• 한국산학기술학회논문지
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• 제14권1호
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• pp.28-32
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• 2013

본 연구에서는 프레스 부품의 스프링 백을 보정하기 위한 새로운 방법론을 제안하였다. 먼저, CAD 데이터와 측정데이터 사이의 오차를 비교하였다. 새로운 방법은 스프링 백을 보정하기 위한 수동적인 모델링 공정 대체가 가능한 3차원 측정데이터 기반의 자동 모델링을 제안하였다. 본 연구를 통해 프레스 부품의 스프링 백 보정을 위한 새로운 방법론을 적용하면 실제 공정에 소요되는 시간 및 비용 절감이 가능할 것으로 기대된다.

• 소성∙가공
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• 제21권7호
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• pp.397-402
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• 2012

The flange hub is a main component in an automotive steering system. In general, the flange hub are fabricated by mechanical machining, which is a process where material waste is inevitable. It is well-known that a net-shape cold forging cannot only reduce material waste but can also improve the mechanical strength of the final product. Thus, a forging process design was conducted for production of a flange hub. Significant spring-back occurs around the flange due to its small thickness in conjunction with the residual stresses after forging. In order to achieve the required dimensional accuracy, a process design with appropriate spring-back control is needed. In this study, a modification of the forging die was designed based on FE analysis with the purpose of spring-back compensation. Four kinds of different die designs were evaluated and the optimum design has two times less spring-back than the initial design. The compensation angle of the optimum design is 0.5 degrees. The results have been experimentally confirmed by cold forging of a flange hub and comparing the amount of spring-back between the actual component and the FE analysis.

• 한국해양공학회지
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• 제22권6호
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• pp.75-82
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• 2008

Flame bending has been extensively used in the shipbuilding industry for hull plate forming In flame bending it is difficult to obtain the desired shape because the residual deformation dependson the complex temperature distribution and the thermal plastic strain. Mechanical bending such as reconfigurable press forming multi-point press forming or die-less forming has been found to improve the automation of hull plateforming because it can more accurately control the desired shape than line heating. Multi-point forming is a process in which external forces are used to form metal work-pieces. Therefore it can be a flexible and efficient forming technique. This paper presents an optimal approach to determining the press-stroke for multi-point press forming of curved shapes. An integrated configuration of Finite element analysis (FEA) and spring-back compensation algorithm is developed to calculate the strokes of the multi-point press. Not only spring-back is modeled by elastic plastic shell elements but also an iterative algorithm to compensate the spring-back is applied to adjust the amount of pressing stroke. An iterative displacement adjustment (IDA) method is applied by integration of the FEA procedure and the spring-back compensation work. Shape deviation between the desired surface and deform￡d plate is minimized by the IDA algorithm.

• 대한조선학회논문집
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• 제48권6호
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• pp.528-538
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• 2011

As a forming method for curved hull plates more efficient than the flame bending, mechanical bending using multi point press forming and die-less forming is discussed in this paper. the mechanical forming is a flexible manufacturing system for automatically forming of hull parts. It is especially suited to varied curved parts. This paper discusses a multiple point pressing machine composed of a pair of reconfigurable punches in order to achieve the rapid forming of curved hull plates using division forming and presents how forming information is obtained from the given design surface. Although the mechanical forming can be efficient in the metal forming, spring back after pressing is a phenomenon which must be carefully considered when quantifying the process variables. If the spring back is not accurately controlled, the fabricated shell plate cannot meet assembly tolerance. This paper describes the principles to calculate the proper stroke of each punch at the divided areas. the strokes are determined by an iterative process of sequential pressing and spring back compensation from an unfolded flat shape to its given design surface. FEA(finite element analysis) is used to simulate the spring back of the plate and the IDA(iterative displacement adjustment) method adjusts the offset of pressing punches from the deformation results and the design surface. The shape deviations of two surfaces due to spring back are compensated by integrated system using FEA and IDA method. For the practical application, It is aimed to develop an integrated system that can automatically perform the compensation process and calculate strokes of punches of the double sides' reconfigurable multiple-press machine and some experimental results obtained with mechanical bending are presented.

• Composites Research
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• 제19권1호
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• pp.29-35
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• 2006

첨단 전자무기체계의 지속적인 발전으로 인하여 현대전의 승패는 적 레이더 탐지의 회피에 크게 좌우된다고 할 수 있다. 반사되는 레이더의 탐지신호를 최소화시키기 위한 다양한 연구가 수행되어 왔는데, 본 연구에서는 뛰어난 기계적, 전자기적 물성으로 응용분야가 지속적으로 확대되고 있는 섬유강화 복합재료를 이용하여 레이더 전자파 흡수체(Radar absorbing structure, RAS)를 제작하고 레이더 단면적(Radar cross section, RCS)을 평가하였다 유리섬유 복합재에 뛰어난 유전적 특성을 지닌 나노 크기의 카본블랙(Carbon-black)을 첨가하여 흡수층을 구성하고, 반사특성이 탁월한 탄소섬유 복합재를 후면의 반사층으로 배치하여 "C" 및 "U" 형상의 하이브리드 복합재 RAS 겔을 제작하였다. RAS 쉘의 제작간 서로 다른 두 재료의 열적물성치 차이로 스프링 백이라 불리는 변형이 발생하였는데, 금형의 굽힘각도 제어를 통하여 효과적으로 보정할 수 있었다. 또한 상용 유한요소해석 프로그램인 ANSYS를 이용하여 스프링 백 보정 결과를 예측하고 실험결과와 비교하였다. 제작된 RAS쉘의 RCS는 근사적 계산기법인 물리광학법을 이용하여 예측하고 컴팩트 레인지(Compact range)를 이용하여 측정한 실힘결과와 비교하였다 두가지 형상의 RCS 모두 측정결과와 예측된 RCS 값이 일치하며 우수한 레이더 전자파 흡수 특성을 지닌 것을 확인하였다.