• Transactions of Materials Processing
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• v.20 no.2
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• pp.154-159
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• 2011

The roll die forming (RDF) process is a new manufacturing technique for producing gear parts such as clutch drum and clutch hub in automotive transmission. In the RDF process, the material is deformed by a roll installed on a die set. Excellent productivity, low forming load and improved dimensional accuracy have quantitatively been shown to be the benefits of the RDF. In this study, the RDF process is applied to manufacture a clutch hub with a gear shaped part. A finite element (FE) analysis was performed in order to investigate the material strain field and dimension of the final product. Based on the result of the FE analysis, a RDF experiment was performed and the dimensional accuracy of the final product was validated. This work demonstrates that RDF is a process capable of producing a sound clutch hub.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.12
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• pp.94-101
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• 2009

In diesel engines, it is inevitable that the torsional vibration is produced by the fluctuation of engine torque. Therefore, it is necessary to establish preventive measures to diminish the torsional vibration. The sleeve spring type damper is one of the preventive measures for reducing the torsional vibration. In this study, 2-roll bending process was proposed to manufacture sleeve spring; The program to calculate the initial radius including springback effect was developed and the FEA method to analyze elasto-plastic problem was verified through analysis of 90 degree bending process. The elasto-plastic analysis of 2-roll bending process was carried out by the FEA method verified to set a new criterion, and the new process design parameter(contact angle) in the 2-roll bending process was proposed.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.10
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• pp.1087-1093
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• 2013

In this study, a measurement method of double ball-bar is proposed to measure the geometric errors of an ultra-precision roll mold machine tool. A volumetric error model of the machine tool is established to investigate the effects of the geometric errors to a radius error and a cylindricity of the roll mold. A measurement path is suggested for the geometric errors, and a ball-bar equation is derived to represent the relation between the geometric errors and a measured data of the double ball-bar. Set-up errors, which are inevitable at the double ball-bar installation, also are analyzed and are removed mathematically for the measurement accuracy. In addition, standard uncertainty of the measured geometric errors is analyzed to determine the experimental condition. Finally, the proposed method is tested and verified through simulation.

• Tribology and Lubricants
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• v.33 no.3
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• pp.98-105
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• 2017

A pin-on-disk test is performed to measure the wear volume of a ductile cast iron (DCI) roll when it wears down using a high carbon steel and two alloy steels at different sliding velocities between the roll and the material (steel). Normal pressure is set as constant and test temperatures are 400, 500 and $600^{\circ}C$. In addition, thermal softening behavior of the DCI roll is examined using a high-temperature micro-hardness tester and the surface hardness variation of the DCI roll is expressed in terms of temperature and heating time. Based on experimental data, a wear coefficient used in Archard's wear model for each material is obtained. The wear volume is clearly observed when the test temperature is $400^{\circ}C$ and sliding velocity varies. However, it is not measured at temperatures of $500^{\circ}C$ and $600^{\circ}C$ even with variations in sliding velocity. From the optical photographs of the pin and disk, the abrasive wear is observed at $400^{\circ}C$ clearly, but no at $500^{\circ}C$ and $600^{\circ}C$. At higher temperatures, the pin surface is not smooth and has many tiny caves distributed on it. It is found that wear volume is dependent on the carbon contents rather than alloy contents. Results also reveal that the variations of wear coefficients are almost linearly proportional to the carbon contents of the material.

• Elastomers and Composites
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• v.6 no.1
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• pp.71-81
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• 1971

The intention of this study is to investigate the properties of polymer blend, NBR/PVC vulcanizates and blending procedures such as roll-mixing temperatures and sequences for polymer blending of NBR and PVC(resin type). The results obtained are as follows: 1. The roll temperature applied for polymer blending is around $150^{\circ}C$. At this temperature region, the degradation of rubber stock, which may be caused by heat, can be minimized and mill processing in practical application in industries can also be facilitated. 2. It is obviously necessary that a small amount of plasticizers should be added to the stock for improving processibility of roll mixing and physical properties. 3. On roll-mixing sequence, it is more effective that PVC compounded with plasticizer is added to NBR milled on hot roll. 4. The vulcanizates of the blends with different degree of polymerization of PVC ale similar to one another in properties. 5. NBR/PVC(70/30) blends shows the better physical characters than eve,-made foreign latex blend except abrasion-resistance. 6. As PVC addition ratio is increased, the physical properties such as resistance to ozone, tear, heat and oil and tensile strength, modulus, hardness have also improved, on the other hand, tension set and rebound character decreased. 7. The curve of ultimate elongation have point of inflection at the ratio of $30\sim40$ part of PVC. 8. While CR is blended, the physical properties such as brittle point, rebound and resistance to oil in high temperature have improved. 9. Polymer blend of NBR and domestic PVC is applied for the industrial utility such as rubber sole and heel, electric wire cover and oil-resistant packing, coating and gasket, printing roll, film for food packing etc.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.9
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• pp.517-524
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• 2019

The overdrive hub clutch is attached to a 6-speed automatic transmission to reduce fuel consumption by using the additional power of the engine. This paper proposes a means to minimize the load and roll-over ratio on the punch during the piercing process for the overdrive hub clutch product. Die clearance, shear angle, and friction coefficient, which can affect the load and roll-over ratio of the punch during processing, were set as the design variables. Sensitivity analysis was also conducted to determine the influence of each design variable on the punch load and roll-over ratio. As a result, shear angle, friction coefficient and die clearance were found to be sensitive to load and roll-over ratio. The punch load and roll-over ratio were set as the objective function and the equation of each design variable and objective function was derives using the Response Surface Method. Finally, the optimal value of the design variables was derived using the Response Surface Method. Application of this model to finite element analysis resulted in 22.14% improvement in the roll-over ratio of the punch load and material.

• Journal of the Society of Naval Architects of Korea
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• v.45 no.2
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• pp.109-123
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• 2008

The present paper presents the CFD result for a beam wave test case. An ONR tumblehome ship model with bilge keels is used. The beam wave test is for zero forward speed and roll and heave 2DOF with wave slope $a_k=0.156$ and wavelength ${\lambda}=1.12L_{PP}$, with $L_{PP}$ the ship length. The problems is solved numerically with an unsteady Reynolds averaged Navier-Stokes approach. The free surface flow is computed using a single-phase level-set method and the motions in each time step are integrated using a predictor-corrector iteration approach which uses dynamic overset grids moving with relative ship motion. The predicted CFD results for motions and forces are compared with experimental data, showing a reasonable agreement.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03a
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• pp.101-109
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• 1996

Mini-mill process which is one of the new steel -marking technologies to be able to produce the hot rolled coils by thin slab caster of ISP(In-Line Strip Production) type, will be completed in the Kwangyang Steel Works of POSCO in August, 1996, SEt-Up Model of finishing mill which consists of 5 stands is the most basic and essential in mini-mill plant. Therefore, the simulation program of Finishing-mill Set-Up model were developed in this research , using new temeprature prediction model, roll gap model and rolling physical model. Using the developed FSU program , pass schedules to produce the strips with target strip thickness of 1.8mm, 2.0mm, 2.3mm, 2.7mm an d3.0mm were also determined respectively.

• International Journal of Aeronautical and Space Sciences
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• v.8 no.1
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• pp.32-45
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• 2007

The T-50 advanced supersonic jet trainer employs the Relaxed Static Stability (RSS) concept to improve the aerodynamic performance while the flight control system stabilizes the unstable aircraft and provides adequate handling qualities. The T-50 flight control laws employ a proportional-plus-integral type controller based on a dynamic inversion method in longitudinal axis and a proportional type controller based on a blended roll system with simple roll rate feedback and beta-betadot feedback system. These control laws are verified by flight tests with various maneuver set flight envelopes and the control laws are updated to resolve flight test issues. This paper describes several concepts of flight control laws used in T-50 to resolve those flight test issues. Control laws for solving the roll-off problem during pitch maneuver in asymmetric loading configurations, improving the departure resistance in negative angle of attack conditions and enhancing the fine tracking performance in air-to-air tracking maneuvers are described with flight test data.

• Transactions of Materials Processing
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• v.26 no.6
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• pp.341-347
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• 2017

Flexibly-reconfigurable roll forming (FRRF) is a novel sheet metal forming technology conducive to produce multi-curvature surfaces by controlling strain distribution along longitudinal direction. Reconfigurable rollers could be arranged to implement a kind of punch die set. By utilizing these reconfigurable rollers, desired curved surface can be formed. In FRRF process, three-dimensional surface is formed from two-dimensional curve. Thus, it is difficult to predict the forming result. In this study, a regression analysis was suggested to construct a predictive model for a longitudinal curvature of FRRF process. To facilitate investigation, input parameters affecting the longitudinal curvature of FRRF were determined as maximum compression value, curvature radius in the transverse direction, and initial blank width. Three-factor three-level full factorial experimental design was utilized and 27 experiments using FRRF apparatus were performed to obtain sample data of the regression model. Regression analysis was carried out using experimental results as sample data. The model used for regression analysis was a quadratic nonlinear regression model. Determination factor and root mean square root error were calculated to confirm the conformity of this model. Through goodness of fit test, this regression predictive model was verified.