• Design & Manufacturing
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• v.16 no.4
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• pp.46-51
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• 2022

The piercing process of creating holes in sheet metals for mechanical fastening generates high shear force. Real-time monitoring technology could predict tool damage and product defects due to this severe condition, but there are few applications for piercing high-strength aluminum. In this study, we analyzed the load signal to predict the punch's wear level during the process with a piezoelectric sensor installed piercing tool. Experiments were conducted on Al6061 T6 with a thickness of 3.0 mm using piercing punches whose edge angle was controlled by reflecting the wear level. The piercing load increases proportionally with the level of tool wear. For example, the maximum piercing load of the wear-shaped punch with the tip angle controlled at 6 degrees increased by 14% compared to the normal-shaped punch under the typical clearance of 6.7% of the aluminum piercing tool. In addition, the tool wear level increased compression during the down-stroke, which is caused by lateral force due to the decrease in the diameter of pierced holes. Our study showed the predictability of the wear level of punches through the recognition of changes in characteristic elements of the load signal during the piercing process.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 2002.10b
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• pp.411-412
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• 2002

Piston-cylinder system are widely used in power engineering applications. In reciprocating refrigeration compressors, where extremely low friction losses are required, ringless pistons are being used to diminish the friction between piston rings and cylinder wall. Since the ringless piston has the freedom of lateral motion there is a potential danger that it will occasionally hit the cylinder wall while moving up and down along it's axis. A good design must therefore provide a smooth and stable reciprocating motion of the piston and ensure that the fluid film separating the piston from the cylinder wall is maintained all times. And the compromise between refrigerant gas leakage through the piston-cylinder clearance and the friction losses is required utilizing a dynamic analysis of the secondary motion for the high efficiency compressor. To this end, the computer program is developed for calculating the entire piston trajectory and the lubrication characteristics as functions of crank angle under compressor running conditions. The results explored the effects of some design parameters and operating conditions on the stability of the piston, the oil leakage, and friction losses.

• Journal of Industrial Technology
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• v.25 no.B
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• pp.121-126
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• 2005

Micro wires manufactured by the straightening process are used in the BT(Bio-Technology), IT(Information-Technology), NT(Nano-Technology). We have developed a novel wire straightener which uses the direct heating method(DHM) for straightening the micro wire and shearing device for burr-less cutting. In this study, we confirm the tendency of micro wire after the shearing process. It is impossible to remove the burr in the shearing process. However, the embodiment of minimum burr size after the shearing process is the best in-process method. In order to minimize the burr size, we have accomplished the various experiment condition such as the U-groove, the effect of the counter punch, the shear angle, clearance.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.498-501
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• 2001

Blanking is one of the most frequently used processes in sheet metal forming. In this paper, attention is paid to the blanking simulation of aluminium foil with $20{\mu}m$ thickness which is used an anode in lithium-ion polymer battery. In order to study the shearing mechanism for the metallic foil, finite element analysis with Crockroft and Latham fracture criterion was performed. The objective of the present work is to evolve a methodology to obtain the optimum punch-die clearance for a given aluminium foil by the simulation of the blanking process using a general purpose FEM code.

• International Journal of Aeronautical and Space Sciences
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• v.10 no.1
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• pp.20-29
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• 2009

There are concerns about the influence of the gust wind caused by helicopters affecting the moving vehicles while hovering over the road during rescue activities. For the understanding of such complicated flow. numerical simulation of a rotor hovering above the ground has been carried out, changing the rotor/ground clearances. The rotor thrust is kept constant. and the rotor control is determined by trim adjustments incorporated into the CFD algorithm. Collective pitch angle and the required power decreases with the rotor/ground clearance which agrees with experience. Changes of the flowfield near the rotor with regard to the rotor height are investigated based on the calculated results.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.12
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• pp.54-60
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• 2000

Research about tool condition monitoring has been done until now for product automation and unmaned system. But it is hard to apply it to the industrial field due to its cost and reliability. This paper presents the new method of tool wear measurement using Marpos gauge. This is a kind of touch sensor, so its cost is lower than vision system. And it is not affected by dust and illumination, which are important in vision system. This proposed method use tool clearance angle to measure flank wear. Experimental results compared with vision system shows that this method is available for tool condition monitoring system.

• Tribology and Lubricants
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• v.20 no.4
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• pp.183-189
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• 2004

The floating ring seal is used in an oxidizer and a fuel pump of the turbo pump unit in the liquid rocket engine to optimize a leakage without rubbing phenomenon. The damper floating ring seal, one of the floating ring seals, is with round hole pattern surfaces. It can reduce the leakage by increased friction factor that obtained from experimental data. In this paper, the leakage test about floating ring seal and damper floating ring seal was conducted. The test result showed the leakage performance of damper floating ring seal was better than the leakage performance of floating ring seal. With the leakage test the lock-up and rotation test about seal was conducted and that position is measured. The relatively large lock-up eccentric ratio was obtained from the test result of damping floating ring seal. The attitude angle of seal increases with increasing of shaft rotation.

• Tribology and Lubricants
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• v.14 no.3
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• pp.51-58
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• 1998

This paper considers analysis of the lubrication between the piston ring and the cylinder liner. Piston ring lubrication analysis considering oil transport is important because oil consumption is an essential factor to design the piston assembly. To develop the lubrication analysis program for the piston ring, oil continuity condition and open-end boundary assumption are used for computational boundaries. Results show that oil continuity can be almost satisfied at any crank angle in and out of the piston ring clearance. Therefore the amount of oil consumption and the dynamic behavior of ring pack can be estimated using this algorithm. And it can be known that the effective width may be smaller than the full width of the piston ring, so oil starvation condition should be considered for the lubrication analysis of the piston ring.

• Transactions of Materials Processing
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• v.14 no.1 s.73
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• pp.57-64
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• 2005

This study deals with the cold forging process design for shaft in the main part of automobile motors with rectangular deep groove. In forging process, the accuracy and die lift is very important because it have influence on reduction of the production cost and the increase of the production rate. Therefore, it is necessary to develop the manufacturing process of shaft by cold forging., process variables are the cropped face angle of billet and the eccentric load of punch. The former is derived from cropping test, the latter is occurred by clearance between container and preform. Also, grooved preform select the process variable for decrease in punch deflection. We investigate that a deflection of punch and a deformation of preform to every process variables. Through this investigation, we suggest the optimal preform and process design, expect to be improved the tool life in forging process.

• Journal of the korean Society of Automotive Engineers
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• v.6 no.3
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• pp.45-54
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• 1984

Bending strength of an internal gear tooth is discussed as tooth form factor taking into account the actual stress magnitude. Stress analysis was carried out by the finite element method(FEM) for the calculation of tooth form factor of an internal gear. This paper also investigated the influences of number of teeth and addendum modification coefficient of the internal gear and the influences of number of teeth, addendum modification coefficient, pressure angle, radius of rounding of tooth tip, and bottom clearance coefficient of the pinion-shaped cutter on tooth form factor of internal gear. Generalizing the resultant data, a simple formula for the tooth form factor of an internal gear was derived for the calculation of tooth bending strength of an internal gear.