• Advances in aircraft and spacecraft science
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• v.2 no.1
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• pp.1-16
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• 2015

In this paper, geometrical and mechanical approaches are proposed for the simulation of the draping of woven fabric onto complex parts. The geometrical discrete approach allows to define the ply shapes and fibres orientation in order to optimize the composite structural properties and the continuum meso-structural mechanical approach allows to take into account the mechanical properties of fibres and resin and the various dominating mode of deformation of woven fabrics during the forming process. Some numerical simulations of forming process are proposed and compared with the experimental results in order to demonstrate the efficiency of our approaches.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.149-152
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• 2000

By using a three-dimensional finite element program HydroFORM-3D based on a rigid-plastic model, the hydroforming process for automobile subfrmae is analyzed in this study. The goal of this study is to accomplish preform design and determine the level of internal pressure for producing final hydroformed subframe component. Prior to hydroforming, the initial tube blank must be bent to the approximate centerline of the final part to enable the tube to be placed in the die cavity, After then, a preforming operation like stamping is carried out to the prebent tube. Finally, hydroforming process is performed to the preformed tube to get the final production. And through ductile fracture theory, the failure, bursting, is predicted during hydroforming process for tube blank with different diameter.

• Transactions of the Korean Society of Automotive Engineers
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• v.9 no.6
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• pp.160-169
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• 2001

To predict busting failure in tubular hydroforming, the criteria for ductile fracture proposed by Oyane is combined with the finite element method. From the histories of stress and strain in each element obtained from finite element analysis, the fracture initiation site is predicted by mean of the criterion. The prediction by the ductile fracture criterion is applied to three hydroforming processes such as a tee extrusion, an automobile rear axle housing and lower am. For these products, the ductile fracture integral I is not only affected by the process parameters, but also by preforming processes. All the simulation results show the combination of the finite element analysis and the ductile fracture criteria is useful in the prediction of farming limit in hydroforming processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.277-280
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• 2005

A shape optimization is applied to achieve a design objective in three-dimensional forging processes. In multi-stage forging processes, among the important design aspects, the die shape fur preforming is regarded as the design variable since it influences the forged part relatively higher than the others. The rigid-plastic finite element method and the sensitivity method are employed and formulated to solve a formulated optimization problem. An approximation scheme is also used for the direction search during the optimization. The upset forging of a square box is selected as a test example in order to demonstrate and verify the optimization process of this study. After the optimization, the optimized shape of the die yields a finial product of desire shape.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.564-569
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• 2008

Strain hardening behavior during hydroforming has been experimentally investigated. The variation of flow stress was used as an index of strain hardening during respective processes and the flow stress was estimated from the correlationship between flow stress and effective strain. The local hardness after hydroformig was also predicted by effective strain. By using the inter-relationships between hardness-flow stress-effective strain at variable pre-strains, the strain hardening behavior during hydroforming has been successfully analyzed. The comparison of predicted hardness with measured hardness confirmed that the methodology used in this study was feasible and the strain hardening behavior can be quantitatively estimated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.286-289
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• 2009

This paper deals with the experimental investigation of the steel cord straightening during the stranding process. The over-twisting and roller straightening process are essential to improve the product quality during the stranding process. To investigate the effectiveness of two processes, four experimental cases are constructed according to the use of an over-twister and two roller straighteners. Three assessment items, such as the residual torsion, the arc-height and the preforming ratio, are measured in each experimental case for the quantitative evaluation of a steel cord. The steel cord shape is also measured to investigate the variation of the straightness efficiently after passing through each process. Finally, the effectiveness of the over-twisting and the roller straightening process is explained based on the experimental results.

• Advanced Composite Materials
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• v.16 no.2
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• pp.135-149
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• 2007

In the automobile industry, structural health monitoring of fiber reinforced polymer composite parts is a widespread need for maintenance before breakdown of the functional elements or a complete vehicle. High performance sensors are generally used in many of the structural health monitoring operations. Within this study, a carbon fiber sewing thread has been used as a low cost laminate failure sensing element. The experimentation plan was set up according to the electrical conductance and flexibility of carbon fiber threads, advantages of preforming operations, and sewing mechanisms. The influence of the single thread damages by changing the electrical resistance and monitoring the impact location by using carbon thread sensors has been performed. Innovative utilization of relatively cost-effective carbon threads for monitoring the delamination of metallic inserts from the basic composite laminate structure is a highlighting feature of this study.

• The Transactions of the Korean Institute of Electrical Engineers
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• v.40 no.2
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• pp.207-216
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• 1991

In the case that the robot manipulator should respond to the variance and uncertainty of the environment in performing preforming precision tasks, it is indispensable that the robot utilizes the various sensors for intrlligence. In this paper, the robot force control method is implemented with a force/torque sensor, two personal computers, and a PUMA 560 manipulator for performing the various application tadks. The hybrid position/force control method is used to control the force and position axis separately. An interface board is designed to read the force/torque sensor output into the computer. Since the two computers should exchange the information quickly, a common memory board is designed. Before the algorithms of application tasks are developed, the basic force commands must be supplied. Thus, the MOVE-UNTIL command is used at the discrete time instant and, the MOVE-COMPLY is used at the continuous time instant for receiving the force feedback information. Using the two basic force commands, three application algorithms are developed and implemented for edge-following, insertion, and grinding tasks.

• Transactions of Materials Processing
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• v.3 no.3
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• pp.347-358
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• 1994

The purpose of the study is to form $\Omega$-type bellows without any defect by specific rollers which are designed based on the volume distribution technique. In the present paper, we proposed a forming process of existing U-type bellows to a value-added $\Omega$-type in a progressive manner. It was developed to shape a perfect $\Omega$-type bellows after preforming from initial U-type bellows to final U-type bellows. To examine the suggested 'processing condition design' some experiments were performed in a real scale. It was found out that the spring back effect played a major role in deviating the geometry of formed bellows from the predicted one. The problems found in the experiment can be used as important information in manufacturing equipment for forming $\Omega$-type bellows.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.7
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• pp.607-612
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• 2019

The softness of the crashpad part is one of the important factors which affect the interior perceived quality of the vehicle interior. And while improving the softness of the crashpad part, every effort to lower the production cost has been going on. The PU foaming process for the crashpad part depends on the understanding of a lot of processes, tools and material properties. Therefore, to achieve the requirement of the customer for the interior part's visual quality, the integrated design techniques are investigated to correlate the processes, tool design, material design and the computer aided analysis. In this paper, IMG (In Mold Grain) designed concept is firstly developed to integrate the skin preforming, plastic injection molding of the substrate and the foaming process in a tool within reduced processes. Through the application of this technology, softness of crashpad is improved by 40% compared to the conventional vacuum molding method, and the existing process is reduced by 50% by integrating the injection process and the manufacturing process. And by integrating the injection mold and the skin mold and removing the foaming mold, the number of molds are reduced from 3 to 1, resulting in 20% reduction in the cost of applying a medium-sized passenger car.