• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.8
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• pp.933-940
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• 2011

Thin sheets with a corrugated structure are generally used for the fabrication of heat exchangers for electronics, airplanes, and vehicles. However, it is difficult to fabricate corrugated structures, especially those with a bent angle, using the conventional stamping process because of its intrinsic formation mechanism. We propose a novel rubber-forming process for the effective pressing of the both tilted sides of a plate under the same pressure to form exact corrugated shapes. We use finite element analysis and experiments to study the rubber-forming process parameters, and we evaluate the maximum allowable bent angle for high-quality formation. We show that the proposed method is effective for the fabrication of bent plates with low cost.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.365-372
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• 2004

The laser welding and its analysis were carried out using high power 6kW $CO_2$ laser for high strength steels such as DP, TRIP and conventional high strength steels. Bead on plate welding of thin sheet was examined to investigate the effect of weld variables of laser welding, and to obtain optimum welding condition. In order to investigate the formability of welded high strength steels, LDH test was added on this work. At high welding speed, the partial penetration was obtained by low heat input. Meanwhile, porosity was formed in the bead at low weld speed because of extremely higher heat input. The optimum welding condition of welding was derived from bead width, penetration and hardness property. It was shown that the DP steels had lower porosity level and smooth bead shape, therefore better laser weldability than TRIP steels and conventional high strength steels. In addition, LDH test shows that the welded DP steels have about $90\%$ formability value of base metal, although TRIP steel and conventional high strength steels have about $80\%$ formability value of its base metal.

• Elastomers and Composites
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• v.44 no.4
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• pp.384-390
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• 2009

Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. The solar cell plate may have millions of patterns, and the analysis of forming considering all the patterns is impossible due to the computational costs. In this study, analyses are carried out for various numbers of patterns and the results are compared. It is shown that the analyses results with four row patterns and twelve row patterns are same. So, it is considered that the analysis can be carried out for only four rows of pattern for the design of incremental roll-to-roll forming process. Also formability is analysed for various number of mesh, protrusion shapes and forming temperature.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.6
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• pp.100-107
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• 2021

As a significant technology in the smartization era promoted by the Fourth Industrial Revolution, the secondary battery industry has recently attracted significant attention. The demand for lithium-ion batteries (LIBs), which exhibit excellent performance, is considerably increasing in different industrial fields. During the manufacturing process of LIBs, it is necessary to join the cathode and anode sheets with thicknesses of several tens of micrometers to lead taps of the cathode and anode with thicknesses of several hundreds of micrometers. Ultrasonic welding exhibits excellent bonding when bonded with very thin plates, such as negative and positive electrodes of LIBs, and dissimilar and highly conductive materials. In addition, ultrasonic welding has a small heat-affected zone. In LIBs, Cu is mainly used as the negative electrode sheet, whereas Cu or Ni is used as the negative electrode tab. In this study, one or two electrode sheets (t0.025 mm Cu) were welded to one lead tab (t0.1 mm Cu). The welding energy and pressure were used as welding parameters to determine the welding strength of the interface between two or three welded materials. Finally, the effects of these welding parameters on the welding strength were investigated.

• Clean Technology
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• v.28 no.4
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• pp.323-330
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• 2022

Microfluidic paper-based analytical devices (μPADs) have recently been in the spotlight for their applicability in point-of-care diagnostics and environmental material detection. This study presents a double-sided printing method for fabricating 3D-μPADs, providing simple and cost effective metal ion detection. The design of the 3D-μPAD was made into an acryl stamp by laser cutting and then coating it with a thin layer of PDMS using the spin-coating method. This fabricated stamp was used to form the 3D structure of the hydrophobic barrier through a double-sided contact printing method. The fabrication of the 3D hydrophobic barrier within a single sheet was optimized by controlling the spin-coating rate, reagent ratio and contacting time. The optimal conditions were found by analyzing the area change of the PDMS hydrophobic barrier and hydrophilic channel using ink with chromatography paper. Using the fabricated 3D-μPAD under optimized conditions, Ni²⁺, Cu²⁺, Hg²⁺, and pH were detected at different concentrations and displayed with color intensity in grayscale for quantitative analysis using ImageJ. This study demonstrated that a 3D-μPAD biosensor can be applied to detect metal ions without special analysis equipment. This 3D-μPAD provides a highly portable and rapid on-site monitoring platform for detecting multiple heavy metal ions with extremely high repeatability, which is useful for resource-limited areas and developing countries.

• Journal of the Korean Vacuum Society
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• v.21 no.3
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• pp.142-150
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• 2012

In this Study, Mo back electrode were deposited as the functions of various working pressure, deposition time and plasma per-treatment on sodalime glass (SLG) for application to CIGS thin film solar cell using by DC sputtering method, and were analyzed Mo change to $MoSe_2$ layer through selenization processes. And finally Mo back electrode characteristics were evaluated as application to CIGS device after Al/AZO/ZnO/CdS/CIGS/Mo/SLG fabrication. Mo films fabricated as a function of the working pressure from 1.3 to 4.9mTorr are that physical thickness changed to increase from 1.24 to 1.27 ${\mu}m$ and electrical characteristics of sheet resistance changed to increase from 0.195 to 0.242 ${\Omega}/sq$ as according to the higher working pressure. We could find out that Mo film have more dense in lower working pressure because positive Ar ions have higher energy in lower pressure when ions impact to Mo target, and have dominated (100) columnar structure without working pressure. Also Mo films fabricated as a function of the deposition time are that physical thickness changed to increase from 0.15 to 1.24 ${\mu}m$ and electrical characteristics of sheet resistance changed to decrease from 2.75 to 0.195 ${\Omega}/sq$ as according to the increasing of deposition time. This is reasonable because more thick metal film have better electrical characteristics. We investigated Mo change to $MoSe_2$ layer through selenization processes after Se/Mo/SLG fabrication as a function of the selenization time from 5 to 40 minutes. $MoSe_2$ thickness were changed to increase as according to the increasing of selenization time. We could find out that we have to control $MoSe_2$ thickness to get ohmic contact characteristics as controlling of proper selenization time. And we fabricated and evaluated CIGS thin film solar cell device as Al/AZO/ZnO/CdS/CIGS/Mo/SLG structures depend on Mo thickness 1.2 ${\mu}m$ and 0.6 ${\mu}m$. The efficiency of CIGS device with 0.6 ${\mu}m$ Mo thickness is batter as 9.46% because Na ion of SLG can move to CIGS layer more faster through thin Mo layer. The adhesion characteristics of Mo back electrode on SLG were improved better as plasma pre-treatment on SLG substrate before Mo deposition. And we could expect better efficiency of CIGS thin film solar cell as controlling of Mo thickness and $MoSe_2$ thickness depend on Na effect and selenization time.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.3
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• pp.49-55
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• 2017

Most motor cases adopt deep drawing products, which are excellent in waterproof functions, concentricity, right angle, and quality. In addition, the blower motor and seat motor, which are installed in the car interior and do not require waterproof function, adopts a multi-forming manufacturing method. The deep drawing process requires an expensive transfer press that can digest approximately 12 processes, such as drawing, trimming and piercing. On the other hand, products can be produced with low investment because the multi-forming method is composed of one multi-forming machine or one multi-forming machine and one press. The multi-forming machine is a high-priced facility that is mostly imported and a bending / shearing process multi-foaming machine, which was developed by domestic small and medium-sized enterprises, is not enough to reduce the production cost. An integral multi - forming machine is used as a limited working method for thin material and small products. A large product and thick material has a high shear load. A large product and thick material has a high shear load and uses a single crank press. After blanking, the worker manually feeds the material to a multi-forming machine. When the bending operation is performed in the multi-forming machine, it is transferred to the press again to calibrate the dimensions. This variance in work processes has resulted in lower cost competitiveness due to the lower productivity, quality issues, and excessive operator input. The aim of this study was to establish a stable and cost - effective production system through bending / shearing process separation and facility automation.

• Journal of the Microelectronics and Packaging Society
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• v.25 no.3
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• pp.61-66
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• 2018

This research scrutinizes the self-annealing characteristics of copper used to metal interconnection for application of DRAM fabrication process. As the time goes after the copper deposited, the grain of copper is growing. It is called self-annealing. We use the electroplating method for copper deposition and estimate two kinds of electroplating chemicals having different organic additives. As the time of self-annealing is elapsed, sheet resistance decreases with logarithmic dependence of time and is finally saturated. The improvement of sheet resistance is approximately 20%. The saturation time of experimental sample is shorter than that of reference sample. We can find that self-annealing is highly efficient in grain growth of copper through the measurement of TEM analysis. The structure of copper grain is similar to the bamboo type useful for current flow. The results of thermal excursion characteristics show that the reliability of self-annealed sample is better than that of sample annealed at higher temperature. The self-annealed sample is not contained in hillock. The self-annealed samples grow until $2{\mu}m$ and develop in [100] direction more favorable for reliability.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.4 s.97
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• pp.57-63
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• 1999

A thin metal plate such as detent spring has the shape deformation due to the phenomenon of spring back after press machining and heat treatment process. This requires the correction of spring shape and force in final inspection process. To do correction of the shape deformation the impact force is manually applied to the bended part of detent spring after measuring the shape deformation and spring force. To develop the automatic spring force correction system, applied force of occurring plastic deformation must be derived from the experimental method. But frequent change of spring shape and material makes it difficult to accomplish the experimental method to be applied. This paper describes the analytical method for detent spring force correction system is to be substituted for the experimental method. FEM(Finite Element Method) is used to find the boundary value between elastic and plastic deformation in the analytical method. To confirm the validity of the analytical method, the result of two methods is compared each other at various applied force conditions. It shows that the simulation result of the analytical method is consistent with the result of the experimental method within the error bound ${\pm}$5%. The result of this paper is useful for development of the automatic spring correction system and reduction of the complicated and tedious processes involved in experimental method.

• International Journal of Automotive Technology
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• v.5 no.1
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• pp.55-59
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• 2004

Spot welding is a very important and useful technology in fabrication of thin sheet structures such as the parts in an automobile. However, because the fatigue strength of the spot welding point is considerably lower than that of the base metal due to stress concentration at the nugget edge, the nugget size must be estimated to evaluate a reasonable fatigue strength at a spot welded lap joint. So far, many investigators have experimentally studied the estimation of fatigue strengths of various spot weldments by using a destructive method. However, these destructive methods poses problems so testing of weldments by these methods are difficult. Furthermore, these methods cannot be applied to a real product, and are time and cost consuming, as well. Therefore, there has been a strong, continual demand for the development of a nondestructive method for estimating nugget size. In this study, the effective nugget size in spot weldments have been analyzed by using thermoelastic stress analysis adopting infrared thermography. Using the results of the temperature distribution obtained by analysis of the infared stress due to adiabatic heat expansion under sinusoidal wave stresses, the effective nugget size in spot welded specimens were estimated. To examine the evaluated effective nugget size in spot weldments, it was compared with the results of microstructure observation from a 5％ Nital etching test.