• 동력기계공학회지
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• 제19권2호
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• pp.70-77
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• 2015

Nowadays, car manufacturers applied many high strength steels such AHSS or UHSS to car bodies for weight lightening. Therefore, a variety of applied steel sheet to car bodies increased and the needs of simulation to evaluate weldability also increased in order to reduce the cost and time. In this study, resistance spot welding simulations for DP 780 Steel with 1.0 and 1.4 mm thickness were conducted with respect to lobe curve. 2 regression models to estimate tensile shear strength were suggested and they were second order polynomial regression model and optimized second order regression model. The performance of these models was evaluated in terms of the coefficient of determinant and average error rate.

• Journal of Welding and Joining
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• 제32권4호
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• pp.69-74
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• 2014

Welding distortions of large steel structures had mainly been estimated with some simplified formula obtained by lots of experience and numerical analyses for small steel structures. However, the large structures would have different characteristics of distortion with welding because of their own stiffness coming from the size itself. Therefore, in order to find some measures for preventing welding distortion of large structure, it is requite in advance to precisely analysis thermal stress and distortion during welding of the structure. Numerical analysis for larger structure has been known to take large amount of calculation time and have a poor convergency problem during the thermo-elasto-plastic calculation. In this study, a hybrid method is proposed to analysis the thermal stress and distortion of a large steel plate with the finite element analysis by incorporating with temperature distribution of the plate calculated by an analytical solution. The proposed method revealed that the thermo-mechanical analysis for welding of the large structure could be performed with a good convergence and produced precise results with much reduced time consumption.

• Journal of Welding and Joining
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• 제21권1호
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• pp.48-53
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• 2003

The object of this study is to examine the effect of short circuit time ratio (SCTR) and current rise delay time (Td) on the spatter generation at low and medium current range in $CO_2$ welding. The spatter was evaluated by the weight generated in the welding of bead-on-plate for 30 seconds (3 times). Td was varied by order of 0, 0.4, 0.8 and 1.2 msec. At each Td, the short circuit time ratio was varied by the output voltage of the welding power source. In the low current range, it was found that the optimum SCTR was 20~25%, and the minimum spatter generation weight was obtained in the case of Td=0.4msec and SCTR=22% even though the remarkable difference was not showed by the application of Td. In the medium current range, it was confirmed that the arc was stable though the SCTR was increased from 20% to 40% by the control of current wave. Spatter generation weight depended on the variation of Td, and the lowest value of spatter generation weight occurred at Td=0.8~1.2msec.

• Journal of Welding and Joining
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• 제14권6호
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• pp.131-139
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• 1996

The response of the arc sensor using the welding current and/or welding voltage as its outputs has been obtained by the analysis and/or experiments of the static characteristics of arc sensor. But in order to improve the reliability of arc sensor, it is necessary to know its dynamic characteristics. So in this paper, it is presented the dynamic model of arc sensor including the power source, arc voltage, electrode burnoff rate, and wire feed rate. A numerical simulation of the dynamic model of arc sensor was implemented, computing the welding current with input of CTWD. The results of computer simulations and experiments of $CO_2$arc welding showed that a linear relationship between weaving center - weld line distance and current area difference was established. Additionally, a real-time weld seam tracking system interfaced with industrial welding robot was constructed, the result of the weld seam tracking experiment for weld line with an initial offset error of 5$^{\circ}$was good.

• 조명전기설비학회논문지
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• 제12권3호
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• pp.22-28
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• 1998

우리 나라 안경테 제조 산업은 대부분의 부품 조립과 용접 과정이 작업의 부정확성과 인력수급의 부족으로 자동화가 요구되고 있다. 이에 본 연구에서는 안경테의 Rim과 Lock의 전기 용접과정을 자통화하기 위해 Rim-Lock 전기 용접기를 설계하였다.Rim-Lock 전기 용접기는 Lock올 공급하기 위한 원형공급기와 직 진공급기. Rim과 Lock을 용접하기 위한 holder. 은납 공급장치 퉁으로 구성되고 주 컨트롤러는 확장성이 좋은 V55 마이크로 프로세서를 사용하였다. 제어프로그램은 C언어를 이용하였으며, 코딩과 프로그랭의 수정 및 보완이 편리하다. 본 연구에서 개발된 Rim-Lock 전기 용접기를 이용한 실제 용접시 Rim-Lock의 모양이 항상 일정하였고 계속적인 작업이 가능하므로 생산력이 향상된다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 춘계학술대회 논문집
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• pp.110-114
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• 2001

The welding pressure in porthole die extrusion is affected by the shape of welding chamber. It is very important to increase the welding pressure when the tube is used particulary as the materials of hydroforming processing. The high circumferential stress of the tube would make the welding pressure increase during the porthole die extrusion. In order to increase the circumferential stress, it is necessary to make the billets pass through the narrow gap between the conical die and the conical mandrel. This paper describes the welding pressure by the experiments with the two types of the chamber. One of them is the chamber between the flat die and straight mandrel, and the other one is the chamber between the conical die and conical mandrel. The result of the experiments show that the conical chamber makes the welding pressure increase by the effect of the reducing the diameteres of tube.

• Journal of Welding and Joining
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• 제21권2호
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• pp.76-81
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• 2003

Due to the environmental problem, automotive companies are trying to reduce the weight of car body. Therefore, WP(Transformation Induced Plasticity) steels, which are hish strength and ductility have been developed. The application of TRIP steel to the members has been reported to increase the energy absorption capability. Welding process is a complex process; therefore deciding the optimal welding conditions is an effective method on the basis of the experimental data. However, using a trial-and-error method from the beginning in such a wide area, in order to decide the optimal conditions requires too many numbers of experiments. To overcome these problems and to decide the optimal conditions, response surface methodology was used. Response surface methodology is a collection of mathematical and statistical techniques that are for the modeling and analysis of problems in which a response of interest is influenced by several variables and the objective is to optimize this response. The introduced method was applied to the resistance spot welding process of the TRIP steel and the welding parameters were optimized. (Received December 6, 2002)

• Journal of Welding and Joining
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• 제27권2호
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• pp.63-68
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• 2009

Microminiature heat exchanger has been applied to the gas turbine in order to increase energy efficiency. During the production of microminiature heat exchanger, however, it is very difficult to weld tube to tubesheet. In this study, therefore, welding process of resistance ring projection was used, and weld tensile tests were performed. Sound weld joint was obtained as a result of applying resistance ring projection welding to microminiature heat exchanger to tubesheet. Cold weld occurred at under 1600A. Even though tensile strength was increased with increasing current, splash occurred and tensile strength decreased at 2000A due to the excessive current. Therefore it was determine that the optimal current is 1900A. As result of tensile tests based on ASME code for tube to tubesheet weldment, rupture position was weldment due to Fs(Fractured section) of nugget, which was smaller than tube thickness (t), and it was proven as a partial strength welding because of the average joint efficiency fr = 0.90.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.810-814
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• 1996

The purpose of this exclusive welding-machine process using the welding Torch-rotation form is to develop a mechanism which can solve the problem of twisted welding wires and cables. The technique was developed by revising the torch position and smooth controlling of both the formal and reverse rotation. Some of the advantages of using the Torch-rotation form over the Work-rotation technique are the practical uses of increased work space and link work with the automation system of the plant. Using this welding machine process, It is possible to design a specific tool in order to solve the implemental problem. And I produced a control plate which can manipulate the progress of the entire process at the work place. Even if another kind of axle casing's welding work is used this process can be utilized if the fixed tip and work is produced and changed. The development if this exclusive welding-machine could reduce the manpower of skilled welding labor and after considerable analysis, this machine was found to increase productivity and better quality product in comparison to the handmade product.

• Journal of Welding and Joining
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• 제26권6호
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• pp.59-66
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• 2008

Recently, automobile parts progress with modularization, which a great many allied products are modularized. Therefore, the purpose of this study is to develope modular housing for modularization of steering gear. Generally, steering gear housing is composed of valve housing and rack housing, it is important to combine two housings. However, housing having the pipe shape is very sensitive to welding distortion, and welding trajectory is very complicated. In order to solve this subject, cooperative control by using robots was constructed. Further, we developed the dedicated system to suit modular housing based on it, and applied laser welding to there. Moreover, welding speed was controlled in the rapid curve section so that the defect in trajectory of housing was reduced to obtain sound weldment. Accordingly, produced housing by this way is presented enough withstanding pressure to $100kg/cm^2$, and roundness and straightness are measured about 10/100 and 0.9/100 respectively.