• Design & Manufacturing
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• v.16 no.4
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• pp.46-51
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• 2022

The piercing process of creating holes in sheet metals for mechanical fastening generates high shear force. Real-time monitoring technology could predict tool damage and product defects due to this severe condition, but there are few applications for piercing high-strength aluminum. In this study, we analyzed the load signal to predict the punch's wear level during the process with a piezoelectric sensor installed piercing tool. Experiments were conducted on Al6061 T6 with a thickness of 3.0 mm using piercing punches whose edge angle was controlled by reflecting the wear level. The piercing load increases proportionally with the level of tool wear. For example, the maximum piercing load of the wear-shaped punch with the tip angle controlled at 6 degrees increased by 14% compared to the normal-shaped punch under the typical clearance of 6.7% of the aluminum piercing tool. In addition, the tool wear level increased compression during the down-stroke, which is caused by lateral force due to the decrease in the diameter of pierced holes. Our study showed the predictability of the wear level of punches through the recognition of changes in characteristic elements of the load signal during the piercing process.

• Transactions of Materials Processing
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• v.32 no.5
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• pp.276-286
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• 2023

The field of sheet metal forming using press technology has become essential in modern mass production systems. Draw bead is often used to enhance formability. However, optimal draw bead design often requires excessive time and cost due to iterative experimentation and sometimes results in some defects. Given these challenges, there is a need to enhance formability by introducing segmented blank holders without draw beads. In this paper, the feasibility of a localized holding strategy using segmented blank holders is evaluated without the use of draw beads. The possibility for improving the formability was evaluated by utilizing a combination of the forming limit diagram and the wrinkle pattern-based defect indicators. Artificial neural networks were used for predicting defect indicators corresponding to arbitrary input holding forces and the NSGA-II optimization algorithm is used to find optimum blank holder forces yielding better defect indicators than the original process with drawbeads. Using optimum holding forces obtained from the proposed procedure, the stamping process with the segmented blank holders can yield better formability than the conventional process with drawbeads.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.11
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• pp.114-123
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• 1996

The major objective of the present paper is to estabilish analytical technique in order to closely understand and analyze the actual shearing process. First of all, isothermal and non-isothermal FE-simulation of the shearing process are carried out using finite element software DEFORM. Based on preliminary simulation using DEFORM, the finite element program to analyze two dimensional shearing process is developed. The ductile fracture criterion and the element kill method are also used to estimate if and where a fracture will occur and to investigate the features of the sheared surface in shearing process. It can be seen that the developed program combined with the ductile fracture criterion and element kill method has enabled the achievement of FE-simulation from initial stage to final stage of shearing process. The effects of punch-die clearance on shearing process are also investigated. In order to verify the effectiveness of the proposed technique the simulation results are compared with the known expermental data. It is found that the results of the present work are in close agreement with the published experimental results.

• Structural Engineering and Mechanics
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• v.86 no.4
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• pp.519-533
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• 2023

This work focuses on the dynamic analysis of thermal barrier coated straight and curved turbine blades modelled as functionally graded sandwich panel under thermal environment. The pre- twisted straight/curved blade model is considered to be fixed to the hub and, the complete assembly of the hub and blade are assumed to be rotating. The functionally graded sandwich composite blade is comprised of functionally graded face-sheet material and metal alloy core. The constituents' material properties are assumed to be temperature-dependent, however, the overall properties are evaluated using Voigt's micromechanical scheme in conjunction with the modified power-law functions. The blade model kinematics is based on the equivalent single-layer shear deformation theory. The equations of motion are derived using the extended Hamilton's principle by including the effect of centrifugal forces, and further solved via 2D- isoparametric finite element approximations. The mesh refinement and validation tests are performed to illustrate the stability and accurateness of the present model. In addition, frequency characteristics of the pre-twisted rotating sandwich blades are computed under thermal environment at various sets of parametric conditions such as twist angles, thickness ratios, aspect ratios, layer thickness ratios, volume fractions, rotational velocity and blade curvatures which can be further useful for designing the blade type structures under turbine operating conditions.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.3
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• pp.198-204
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• 1993

The study is concerned with finite element analysis and design of axisymmetric deep drawing by local heating. When the bottom shape of a cup is not flat but in complex-shaped, i.e., hemispherical, the cup cannot be drawn in one or two processes in the conventional deep drawing process and the limit drawing ratio is limited as well. By introducing local heating selectively with regards to the heating position, the formability of the sheet metal can be greatly increased with the reduced number of processes. In the Process analysisthe rigid- viscoplastic finite element method is employed and the temperature effect is incorporated. Bishop's step-wise decoupled method is employed to analyze the thermomechanical interaction between deformation and heat transfer. Axisymmetric deep drawing of a hemisphere-bottomed cup has been analyzed for various combinations of heat application in the punch and the die. At the first stage of deep drawing stretch forming is practically carried out by firmly pressing the blankholder with the punch and the die heated at various levels of temperature. Then at the second stage the same cup is drawn for the saame or different combination of temperature. From the computation, it has thus been shown that the fromability of a cup is greatly increased in two-stage deep drawing with increased limet drawing ratio.

• Advances in nano research
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• v.17 no.2
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• pp.109-124
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• 2024

In the era of smart manufacturing, precise prediction of springback-a common issue in ultra-thin sheet metal forming- and forming limits are critical for ensuring high-quality production and minimizing waste. This paper presents a novel approach that leverages the Internet of Things (IoT) and Artificial Neural Networks (ANN) to enhance springback and forming limits prediction accuracy. By integrating IoT-enabled sensors and devices, real-time data on material properties, forming conditions, and environmental factors are collected and transmitted to a central processing unit. This data serves as the input for an ANN model, which is trained with crystal plasticity simulations and experimental data to predict springback with high precision. Our proposed system not only provides continuous monitoring and adaptive learning capabilities but also facilitates real-time decision-making in manufacturing processes. Experimental results demonstrate significant improvements in prediction accuracy compared to traditional methods, highlighting the potential of IoT and ANN integration in advancing smart manufacturing. This approach promises to revolutionize quality control and operational efficiency in the industry, paving the way for more intelligent and responsive manufacturing systems.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.35 no.1
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• pp.44-49
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• 2022

In this paper, we investigated current (I)- and voltage (V)-sweeping properties in a double-stack structure, Ge₂Sb₂Te₅/Ti/W-doped Ge₈Sb₂Te₁₁, a candidate medium for applications to multilevel phase-change memory. 200-nm-thick and W-doped Ge₂Sb₂Te₅ and W-doped Ge₈Sb₂Te₁₁ films were deposited on p-type Si(100) substrate using magnetron sputtering system, and the sheet resistance was measured using 4 point-probe method. The sheet resistance of amorphous-phase W-doped Ge₈Sb₂Te₁₁ film was about 1 order larger than that of Ge₂Sb₂Te₅ film. The I- and V-sweeping properties were measured using sourcemeter, pulse generator, and digital multimeter. The speed of amorphous-to-multilevel crystallization was evaluated from a graph of resistance vs. pulse duration (t) at a fixed applied voltage (12 V). All the double-stack cells exhibited a two-step phase change process with the multilevel memory states of high-middle-low resistance (HR-MR-LR). In particular, the stable MR state is required to guarantee the reliability of the multilevel phase-change memory. For the Ge₂Sb₂Te₅ (150 nm)/Ti (20 nm)/W-Ge₈Sb₂Te₁₁ (50 nm), the phase transformations of HR→MR and MR→LR were observed at t<30ns and t<65ns, respectively. We believe that a high speed and stable multilevel phase-change memory can be optimized by the double-stack structure of proper Ge-Sb-Te films separated by a barrier metal (Ti).

• Proceedings of the Korean Vacuum Society Conference
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• 2012.08a
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• pp.375-375
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• 2012

Graphene is a sp2-hybridized carbon sheet with an atomic-level thickness and a wide range of graphene applications has been intensely investigated due to its unique electrical, optical, and mechanical properties. In particular, hybrid graphene structures combined with various nanomaterials have been studied in energy- and sensor-based applications due to the high conductivity, large surface area and enhanced reactivity of the nanostructures. Conventional metal-catalytic growth method, however, makes useful applications difficult since a transfer process, used to separate graphene from the metal substrate, should be required. Recently several papers have been published on direct graphene growth on the two dimensional planar substrates, but it is necessary to explore a direct growth of hierarchical nanostructures for the future graphene applications. In this study, uniform graphene layers were successfully synthesized on highly dense dielectric nanowires (NWs) without any external catalysts. We also demonstrated that the graphene morphology on NWs can be controlled by the growth parameters, such as temperature or partial pressure in chemical vapor deposition (CVD) system. This direct growth method can be readily applied to the fabrication of nanoscale graphene electrode with designed structures because a wide range of nanostructured template is available. In addition, we believe that the direct growth growth approach and morphological control of graphene are promising for the advanced graphene applications such as super capacitors or bio-sensors.

• Structural Engineering and Mechanics
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• v.63 no.3
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• pp.361-370
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• 2017

Through the use of finite element analysis and acoustic emission techniques we have evaluated the interfacial failure of a carbon fiber reinforced polymer (CFRP) repair patch on a notched aluminum substrate. The repair of cracks is a very common and widely used practice in the aeronautics field to extend the life of cracked sheet metal panels. The process consists of adhesively bonding a patch that encompasses the notched site to provide additional strength, thereby increasing life and avoiding costly replacements. The mechanical strength of the bonded joint relies mainly on the bonding of the adhesive to the plate and patch stiffness. Stress concentrations at crack tips promote disbonding of the composite patch from the substrate, consequently reducing the bonded area, which makes this a critical aspect of repair effectiveness. In this paper we examine patch disbonding by calculating the influence of notch tip stress on disbond area and verify computational results with acoustic emission (AE) measurements obtained from specimens subjected to uniaxial tension. The FE results showed that disbonding first occurs between the patch and the substrate close to free edge of the patch followed by failure around the tip of the notch, both highest stress regions. Experimental results revealed that cement adhesion at the aluminum interface was the limiting factor in patch performance. The patch did not appear to strengthen the aluminum substrate when measured by stress-strain due to early stage disbonding. Analysis of the AE signals provided insight to the disbond locations and progression at the metal-adhesive interface. Crack growth from the notch in the aluminum was not observed until the stress reached a critical level, an instant before final fracture, which was unaffected by the patch due to early stage disbonding. The FE model was further utilized to study the effects of patch fiber orientation and increased adhesive strength. The model revealed that the effectiveness of patch repairs is strongly dependent upon the combined interactions of adhesive bond strength and fiber orientation.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.5
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• pp.184-189
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• 2018

Recently, research on lightweight automobiles is increasing continuously to respond to the high safety standards and environmental regulations. The application of high strength steel is one of the effective methods for developing lightweight car bodies. A TWB (Tailor Welded Blank) is major method that allows partial high strength with light weighting using a multi-thickness and multi-material welded blank. On the other hand, additional welding process is required to prepare the blank and quality control for the welding process also required. To secure this point, the TRB (Tailor Rolled Blank) method was suggested. In the TRB method, the thickness of sheet is controlled by the rolling presses and the production efficiency is much higher than welding in TWB methods. In this study, the formability of high strength TRB steel plate was analyzed to examine the rolling effect of the blank. The formability of the specimen was tested using 0.8 and 1 mm thick steel sheets for the TRB plate. The strain was analyzed by the digital image sensing of grid markings on the specimen and the forming limit diagram was calculated. An Erichsen test for the 0.8 and 1 mm thick TRB specimens was carried out and the formability was investigated by comparing with FE analysis.