• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.82-87
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• 2012

The purpose of this study is to produce a side impact beam with high tensile steel using a roll forming process. The door side impact beam plays an important roll in a car because it protects passengers from external crash. The roll forming process is a continuous bending process wherein a long metal sheet is bended as it continuously passes several rolls. The characteristic of this study is that an impact beam is produced by a continuous process using a ultra high strength steel without a hardening heat treatment. A model was determined by analysing plasticity of a cross section shape considering high strength. Design parameters of the impact beam was determined by crash-analysing the model. Workpiece products were manufactured by designing dies for roll forming and setting them up in a following process line. Results of a bending test and a FEM analysis was considered and reviewed.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.6
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• pp.1-8
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• 2007

The ultra-fine tungsten carbide(WC) powders have been actively used in the cemented carbides industry, because they have excellent mechanical properties such as high hardness, strength, and toughness. In this study, ultra-fine WC-Co alloys powders have been fabricated by thermochemical and thermomechanical process such as spray conversion process or high energy ball milling. The non-coated end-mill which is made of ultra-fine tungsten carbide is investigated by measuring cutting force, tool wear, tool life, and surface roughness profile according to cutting length. The machining test was conducted with high hardened workpiece and their performances are investigated in high speed cutting conditions. Also, the relationship between the machining characteristics and the Co contents are investigated under various high speed cutting conditions.

• Design & Manufacturing
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• v.17 no.2
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• pp.15-21
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• 2023

In this study, a diamond turning machine and a laser-assisted machining module were utilized for the complex combined cutting of aspheric shapes and fine patterns on the surface of high-hardness brittle material, silicon. The analysis of material's form accuracy and corrective machining was conducted based on key factors such as laser output, rotational speed, feed rate, and cutting depth to achieve form accuracy below 1 ㎛ and surface roughness below 0.1 ㎛. The cutting condition and corrective machining methods were investigated to achieve the desired form accuracy and surface roughness. The rotational speed of the spindle and the linear feed rate of the diamond turning machine were varied in five stages for the cutting condition test. Surface roughness and form accuracy were measured using both a contact surface profilometer and a non-contact surface profilometer. The experimental results revealed a tendency of improved surface roughness with increased rotational speed of the workpiece, and the best surface roughness and form accuracy were observed at a feed rate of 5 mm/min. Furthermore, based on the cutting condition experiments, corrective machining was performed. The experimental results demonstrated an improvement in form accuracy from 0.94 ㎛ to 0.31 ㎛ and a significant reduction in the average value of the surface roughness curve from 0.234 ㎛ to 0.061 ㎛. This research serves as a foundation for future studies focusing on the machinability in relation to laser output parameters.

• Composites Research
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• v.33 no.5
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• pp.262-267
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• 2020

With increasing demands for high-speed machining and lightweight design of machine tools, increasing likeliness of generation of machine tool spindle vibrations has become an important issue. Spindle vibration has a significant impact on the surface finish of the workpiece in ultra-precision machining. It is necessary to resolve the machine tool spindle vibration in various machining processes to improve machining accuracy. In this paper, a TiC-SKH51 metal-matrix composite was used to suppress the vibration of the machine tool spindle. To confirm the dynamic characteristic of the TiC-SKH51 composite, impact hammer tests were conducted. After verifying the reliability of a finite element analysis (FEA) by comparing the results of the impact hammer test with the modal analysis using FEA, the analysis of the machine tool spindle model was performed. The FEA results show that the TiC-SKH51 composite applied machine tool spindle can be utilized to suppress the vibration generation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.905-909
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• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.1
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• pp.97-103
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• 2013

This study proposes a path generation technique for simultaneous five-axis driving for ball bar measurement, which is equivalent to cone frustum machining as mentioned in the NAS979 standard. The technique is generalized for a 3D circular path, and it is applicable to all machine tools regardless of their structural configurations. A mathematical machine input model that consists of a five-axis machine tool, ball-bar measurement and conical path information as inputs is presented for easy NC code generation, simulation for various test conditions, and a measurement test. The movement range of rotary axes, which depends on various conditions, is mathematically analyzed based on the proposed conical path model. Moreover, the effect of the movement range on various conditions (apex angle and inclination angle, ball bar tilting acceptance angle, offset position of workpiece ball, etc.) is analyzed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.9
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• pp.1438-1443
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• 2001

The significance of the casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to reduce press capacity and material cost. Firstly, a hot compression test was performed with cast cylindrical billets in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from 420$\^{C}$ to 450$\^{C}$. The suitable strain rate was 1.5 sec(sup)-1. The deformation amount of a preform of a preform in a forging process is a key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of case preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeded 0.7. From the result of FE analysis, optimal configurations of the cast preform and the die were designed for a large flange. The filling and solidification analysis for a sound cast-preform was carried out with MAGMA soft. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Journal of Powder Materials
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• v.21 no.4
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• pp.301-306
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• 2014

Titanium alloys are extensively used in high-temperature applications due to their excellent high strength and corrosion resistance properties. However, titanium alloys are problematic because they tend to be extremely difficult-to-cut material. In this paper, the powder synthesis, spark plasma sintering (SPS), bulk material characteristics and machinability test of hybrid $Ti_2AlC$ ceramic bulk materials were systematically examined. The bulk samples mainly consisted of $Ti_2AlC$ materials with density close to theoretical value were synthesized by a SPS method. Random orientation and good crystallization of the $Ti_2AlC$ was observed at $1100^{\circ}C$ for 10 min under SPS sintering conditions. Scanning electron microscopy results indicated a homogeneous distribution and nano-laminated structure of $Ti_2AlC$ MAX phase. The hardness and electrical conductivity of $Ti_2AlC$ were higher than that of Ti 6242 alloy at sintering temperature of $1000^{\circ}C{\sim}1100^{\circ}C$. Consequently, the machinability of the hybrid $Ti_2AlC$ bulk materials is better than that of the Ti 6242 alloy for micro-EDM process of micro-hole shape workpiece.

• Journal of Computational Design and Engineering
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• v.1 no.3
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• pp.187-193
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• 2014

One of the hottest challenges in automotive industry is related to weight reduction in sheet metal forming processes, in order to produce a high quality metal part with minimal material cost. Stamping is the most widely used sheet metal forming process; but its implementation comes with several fabrication flaws such as springback and failure. A global and simple approach to circumvent these unwanted process drawbacks consists in optimizing the initial blank shape with innovative methods. The aim of this paper is to introduce an efficient methodology to deal with complex, computationally expensive multicriteria optimization problems. Our approach is based on the combination of methods to capture the Pareto Front, approximate criteria (to save computational costs) and global optimizers. To illustrate the efficiency, we consider the stamping of an industrial workpiece as test-case. Our approach is applied to the springback and failure criteria. To optimize these two criteria, a global optimization algorithm was chosen. It is the Simulated Annealing algorithm hybridized with the Simultaneous Perturbation Stochastic Approximation in order to gain in time and in precision. The multicriteria problems amounts to the capture of the Pareto Front associated to the two criteria. Normal Boundary Intersection and Normalized Normal Constraint Method are considered for generating a set of Pareto-optimal solutions with the characteristic of uniform distribution of front points. The computational results are compared to those obtained with the well-known Non-dominated Sorting Genetic Algorithm II. The results show that our proposed approach is efficient to deal with the multicriteria shape optimization of highly non-linear mechanical systems.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.10
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• pp.155-161
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• 2000

Recently, environmental pollution has become a big problem in industry and many researches have been done in order to preserve the environment. In the grinding process, the coolant has great influence on environment. It contains several chemicals(sulfur, phosphorus and chlorine) to improve the grinding efficiency. If these additives go into the workplace atmosphere, it is harmful for workers. It can also cause the environment pollution. Because of these reasons many studies have been done to minimize the amount of coolant. However the small amount of coolant can cause the thermal defect on the ground surface layer. This study forced the effects of the compressed cold air when the spindle shaft materials(SCM4 & SCM21) were cylindrical ground with WA wheel. The compressed cold air was used as the coolant and grinding performance was compared with that of the conventional grinding fluids(emulsion). Many experiments were carried out with these two cooling materials. The surface roughness, residual stress, and roundness were measured for the cylindrical grinding. The test results showed that the compressed cold air was very useful as the cooling materials for grinding process. It was also efficient to minimize the thermal defects of workpiece and could also play a role in solving environmental pollution.