• 연구논문집
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• s.23
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• pp.127-140
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• 1993

The drive pulley, which is employed for loading and unloading raw materials in a steel mill, is usually manufactured by use of various welding processes. In this study the weldment in the pulley, in which TIG and $CO_2$ welding processes are used, has been analyzed from view point of fracture mechanics. Fracture toughness tests have been performed according to ASTM E813. A servo-hydraulic testing machine (10kN) has been employed. Also the crack propagation tests (Mode I) have been performed with compact tension specimen in compliance with ASTM E647. To predict the critical crack size in the weldment, finite element stress analysis for the drive pulley under real operating conditions have been performed. In addition, the residual stresses at the weldment and in heat-affected zone have been obtained by hole drilling method. The planar critical crack size have been predicted for the drive pulley by considering the stress analysis results and the residual stresses due to welding process. For the drive pulley considered in this study, it has been concluded that the most important factor in determining the critical crack size is the welding residual stress in the transverse direction. Also the effect of stress concentration at the root of the weldment have been noticeable. For the planar crack, the fatigue crack growth life from an initial crack size of 2mm to the critical crack size obtained as in the above have been predicted. The predicted lives were between 55, 900 and 72, 000 cycles depending on the shape of the elliptical crack. The predicted lives were in fairly good agreement for the drive pulley considered in this study.

• Journal of Adhesion and Interface
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• v.4 no.2
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• pp.1-9
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• 2003

Epoxy-amine liquid prepolymers are extensively applied onto metallic substrates and cured to obtain painted materials or bonded joint structures. Overall performances of such systems depend on the created interphase between the organic layer and the substrate. When epoxy-amine liquid mixtures are applied onto more or less hydrated metallic oxide layer, concomitant amine chemical sorption and hydroxide dissolution appear lending to the chelate formation. As soon as the chelate concentration is higher than the solubility product, these species crystallize as sharp needles. Moreover, intrinsic and thermal residual stresses are developed within painted or bonded systems. When residual stresses are higher than the organic layer/substrate adhesion, buckling, blistering, debonding may occur leading to a catastrophic drop of system performances. Practical adhesion can be evaluated with either ultimate parameters (Fmax or Dmax) or the critical strain energy release rate, using the three point flexure test (ISO 14679-1997). We observe that, for the same system, the ultimate load decreases while residual stresses increase when the liquid/solid time increases. Ultimate loads and residual stresses depend on the metallic surface treatment. For these systems, the critical strain energy release rate which takes into account the residual stress profile and the Young's modulus gradient remains quite constant whatever the metallic surface treatment was. These variations will be discussed and correlate to the formation mechanisms of the interphase.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.3
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• pp.79-85
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• 2004

The lightness of components required in automobile and machinery industry is requiring high strength of components. In particular, fatigue failure phenomena, which happen in metal, bring on danger in human life and property. Therefore, antifatigue failure technology takes an important part of current industries. Currently, the shot peening is used for removing the defects from the surface of steel and improving the fatigue strength on surface. Therefore, in this paper the effect of compressive residual stress of spring steel(JISG SUP-9)by shot peening on fatigue crack growth characteristics in stress ratio(R=0 1, R=0 3, R=0 6)was investigated considering fracture mechanics. By using the methods mentioned above, I arrived at the following conclusions: (1) The fatigue crack growth rate(da/dN) of the shot peening material was lower than the unpeening material And in stage I, ${\Delta}K_{th}$, the threshold stress intensity factor, of the shot peening material is high in critical parts unlike the unpeening material. (2) Fatigue life shows more Improvement in the shot peening material than in the unpeening material. And compressive residual stress of surface on the shot peening processed operate the resistance of fatigue crack propagation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.5
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• pp.932-938
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• 2002

In structural applications, brittle materials such as soda-lime glasses and ceramics are usually subjected to multiaxial stress state. Brittle materials with cracks or damage by foreign object impacts are apt to fracture abruptly from cracks, because of their properities of very high strength and low fracture toughness. But in most cases, the residual strength of structural members with damage has been tested under uniaxial stress condition such as the 4-point bend test. Depending upon the crack pattern developed, the strength under multiaxial stress state might be different from the one under uniaxial. A comparative study was carried out to investigate the influence of stress state on the residual strength evaluation. In comparable tests, the residual strength under biaxial stress state by the ball-on-ring test was greater than that under the uniaxial one by the 4-point bend test, when a small size indendation crack was introduced. In the case that crack having an angle of 90deg. to the applied stress direction, the ratio of biaxial to uniaxial flexure strength was about 1.12. The residual strength was different from crack angles to loading direction when it was evaluated by the 4-point bend test. The ratio of residual strength of 45deg. crack to 90deg. one was about 1.20. In the case of specimen cracked by a spherical impact, it was shown that an overall decrease in flexure strength with increasing impact velocity, and the critical impact velocity for formation of a radial and/or cone crack was about 30m/s. In those cases that relatively large cracks were developed as compared with the case of indented cracks, the ratio of residual strength under biaxial stress state to one uniaxial became small.

• Journal of the Korean Society of Safety
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• v.13 no.4
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• pp.213-220
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• 1998

Welding structures will be occurred sudden crack or failure by reduced fracture toughness in case of low temperature. To protect these unstable fracture is very important. Because fracture of welding part come from welding faults or residual stress, critical stress intensity factors are acquired at temperatures between $22^{\circ}C$ and $-70^{\circ}C$ from base metal, welding metal and H.A.Z. It was studied effectiveness of annealing and affection of residual stress under low temperatures. In case of fracture toughness test, it showed that fracture toughness value decreased, according to the decrease of temperature. Expecially In case that compressive residual stress was existed, $K_C$ increased.

• Proceedings of the KIEE Conference
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• 1998.07g
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• pp.2521-2523
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• 1998

Freestanding flexible microstructures fabricated from deposited thin films become mechanically unstable when internal stresses exceed critical values. The residual stress and stress gradient of aluminum thin film were examined to make sure of fabricating the reproduceable aluminium structure. For good shape of micro mirror array and microstructures, the experiment was done varying thickness and deposition rate. As the aluminium film thickness increased from 0.8${\mu}m$ to 1.6${\mu}m$, the stress gradient decreased from 11.62MPa/${\mu}m$ to 2.62MPa/${\mu}m$. The residual stress values are from 42.4MPa to 62.24MPa of tensile stresses.

• Transactions of the Korean Society of Automotive Engineers
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• v.12 no.1
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• pp.196-202
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• 2004

The development of new materials with light weight and high strength has become vital to the machinery, aircraft and auto industries. However, there are a lot of problems with developing such materials that require expensive tools, and a great deal of time and effort. Therefore, the improvement of fatigue strength and fatigue life are mainly focused on adopting residual stress(in this thesis). The compressive residual stress was imposed on the surface according to each shot velocity(57, 70, 83, 96 m/sec) based on Shot-peening, which is the method of improving fatigue life and strength. By using the methods mentioned above, the following conclusions have been drawn. 1. The fatigue crack growth rate(da/dN) of the Shot-peened material was lower than that of the Un-peened material. And in stage I, ΔKth, the threshold stress intensity factor, of the shot-peen processed material is high in critical parts unlike the Un-peened material. Also m, fatigue crack growth exponent and number of cycle of the Shot-peened material was higher than that of the Un-peened material. That is concluded from effect of da/dN. 2. Fatigue life shows more improvement in the Shot-peened material than in the Un-peened material. And compressive residual stress of surface on the Shot-peen processed operate resistance force of fatigue crack propagation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.10 s.181
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• pp.2513-2519
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• 2000

Free vibration characteristics of an initially stressed CD/DVD disk, which is designed for increasing critical speeds of current optical disks, are analyzed using the Rayleigh-Ritz technique based on variational formulations. Natural frequencies of the new disk depend on membrane stresses caused by disk rotation as well as residual stresses imposed during the cooling process of the injection molding. Critical speeds are calculated for the various initial patterns of radial and circumferential stresses. Initially imposed tensile stresses increase the natural frequencies of all the vibration modes except zero nodal diameter mode, whose natural frequency is independent of circumferential stress. A new disk with initial tensile stress of 0.5MPa is shown to have its critical speed about 30 % higher than the current optical disk.

• Journal of Welding and Joining
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• v.5 no.3
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• pp.53-61
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• 1987

Post weld heat treatment(PWHT) is usually carried out to remove the residual stress and to improve the microstructure and mechanical properties of welded joints. By the way, welding structure transformed owing to PWHT and reheating for repair loads the random cycles fatigue as offshore welding structure of constant low cycle fatigue as pressure vessel, and then, pre-existing flaws or cracks exist in a structural component and those cracks grow under cyclic loading. Therefore, the effects of PWHT and stress ratio on fatigue crack growth behaviors were studied on the three regions such as HAZ, sub-critical HAZ and deposit metal of welded joints in SM53 steel. Fatigue crack growth behavior of as-weld depended on microstructure and fatigue crack growth rate of HAZ was the lowest at eac region, but after PWHT it was somewhat higher than that of as-wel. In case of applying the stress($10kg/mm^2$) during PWHT, fatigue crack growth resistance tended to increase in the overall range of .DELTA.K.

• Tunnel and Underground Space
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• v.5 no.4
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• pp.363-375
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• 1995

Critical literature review in this study revealed that there can be a significant influence of the residual stress on the engineering properties of rock. The review also showed that few number of research works on the quantification of the influence was attributed to the limitation of the two classical measurement techniques, viz, X-ray diffraction and mechanical relaxation method. In this study, a new way of approach was sought based on the assumption that residual stress up to the failure. A series of hoop tests conducted onthe samples from the limb of Carboniferous Limestone in Clevedon, England, revealed that (i) there is no preferential orientations of microcracks and minerals which have been widely believed as the main source of the strength anisotropy of rock; (ii) the anisotropy of the tensile strength of the limestone results from the influence of the residual stress; (iii) since jointing commenced within the fold, residual stored strain energy has been released preferentially in the direction perpendicular to the major joints(o$^{\circ}$ and 90$^{\circ}$); (ⅳ) during the hoop test making it much easier to create tensile fracture in these directons, viz 45$^{\circ}$ and 135$^{\circ}$)was released during the hoop test making it much easier to create tensile fracture in these directions, viz 45$^{\circ}$and 135$^{\circ}$;(v) the direction in which the stored strain energy may be presumed to be the least, required the greatest work to cause failure.