• Design & Manufacturing
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• v.17 no.2
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• pp.47-54
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• 2023

The research direction of the automobile industry worldwide is speeding up research to improve fuel efficiency through weight reduction as the weight of automobiles increases due to environmental problems, convenience demands, and safety problems. As a way to solve weight reduction, there is a method of improving mechanical properties by improving the development and manufacturing method of lightweight materials with replaceable mechanical properties. Therefore, research on the molding and processing technology of aluminum, which is a lightweight material, is being actively conducted. In this study, aluminum material was applied. By using Autoform S/W, a press forming analysis program, the blank holding force, mold die R, and bead restraint force were selected in three levels, respectively, and the results and optimization of formability and shape freezing were carried out. In this study, aluminum material was applied. By using Autoform S/W, a press molding analysis program, the blank holding force, mold die R, and bead restraint force were selected in three levels, respectively, and the results and optimization of formability and shape freezing were carried out. The optimized results were confirmed by comparative analysis of formability and Spring Back. As a result of the experiment, it was possible to confirm the result value of the Spring Back of the final product according to the tensile change of the material.

• Design & Manufacturing
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• v.15 no.2
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• pp.63-69
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• 2021

Springback is an essential task to be solved in order to make high-precision products in sheet metal forming. In this study, materials with four different elastic regions were used. For the forming analysis, the change of springback caused by the frictional force generated in the flange part during hat shape forming was considered by using the AutoForm analysis program. Factors affecting frictional force were blank holder force, friction coefficient, bead R and bead height. As a result of the forming analysis, the springback increases as the material with a larger elastic region increases. In addition, as the frictional force of the flange part increased, the tensile force in the forming direction increased and the springback decreased. In particular, the blank holder force and friction coefficient had a great effect on springback in mild materials (DC04, Al6016), and the bead effectively affects all materials. Through this study, it was considered that the springback decreased as the material with a smaller elastic region and the tensile force in the forming direction increased.

• International Journal of Korean Welding Society
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• v.1 no.1
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• pp.17-22
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• 2001

Because the quantitative relationships between welding parameters and welding result are not yet blown, optimal values of welding parameters for $CO_2$ robotic arc welding is a difficult task. Using the various artificial data processing methods may solve this difficulty. This research aims to develop an expert system for $CO_2$ robotic arc welding to recommend the optimal values of welding parameters. This system has three main functions. First is the recommendation of reasonable values of welding parameters. For such work, the relationships in between the welding parameters are investigated by the use of regression analysis and fuzzy system. The second is the estimation of bead shape by a neural network system. In this study the welding current voltage, speed, weaving width, and root gap are considered as the main parameters influencing a bead shape. The neural network system uses the 3-layer back-propagation model and a generalized delta rule as teaming algorithm. The last is the optimization of the parameters for the correction of undesirable weld bead. The causalities of undesirable weld bead are represented in the form of rules. The inference engine derives conclusions from these rules. The conclusions give the corrected values of the welding parameters. This expert system was developed as a PC-based system of which can be used for the automatic or semi-automatic $CO_2$ fillet welding with 1.2, 1.4, and 1.6mm diameter the solid wires or flux-cored wires.

• Journal of Welding and Joining
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• v.34 no.6
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• pp.69-74
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• 2016

Because the pure titanium has superior corrosion resistance and formability compared with different material, it is widely used as material of welded heat exchanger. When the welding of heat exchanger is carried out, certain area in which welding start and end are overlapped occurs. The humping of back bead is formed in the overlap area due to partial penetration. Thus in this study, the experiments were carried out by changing the length and wave shape of overlap area, and then the weldabiliay was evaluated through the observation of microstructure, the measurement of hardness and tensile-shear strength test in the overlap area. When overlap length was 9.8mm, humping bead was suppressed. The microstructure of overlap area coarsened and its hardness increased due to remelting. As a result of tensile-shear strength test in the overlap area according to applying the wave shape control, it was confirmed that the overlap area applied wave shape control had more excellent yield strength and ductility.

• Journal of Power System Engineering
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• v.9 no.4
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• pp.102-109
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• 2005

An attachment part of the construction equipment frequently claimed from the crack occurrence that takes especially at the bucket. therefore we execute the fatigue examination and changes the welding method at the same materials. we executed a fatigue crack propagation experiment and got the conclusions at the normal temperature and Frequency 10Hz. We carried out butt welding for structure steel of SM490A and make three kinds of specimen of different weld method each. The fatigue limit of CASE 1 was determined to the low than CASE 2, CASE 3. the CASE 2 putting the interval of the 2mm creates back plate and make fatigue limit to high. Bead shapes and weld surfaces shape influence on fatigue life of materials. Specially, the crack growth becomes starting point that gap of back-plate and boundary surface of bead. It is confirmed by fracture showing on this study.

• Journal of Welding and Joining
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• v.17 no.5
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• pp.47-54
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• 1999

It is well known that solidification cracking often occurs in welds of root pass for one-side welding under the conditions of high welding currents and speeds. In this study, the solidification in 590MPa class steel for pressure vessels SPPV490 was investigated by using flux-cored arc welding(FCAW) with 4 types of welding wires and welding conditions of 200∼280A and 2.8∼ 4.2mm/sec. In order to compared the result of cracking in SPPV490, 0.2%C steel for welded structure of SWS400 and 0.45%C steel for machine structural SM45C were also used as base metals. As the results, all the cracks formed in some welding conditions were observed near the center of weld bead. The solidification cracks were generally initiated near the upper surface of bead and propagated toward the inner part. The solidification cracking generally increased with welding current and welding speed in the same base metal and welding material. In cracking susceptibility, SPPV490 showed higher cracking susceptibility than SWS400 in all welding conditions and welding materials. It was considered that cracking susceptibility could not be evaluated with the hardness of weld metals. The cracking ratio increased with decreasing of a/b(a and b; the width of the upper surface and the back surface of the bead) as shape factor of bead. The cracking tendency with shape factor of bead was extended under the condition of higher welding currents.

• Journal of the Korean GEO-environmental Society
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• v.14 no.9
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• pp.39-47
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• 2013

Local deformations in back filling materials of two sands and one glass bead with different particle shapes behind a rigid retaining wall were studied. Two kinds of boundary conditions were compared: active wall translation and active rotation of the wall about its toe. Effect of the speed of active wall translation was also investigated. The digital image correlation method was used to analyze local deformation developments inside the materials. Test results showed that particle shape and density mainly influence the inclination angle and width of the shear band. The general shear band pattern is strongly dependent on the wall movement mode, while it was little influenced by particle shape. Within a limited range of wall speed in this study, shear band became wider and local deformation became larger with increase of wall speed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.2 s.233
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• pp.303-310
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• 2005

The systems with probe and SIL(Solid Immersion Lens) mechanisms have been researched as the technology to perform NFR(Near Field Recording). Most of them use the flying head mechanism to accomplish high recording density and fast data transfer rate. In this paper, ABS shape of flying head was optimized with the object of securing the maximum compliance ability of OFH. We suggest low different optimization processes to predict the static flying characteristics for the OFH. Two different approximation methods, regression analysis and back propagation neural network were used. And we compared the result of directly connected(between CAE and optimizer) method and two approximated optimization results. Design Optimization Tool(DOT) and ${\mu}GA$ were used as the optimizers.

• Journal of Welding and Joining
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• v.33 no.1
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• pp.54-60
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• 2015

Laser-arc hybrid welding has been considered as an effective pipe girth welding process since early 2000's. Tolerance for fit-up offsets such as gap and edge misalignment is one of most important requirements in pipe girth laser-arc hybrid welding, and several approaches using parameter optimization, a laser beam scanning and an arc oscillation have been tried. However the required offset tolerance has not been fully accomplished up to now and laser-arc hybrid welding has not been widely applied in pipeline construction than expected, despite of its high welding speed and deep penetration. In this study, internal welding was adopted to ensure the offset tolerance and sound back bead. The effect of welding parameters on bead shape was investigated at the flat position. Also tolerances for gap and edge misalignment were verified as 0.5 mm and 2.0 mm, respectively. The position welding trials were conducted at several welding positions from the flat to the overhead position in a downward direction. With the fixed welding speed, arc current for gas metal arc welding current and laser output power, adequate welding voltages for gas metal arc welding were suggested for each position.

• Design & Manufacturing
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• v.12 no.2
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• pp.40-45
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• 2018

Recently, in construction equipment machinery production, development has focused on environmentally-friendly functions to improve existing production capacity. For excavators as well, emphasis has been placed on response to environmental regulations, miniaturization, and noise reduction, while technology is being developed considering cost reduction and safety.Accordingly, the front support, an inner reinforcement part of the excavator, as well as high-strength steel plates to improve safety and reduce weight, are being applied.However, in the case of high-strength materials, Springback occurs in the final formed part due to high residual stress during product forming. Derivation of a forming or product shaping process to reduce springback is needed. Accordingly, regarding the front support, an inner reinforcement part of the excavator, this study derived a method to improve springback and secure shape stiffness through analysis of the springback occurrence rate and springback causes through a forming analysis.As for the results of analyzing the springback occurrence rate of existing products through forming analysis, springback of -22.6 mm < z < 27.35 mm occurred on the z-axis, and it was confirmed that springback occurred due to the stiffness reinforcing bead of the upper and middle parts of the product.To control product residual stress and springback, we confirmed a tendency of springback reduction through local pre-cutting and stiffness reinforcement bead relocation.In the local pre-cutting model, springback was slightly reduced by 5.3% compared with the existing model, an insignificant reduction effect. In the stiffness reinforcement bead relocation model, when an X-shaped stiffness reinforcement bead was added to each corner portion of the product, springback was reduced by at least 80%.The X-shaped bead addition model was selected as the springback reduction model, and the level of stiffness compared to the existing model was confirmed through a structural analysis.The X-shaped bead additional model showed a stress springback of 90% and springback reduction of 7.4% compared with the existing model, indicating that springback and stiffness will be reinforced.