• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.3
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• pp.164-170
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• 2016

A proposed pneumatic cylinder-driven roll feeder and an air press were designed to be operated automatically by a PLC. The accuracy of the intermittent feed pitch of the roll feeder was evaluated by measuring lengths of cut-offs of a strip stock by a digimatic vernier caliper. At each predetermined feed pitch, the proposed roll feeder was tested 100 times by varying the feed/cut intervals as 2.0/1.5, 3.0/2.0, and 3.5/2.5 s as test sets. The lengths of the cutoffs of the strip stock ranged from 9.89-10.34, 12.1-12.65, and 15.21-15.67 mm at the predetermined 10, 12, and 15 mm feed pitch, respectively, among the total of 300 samples in each feed pitch, regardless of the feed/shear interval. Therefore, the feed/cut interval at each selected feed pitch was found to have no effect on the accuracy of the intermittent advancing of the strip stock.

• Advances in aircraft and spacecraft science
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• v.2 no.4
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• pp.391-401
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• 2015

Crashworthiness design and certification have been and will continue to be the main concern in aviation safety. The effects of roll angles on fuselage section crashworthiness for typical civil transport category aircrafts were investigated. A fuselage section with waved-plates under cargo floor is suggested, and the finite element model of fuselage section is developed to simulate drop test subjected to 7 m/s impact velocity under conditions of 0-deg, 5-deg, 10-deg and 15-deg roll angles, respectively. A comparative analysis of failure modes, acceleration responses, and energy absorption of fuselage section under various conditions are given. The results show that the change of roll angles will significantly affect fuselage deformation, seat peak overloads, and energy absorption. The crashworthiness capability of aircraft can be effectively improved by choosing appropriate landing way.

• Advances in materials Research
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• v.8 no.1
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• pp.1-10
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• 2019

Roll bonding (RB) process of bi-metal laminates as a new noble method of bonding has been widely used in the production of bimetal laminates. In the present study, asymmetric roll bonding process as a new noble method has been presented to produce Al/Cu bimetallic laminates with the thickness reduction ratios 10%, 20% and 30% together with mismatch rolling diameter ($\frac{R_2}{R_1}$) ratio 1:1, 1:1.1 and 1:1.2. ABAQUS as a finite element simulation software was used to model the deformation of samples. The main attention in this study focuses on the bonding properties of Al/Cu samples. The effect of the $\frac{R_2}{R_1}$ ratios was investigated to improve the bond strength. During the simulation, for samples produced with $\frac{R_2}{R_1}=1:1.2$, the vertical plastic strain of samples was reach the maximum value with a high quality bond. Moreover, the peeling surface of samples after the peeling test was investigated by the scanning electron microscopy (SEM).

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.544-548
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• 2007

In general, final width of hot strip should be accomplished in this stage because width reduction of strip hardly appears during typical finishing mill. However, it is difficult to control the width of strip in the roughing mill process as the horizontal rolling of strip is subsequently performed after the vertical rolling. It is therefore important to obtain the deformation rolling direction on strip width to minimize the width spread of strip during horizontal rolling after vertical rolling. Generally there is Sizing press type and Edger-roll type. The width reduction process in sizing press has small amount of width spread compared with the edger. However, productivity by the sizing press process is much lower than those of the edger. In this study, sizing press and Edger-roll process parameters in a sheet rolling mill were set at specified values and the effect of the change in these parameters on product quality and process performance were evaluated.

• Design & Manufacturing
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• v.17 no.3
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• pp.15-20
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• 2023

In the fine blanking process, which is a press operation known for producing parts with narrow clearances and high precision through the application of high pressure, die roll often occurs during the shearing process when the punch penetrates the material. This die roll phenomenon can significantly reduce the functional surface of the parts, leading to decreased product performance, strength, and fatigue life. In this research, we conducted an in-depth analysis of the factors influencing die roll in the curvature area of the fine blanking process and identified its root causes. Subsequently, we designed and experimentally verified a die roll reduction process specifically tailored for the door latch manufacturing process. Our findings indicate that die roll tends to increase as the curvature radius decreases, primarily due to the heightened bending moment resulting from reduced shape width-length. Additionally, die roll is triggered by the absorption of initial punch energy by scrap material during the early shearing phase, resulting in lower speed compared to the product area. To mitigate the occurrence of die roll, we strategically selected the Shaving process and carefully determined the shaving direction and clearance area length. Our experiments demonstrated a promising trend of up to 75% reduction in die roll when applying the Shaving process in the opposite direction of pre-cutting, with the minimum die roll observed at a clearance area length of 0.2 mm. Furthermore, we successfully implemented this approach in the production of door latch products, confirming a significant reduction in die roll. This research contributes valuable insights and practical solutions for addressing die roll issues in fine blanking processes.

• Transactions of Materials Processing
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• v.17 no.5
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• pp.350-355
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• 2008

Currently, in the automotive industry, the efforts to reduce the manufacturing cost by changing the manufacturing process are continually performed. In this paper, we proposed a new manufacturing process, the roll bending process of a ring plate of automotive fuel tank instead of conventional press blanking process to reduce material loss and manufacturing cost. Finite element analysis was used to optimize the roll bending process to assure rectangular cross-section of the ring plate. Also, spring-back analysis after the roll bending process was performed and dimension of the bending die considering spring-back was analyzed. Finally, we verified a possibility for realization of the proposed method with prototypes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.423-427
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• 2005

Sandwich structures, which are composed of a thick core between two thin faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Depending on the application of a particular sandwich structure, various types of cores can be used. The production of sandwich sheets by a rolling process, which is a more efficient and economical approach compared to other types of processes, has become an increasingly important subject of study. In this paper, we have studied the embossing structure of sheet type and developed embossing roll mold with $\Phi3$ pattern and roll forming system.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.319-322
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• 2009

Roll bending process has been used for manufacturing the pipes. However, it is not suitable process for the thick pipes. Knife press forming is acceptable process for the thick pipes. Recently, the knife press forming process using brake bending press have been performed. In this study, the estimation on formability of knife press forming process for the thick pipes is carried out. From the results, it is ensured that the thick pipes could be obtained by the knife press forming process.

• Advances in Automotive Engineering
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• v.1 no.1
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• pp.1-20
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• 2018

The aim of this study is the optimization of the parameters of interconnected Hydro-Pneumatic (HP) suspension system of a three-axle vehicle for ride comfort and handling. For HP suspension systems of equivalent vertical stiffness and damping characteristics, interconnected HP suspension systems increase roll and pitch stiffness and damping characteristics of the vehicle as compared to unconnected HP suspension systems. Thus, they result in improved handling and braking/acceleration performances of the vehicle. However, increased roll and pitch stiffness and damping characteristics also increase roll and pitch accelerations, which in turn result in degraded ride comfort performance. Therefore, in order to improve both ride comfort and vehicle handling performances simultaneously, an optimum parameter set of an interconnected HP suspension system is obtained through an optimization procedure. The objective function is formed as the sum of the weighted vertical accelerations according to ISO 2631. The roll angle, one of the important measures of vehicle handling and driving safety, is imposed as a constraint in the optimization study. Upper and lower parameter bounds are used in the optimization in order to get a physically realizable parameter set. Optimization procedure is implemented for a three-axle vehicle with unconnected and interconnected suspension systems separately. Optimization results show that interconnected HP suspension system results in improvements in both ride comfort and vehicle handling performance, as compared to the unconnected suspension system. As a result, interconnected HP suspension systems present a solution to the conflict between ride comfort and vehicle handling which is present in unconnected suspension systems.

• Transactions of Materials Processing
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• v.25 no.1
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• pp.29-35
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• 2016

In the current study, finite element analysis was conducted for the press hemming of automotive panels in order to predict various hemming defects such as roll-in and turn down. The analysis used the exact punch movement based on the cam location and considered the sealer between the inner and outer panels with an artificial contact thickness. The analysis results quantify the hemming defects especially at the flange edge in the matching region of the head lamp. A design of experiments along with the parameter study was used to obtain the optimum process parameters for minimizing hemming defects. The optimization process selects the intake angle, bending angle of the hemming punch, and the flange height of the outer panel. The optimum design process determines an appropriate tool angle and flange height to reduce the roll-in and turn-down as compared to the initial design.