 2.74$\times$10(sup)11/$m^2$, and collection efficiencies on the range 99.84 to 99.96%, Finally, results of long term performance test showed that filters were conditioned after 170hrs. Experimental conditions for effective filtration were examined under the condition 10 cm/sec face velocity, 3kg/$\textrm{cm}^2$ pulsing pressure, 5 min filtration cycle, and 300msec pulse opening time.