• 한국정밀공학회지
• /
• 제21권7호
• /
• pp.136-144
• /
• 2004

Optimal process and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from a cold rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• 소성∙가공
• /
• 제21권3호
• /
• pp.179-185
• /
• 2012

In this paper, it is proposed to produce high precision screws with a diameter of $800{\mu}m$ and a thread pitch of $200{\mu}m$ ($M0.8{\times}P0.2$) by means of a cold thread rolling process. In this part II of the study, the focus is on the production and reliability testing of the prototype $M0.8{\times}P0.2$ micro-screw. Designs for two flat dies were developed with the aid of the literature and previous studies. Process parameters during the cold thread rolling process were established through FE simulations. The simulation results showed that the threads of the micro-screw are completely formed through the rolling process. Prototype $M0.8{\times}P0.2$ micro-screw were fabricated with a high precision thread rolling machine. In order to verify the simulation results, the deformed shape and dimensions obtained from the experiment were compared with those from the simulations. Hardness and failure torque of the fabricated micro-screw were also measured. The values obtained indicate that the CAE based process design used in this paper is very appropriate for the thread rolling of micro-sized screws.

• 소성∙가공
• /
• 제20권8호
• /
• pp.581-587
• /
• 2011

The production of high-precision micro-sized screws, used to fasten parts of micro devices, generally utilizes a cold thread-rolling process and two flat dies to create the teeth. The process is fairly complex, involving parameters such as die shape, die alignment, and other process variables. Thus, up-front finite-element(FE) simulation is often used in the system design procedure. The final goal of this paper is to produce high-precision screw with a diameter of $800{\mu}m$ and a thread pitch of $200{\mu}m$ (M0.8${\times}$P0.2) by a cold thread rolling process. Part I is a first-stage effort, in which FE simulation is used to establish process parameters for thread rolling to produce micro-sized screws with M1.4${\times}$P0.3, which is larger than the ultimate target screw. The material hardening model was first determined through mechanical testing. Numerical simulations were then performed to find the effects of such process parameters as friction between work piece and dies, alignment between dies and material. The final shape and dimensions predicted by simulation were compared with experimental observation.

• 한국대기환경학회지
• /
• 제25권6호
• /
• pp.523-538
• /
• 2009

Recently, there has been a keen demand for real-time automatic monitoring of VOCs not only in Korea but other developed countries. We carried out this study to evaluate and to optimize the performance of a continuous automatic monitoring system for hazardous VOCs (HVOCs) in the ambient atmosphere, using an on-line GC system. The online system normally consisted of a Nafion dryer prior to a cold trap of an automatic thermal desorption apparatus and a GC system equipped with two detectors, i.e. PID and ECD. Preliminary tests conducted to check out any contamination of the system revealed an evidence of significant artifact formation of benzene, and it was found that the Nafion dryer (even brand new one) is the source of the benzene artifact. Thus, all the subsequent experiments in this study was carried out inevitably by removing the Nafion dryer. The on-line GC method was investigated with a variety of QC/QA performance criteria such as repeatability, linearity, lower detection limits, and accuracy. In order to find out the best operating condition for the on-line GC system, three different types (in terms of adsorption strength) of cold trap combinations were tested, i.e. (i) Tenax-TA and Carbopack-B combination (weak and hydrophobic); (ii) Tenax-TA, Carbopack-X and Carboxen-1000 combination (strong and hydrophilic); and (iii) Tenax-TA and Carbopack-X combination (medium and hydrophobic/hydrophilic). The USEPA TO-17 manual method was selected as a reference method to evaluate the performance of the on-line method. A series of experiments revealed that the system performance was superior to others when a cold trap packed with hydrophilic adsorbents (Tenax-TA/Carbopack-X/Carboxen-1000 combination) was used and operated at $25^{\circ}C$. However, the system with a cold trap packed with a combination of Tenax-TA and Carbopack-X is more recommended for field applications since the carboxen-1000 adsorbent is too sensitive to water vapor, and hence the performance of the system might be very unstable to humid samples or during rainy days. Furthermore, the precision and accuracy criteria of the Tenax-TA/ Carbopack-X combination were generally compatible with the triple adsorbents cold trap. The continuous automatic monitoring method is, thus, considered very useful to real-time monitoring to understand the variations of VOCs concentrations in ambient air, as it adopts much simpler procedures in sampling, analysis, and data integration steps than manual monitoring methods. However, it should be noted that there is a high possibility of benzene artifacts formation through the Nafion dryer, which is often installed to remove water vapor in air samples before being adsorbed onto the cold trap. Therefore, if a Nafion dryer is used in any studies of monitoring VOCs, the benzene contamination should be carefully examined before carrying out obtaining the data.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2004년도 춘계학술대회 논문집
• /
• pp.170-173
• /
• 2004

Recently many kinds of gears have been produced by forging in order to enhance the mechanical properties of the gears and the productivity of the process. Developments in forging technology are the reason for the increased usage. However, a critical problem of the forged gears is the dimensional change or distortion caused by elastic recovery after forging, and relief of the residual stresses during subsequent heat treatments. Distortion is of great concern to the manufacturers of precision parts, because it influences directly the dimensional accuracy and the grade of carburized bevel gears. In the present paper, distortion due to elastic and heat treatment of bevel gears Is investigated. Distortions of forged gears, machined gears and die aremeasured and compared. Numerical analysis is used to simulate the complete cold forged process and heat treatment process for the machined gears and shows good agreement with the experimental measurements.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2002년도 제7회 단조 심포지엄
• /
• pp.85-91
• /
• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• 한국산업융합학회 논문집
• /
• 제5권4호
• /
• pp.367-372
• /
• 2002

Experimental study was conducted for lapping process after WEDMed specimen. In order to decide the lapping depth of the specimen, the number of the grain size was increased from 400, 600 to 800 to obtain the better surface. Observation of scanning electron microscope, hardness test, surface roughness test and energy dispersive spectrum(EDS) analysis were used for this experimental study. From the comparison and analyses of the results of between the wire-cut electrical discharge machining and the lapping, the following results were obtained. The surface roughness after lapping was found to be improved as increasing the number of lapping process like 1st, 2nd, 3rd lapping and the number of grain size such as 400, 600, 800. The surface hardness after increasing the lapping depth of the specimen was slowly increased. It was found that after 3rd lapping process the hardness was reached the hardness of original base material. It was found that the small amount of coating components within 3% was remained after the 1st lapping process, compared to that approximately 16% after WEDM process.

• 한국추진공학회:학술대회논문집
• /
• 한국추진공학회 2008년 영문 학술대회
• /
• pp.866-870
• /
• 2008

In this study, we designed cold gas propulsion system with minimum 0.25 mm nozzle and micro-thrust measurement system to analyze flow characteristic of micro propulsion system in ambient and vacuum condition. Argon and Nitrogen are used for propellant and the result of experiments is compared with CFD analysis and theory. But there is a point where reduced scale versions of conventional propulsion systems will no longer be practical. Therefore, a fundamentally different approach to propulsion systems was taken. That is thermal transpiration based micro propulsion system. It has no moving parts such as lubricants, pressurizing system and can pump the gaseous propellant by temperature gradient only(cold to hot). We are advancing basic research of propulsion system based on thermal transpiration in vacuum conditions and had tried experiment process and theoretical access in advance. To characterize membrane of Knudsen pump, we select Polyimide material that has low thermal conductivity(0.29 W/mK) and can stand high temperature($300^{\circ}C$) for long time. And we fabricated hole diameter 1, 0.5, 0.2, 0.1 mm using precision manufacturing. Experimental results show that pressure gradient efficiency of Knudsen pump is increased to maximum 82% according to Knudsen number and thick membranes are more effective than thin membranes in transition flow regime.

• 한국산학기술학회논문지
• /
• 제16권6호
• /
• pp.3692-3697
• /
• 2015

나사는 나선형의 홈으로 구성된 체결용 기계요소이다. 최근의 모바일 기기의 소형화 추세로 인하여 나사의 소형화 및 경량화 요구도 크게 증가하고 있는 실정이다. 우수한 기계적 성질과 높은 정밀도의 나사를 생산하기 위해서는 금형 및 공정설계가 성공적으로 수행되어야 한다. 본 연구에서는 유한요소해석을 통하여 초소형 나사의 머리부 냉간 단조 성형에 대한 공정설계를 수행하였다. 특히, 금형의 형상과 마찰력이 성형에 미치는 영향을 분석하기 위하여 실험계획법을 적용하였고, 그 결과 마찰력이 성형 시 발생하는 접힘 결함의 지배적인 요인임을 밝혀내었다. 이러한 결과로부터 금형 형상을 개선하였고, 개선된 금형으로 단조 실험을 수행하였고, 실험 결과로부터 접힘 결함 불량이 해소된 것을 확인하였다.

• 대한기계학회:학술대회논문집
• /
• 대한기계학회 2007년도 춘계학술대회B
• /
• pp.2817-2822
• /
• 2007

The purpose of this paper is to study the influence of operating condition and ejector geometries on the hydrodynamics and on the mass transfer characteristic of ejector. The CFD results were validated with available experimental data. Flow field analyses and predictions of ejector performance were also carried out. Variation on the operating conditions was made by varying the gas-liquid flow rate ratio in the range of 0.2 to 1.2. The ejector configuration was also varied on the length to diameter ratio of mixing tube ($L_M/D_M$) in the range of 4 to 10. CFD studies show that at $L_M/D_M$ 5.5, the volumetric mass transfer coefficient increases with respect to gas flow rates. Meanwhile, at $L_M/D_M$ 4, the plot of volumetric mass transfer coefficient to gas-liquid flow rates ratio reach maximum at gas-liquid flow rates ratio of 0.6. This study also shows that volumetric mass transfer coefficient decrease with respect to the increase of mixing tube length.