• 비파괴검사학회지
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• 제15권4호
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• pp.531-539
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• 1996

본 연구에서는 초음파 신호형상인식법을 이용하여 용접부의 인공 결함을 분류하기 위한 연구를 실시하였다. 이를 위해 신호처리 및 특징 변수를 추출할 때에 많은 사용자 정의 변수를 가지는 신호 형상 인식 패키지를 개발하였으며 디지탈 신호처리, 특징 변수 추출, 특징 변수의 선택, 분류기 선정 등의 과정을 일괄적으로 처리하였다. 특히, 선형 분류기, 경험적 Bayesian 분류기 등의 통계적 분류기와 신경회로망 분류기를 함께 사용하여 비교, 검토하였다. 이에 관한 적용 연구로 노치와 구멍으로 이루어진 인공 결함을 분류하였다. 그 결과 인공결함 분류에서 높은 인식률을 얻었으며, 특히 적절히 학습 시켰을 경우 신경회로망 분류기가 통계적 분류기에 비하여 인식률 면에서 유리하였다.

• Design & Manufacturing
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• 제14권2호
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• pp.34-41
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• 2020

Typical characteristics of medical device parts are that they can not be reused and there are many disposable products. Therefore, there is a need for an injection molding machine having excellent repeatability of molding conditions and a precision injection mold for mass production. Recently, the performance of an injection machine has made a remarkable evolution compared to the past. However, defects such as short-shot, flash, weld line, gas burning, warpage, and deformation, which are typical defects, still do not disappear at all. This is due to the lack of gas ventilation from the product cavities, even if the gas is smoothly vented from the sprue and runner of the mold. For this reason, the internal pressure of the cavity rises and is directly connected to the quality defects. In this study, an active gas vent system was designed to prevent defects due to trapped gas in the cavity. Since it can be easily adjustable in response to the molding conditions and the mold temperature changes, it is expected to improve productivity due to the reduction of the defective ratio.

• Journal of Welding and Joining
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• 제32권5호
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• pp.50-57
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• 2014

Friction Stir Welding (FSW) is a complex process with several mutually interdependent parameters. A slight difference from known settings may lead to imperfections in the stirred zone. These inhomogeneities affect on the mechanical properties of the FSWed joints. In order to prevent the failure of the welded joint it is necessary to detect the most critical defects non-destructive. Especially critical defects are wormhole and lack of penetration (LOP), because of the difficulty of detection. Online thermography is used process-accompanying for defect detecting. A thermographic camera with a fixed position relating to the welding tool measures the heating-up and the cool down of the welding process. Lap joints with sound weld seam surfaces are manufactured and monitored. Different methods of evaluation of heat distribution and intensity profiles are introduced. It can be demonstrated, that it is possible to detect wormhole and lack of penetration as well as surface defects by analyzing the welding and the cooling process of friction stir welding by passive online thermography measurement. Effects of these defects on mechanical properties are shown by tensile testing.

• 대한기계학회논문집A
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• 제22권3호
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• pp.644-653
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• 1998

In resistance spot weld, the assurance of weld quality has been a long-standing problem. Since the weld nuggets if resustance spot welding form between the workpieces, visual detection of defects in usually impossible. Welding quality of resistance spot welding can be verified by non destructive and destructive inspections such as X-Ray inspection and testing of weld strength. But these tests, in addition to being time-consuming and costly, can entail risks due to sampling basis. The purpose of this study is the development of the monitoring system based on fuzzy inference, aimed at diagonosis of quality in resistance spot welding. The fuzzy inference system consists of fuzzy input variables, fuzzy membership functions and fuzzy rules. For inferring the welding quality(strength), the experimental data of the spot welding were acquired in various welding conditions with the monitoring system designed. Some fuzzy input variables-maximum, slop and difference values of electrode movement signals-were extracted from the experimental data. It was confirmed that the fuzzy inference values of strength have a .${\pm}$5% error in comparison with actual values for the selected welding conditions(9-10.5KA, 10-14 cycle, 250-300 $kg_f$). This monitoring system can be useful in improving the quality assurance and reliability of the resistance spot welding process.

• 한국강구조학회 논문집
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• 제18권3호
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• pp.331-337
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• 2006

최근 고성능 대형 강구조물에 많이 적용되고 있는 TMC 강재에 대해 두께 20m, 60m, 82m의 후판을 6m~16mm의여러 용접치수로 필릿용접하여 겹이음부가 있는 시험체를 제작하고, 인장시험을 통하여 필릿용접부의 강도를 측정하였다. 측정된 필릿용접부의 강도는 모재의 두께, 용접 치수, 용접축에 대한 힘의 작용방향 등을 달리한 모든 경우에 설계기준에서 적용하고 있는 강도 계산식에 의한 공칭강도의 값보다 더 큰 것으로 나타났다. 특히 60mm와 82mm 두께의 모재에 대해 국내도 로교설계기준에서 요구하고 있는 최소 용접치수보다 더 작은 용접치수를 적용한 경우에도 시험체 제작과정에 용접의 어려움이나 용접부의 결함, 균열 등이 발견되지 않았으며, 용접부의 강도도 다른 경우와 거의 동일한 수준인 것으로 나타났다.

• Journal of Welding and Joining
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• 제23권3호
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• pp.76-82
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• 2005

Recently the application of laser welding technology has been considered to shipbuilding structure. However, when this technology is applied to primer coated steel, good quality weld beads are not easily obtained. Because the primer-coated layer caused the spatter, humping bead and porosity which are main part of the welding defect attributed to the powerful vaporizing pressure of zinc. So we performed experiment with objectives of understanding spatter and porosity formation mechanism and producing sound weld beads in 6mmt primer coated steels by a $CO_2$ CW laser. The effects of welding parameters; defocused distance, welding speed, coated thickness and coated position; were investigated in the bead shape and penetration depth on bead and lap welding. Alternative idea was suggested to suspend the welding defect by giving a reasonable gap clearance for primer coated thickness. The zinc of primer has a boiling point that is lower than melting point of steel. Zinc vapor builds up at the interface between the two sheets and this tends to deteriorate the quality of the weld by ejecting weld material from lap position or leaving porosity. Significant effects of primer coated position was lap side rather than surface. Therefore introducing a small gap clearance in the lap position, the zinc vapor could escape through it and sound weld beads can be acquired. In conclusion, formation and suspension mechanism of the welding defects was suggested by controling the factors.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.1312-1316
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• 2007

Strip casted and rolled magnesium sheet is become exiting material for car manufacturer, due to its better formability and specific strength compare with conventional extruded sheet. TWB technology was attractive for car body designer, because it saves the weight of the car without strength loss. In this study, the laser welding performance of magnesium sheet was investigated for Mg TWB panel manufacturing. The material was strip casted and rolled magnesium alloy sheet contains 3 wt% Al and 1 wt% Zn (AZ31). Lamp pumped Nd:YAG laser of 2kW was used and its laser light was delivered by optical fiber of 0.6mm core diameter to material surface with focusing optics of 200mm focal length for TWB welding. The microstructure of weld bead was investigated to check internal defects such as inclusion, porosity and cracks. Also mechanical properties and formability were evaluated for press forming of car body. For the results, there was no crack but inclusion or porosity on weld at some conditions.The tensile strength of weld was over 95% of base metal. Inner and outer panel of engine hood were press formed and assembled at elevated temperature.

• 소성∙가공
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• 제27권2호
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• pp.81-86
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• 2018

In the cold forming process, it is not easy to fabricate a asymmetric type nut, due to the difficulty in the exact prediction of metal-flow. As we have identified, in that case, it often results in the various forging defects such as burrs, and an incomplete shape, as well as other problems because of this issue. In the current study, we introduce the development of an unparalleled shape Weld Nut by using a forging analysis tool (AFDEX). For the multi-forming machine, the optimized shapes of each intermediate product (step product) could be found by the use of a model for the prediction and analysis of various types, sizes and heights. Chiefly, forging tools were prepared based on the simulation results and an unparalleled shape could be prepared at one time without any burrs, incomplete shape and size.

• 한국해양공학회지
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• 제26권1호
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• pp.64-69
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• 2012

Dissimilar friction welds were produced using 15-mm diameter solid bars of chrome molybdenum steel (KS SCM440) and carbon steel (KS SM20C) to investigate their mechanical properties. The main friction welding parameters were selected to ensure good quality welds on the basis of visual examination, tensile tests, Vickers hardness surveys of the bond area and HAZ, and macro-structure investigations. The specimens were tested as-welded and post-weld heat treated (PWHT). The tensile strength of the friction welded steel bars was increased to 100% of the SM20C base metal under the condition of a heating time of more than four seconds. Optimal welding conditions were n = 2,000 (rpm), HP = 60 (MPa), UP = 100 (MPa), HT = 5 (s),and UT = 5 (s), when the total upset length was 7.8 (mm). The hardness distribution peak of the friction welded joints could be eliminated using PWHT. The two different kinds of materials were strongly mixed to show a well-combined structure of macro-particles, with no molten material, particle growth, or defects.

• Journal of Advanced Marine Engineering and Technology
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• 제30권5호
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• pp.623-628
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• 2006

Laser material processing is a very fast advancing technology for various industrial applications. because of many advantages. Its major advantage of less and controlled heat input has been exploited successfully for the very critical application of aluminium alloy welding. This study suggested the occurrence source of weld-defects and its solution methods in a welding of lithium ion battery by pulsed Nd:YAG laser. In experiment. battery case has changed over joint geometry from welding of side position to flat one. In the case of a electrolyte injection hole in order to seal it. welding is carried out after pressing Al ball. At this time. an eccentric degree. contact length and gap are worked as a major parameters. As improving the method of Al ball pressing. it was able to reduce an eccentricity. increase the contact length and decrease gap. As a results of a experiment. a sound weld bead shape and crack-free weld bead can be obtained.