• Journal of the Korean Society for Precision Engineering
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• v.34 no.3
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• pp.217-224
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• 2017

Structural pipe frames are usually manufactured by complex processes, in which a straight pipe with an arbitrary cross-section is prepared via a roll-forming process and then fabricated into three-dimensional shapes by a secondary process. These conventional processes have low productivity. Recently, the inefficiency of the conventional processes has created the need to develop new forming technologies. In this study, a new incremental roll-forming process is proposed. The study is aimed at verifying the feasibility of the proposed process and investigating the fundamental process parameters using finite-element simulations. The result of the simulation demonstrates that the proposed process can be used effectively for cold fabrication of various shapes of structural pipes. In addition, the result of the investigation of parameters shows that the forming amount, number of roll sets, and distance between roll sets are significant factors to be considered in resolving dimensional errors of the product and improving its quality.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.499-502
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• 2005

A process map has been developed, which can identify the process conditions for weak mechanical bonding at the contact surface during the direct extrusion of a Cu-Ti bimetal bar. Bonding mechanism between Cu and Ti was assumed as a cold pressure welding. Then, the plastic deformation at the contact zone causes mechanical bonding and a new bonding criterion for pressure welding was developed as a function of the principal stretch ratio and normal pressure at the contact surface by analyzing micro local extrusion at the contact zone. Finite element analyses for extrusion of Cu-Ti bimetal bars were performed for various process conditions. The deformation history at the contact surface was traced and the proposed new bonding criterion was applied to predict whether the mechanical bonding at the Cu-Ti contact surface happens. Finally, a process map for the extrusion of Cu-Ti bimetal bar is suggested.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.12
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• pp.168-173
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• 1999

It is investigated that internal defect of planetary gear which consists of two gears with different number of teeth on both side. The internal defect, central burst, begin to form at the place of adiabatic shear band which usually has maximum ductile fracture value during the forming operation, forward and backward extrusion. It makes the plastic forming of planetary gear difficult. The prediction of defect to minimize the cost to produce the planetary gear. The finite element simulation code DEFORM is applied to analyze the defects. In the analysis, the toothed gears are assumed as axisymmetric cylinders whose diameters are equal to those of pitch circles of the each gears. Experiments were carried out with the SCM415 alloy steel as billet material and AIDA 630-ton knuckle-joint press. The calculated results and experimental inspections are compared to design a die and blank without defects and the results are useful to predict the internal defect.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.4
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• pp.161-169
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• 2004

In this study, we investigated fatigue crack growth behavior of laser welded sheet metal due to a single overload. Fatigue specimens were made using butt joint of cold rolled sheet metal that was welded by $CO_2$ laser. The fatigue crack propagation tests were performed in such a way that fatigue loading was parallel to the weld line while crack propagation was perpendicular to the weld line. Single overload was applied when fatigue crack tip was arrived near the weld line. The distances between the crack tip and the weld line at which a single overload was applied were 6, 4 and 2mm. The effect of specimen thickness and overload ratio on the fatigue behavior was determined. The plastic zone size of crack tip due to the single overload was determined from the finite element analysis. For investigating fatigue crack growth behavior, we used different thickness specimen 0.9mm and 2.0mm, and variable overload ratio applied fatigue crack propagation test. Also we used finite element analysis for investigating the plastic zone size of crack tip when single overload applied

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.575-578
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• 2000

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation for the die wear is too hard because the prediction of the die wear is determined with many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard's wear model in order to reduce the rapid wear rate that is generated for the backward extrusion product exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat, angle, and round of the punch nose part. As the flat and angle of the punch nose are larger, the surface expansion is reduced. and, the wear rate is decreased according to the reduction of the punch round. These results obtained through this study are applied to the real manufacturing process, it is implemented the reduction of the wear rate.

• Journal of the Korean Society for Precision Engineering
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• v.9 no.3
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• pp.83-101
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• 1992

A systematic method of remeshing is required due to severe mesh distortion after some finite deformation in the finite element analysis of practical forging processes. In order to cope with the problem of mesh degeneracy during deformation, the proper design of meshes plays an improtant role in the analysis. In so-called "Modular Remeshing", the physical characteristics of metal flow and geometric characteristics are incorporated in "Module", which can be applied to the mesh design for a certain mode of deformation in so far as the topology of deforming region remains the same. For the purpose of more effective and systematic use of the modular remeshing scheme, an expert system has been developed in the framework of the proposed remeshing schemel. In oredr to show the effectiveness of the method, the rib-web type forging with axial relief or radial relief and spike forging are simulated. It has been thus shown that the proposed method of automatic remeshing by using modular remeshing and expert system can be futher extended and applied to various forging problems with complicated geometrical configurations.ical configurations.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.10
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• pp.180-187
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• 2004

Die design to minimize the die wear in the cold forging process is very important as it reduce the production cost and the increase of the production rate. The quantitative estimation fur the die wear is too hard because the die wear is caused by many process variables. So, in this paper, the optimal shape of the backward extrusion punch is newly designed through the FE-analysis considering the surface expansion and Archard wear model in order to reduce the rapid wear rate that is generated for the backward extruded products exceeding the forming limit. The main shape variables of the backward extrusion punch are the flat diameter, angle, and round of the punch nose part. As the flat diameter and angle of the punch nose are larger, the surface expansion is reduced and the wear rate is decreased according to the reduction of the punch round. These results obtained through this study can be applied to the real manufacturing process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.1051-1055
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• 1997

Hot forging is widely used in the manufacturing of automotive component. The mechanical, thermal load and thermal softening which is happened by the high temperature die in hot forging. Tool life of hot forging decreases considerably due to the softening of the surface layer of a tool caused by a high thermal load and long contact time between the tool and workpieces. The service life of tools in hot forging process is to a large extent limited by wear, heat crack, plastic deformation. These are one of the main factors affecting die accuracy and tool life. It is desired to predict tool life by developing life prediction method by FE-simulation. Lots of researches have been done into the life prediction of cold forming die, and the results of those researches were trustworthy, but there have been little applications of hot forming die. That is because hot forming process has many factors influencing tool life, and there was not accurate in-process data. In this research, life prediction of hot forming die by wear analysis and plastic deformation has been carried out. To predict tool life, by experiment of tempering of die, tempering curve was obtained and hardness express a function of main tempering curve.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.08a
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• pp.197-203
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• 2004

A full finite element (FE)-based approach is presented for the precision analysis of the strip profile in flat rolling. Basic FE models for the analysis of the mechanical behavior of the strip and of the rolls are described in detail. Also described is an iterative strategy for a rigorous treatment of the mechanical contact occurring at the roll-strip interface and at the roll-roll interface. Then, presented is an integrated FE process model for the coupled analysis of the mechanical behavior of the strip, work roll, and backup roll in four-high mill. A series of process simulation are conducted and the results are compared with the measurements made in hot and cold rolling experiments.