• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.505-506
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• 2006

This study is focused on the manufacturing technique of powder injection molding of watch case made from zirconia powder. A series of computer simulation processes were applied to the prediction of the flow pattern in the inside of the mould and defects as weld-line. The material properties of melted feedstock, including the PVT graph and thermal viscosity flowage properties were measured to obtain the input data to be used in a computer simulation. Also, a molding experiment was conducted and the results of the experiment showed a good agreement with the simulation results for flow pattern and weld line location. On the other hand, gravity and inertia effects have an influence on the velocity of the melt front because of the high density of ceramic powder particles during powder injection molding in comparison with polymer's injection molding process. In the experiment, the position of the melt front was compared with the upper gate and lower gate positions. The gravity and inertia effect could be confirmed in the experimental results.

• Transactions of Materials Processing
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• v.7 no.6
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• pp.519-529
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• 1998

In automotive industries the stamping of laser-welded blank gives many merits which bring about dimensional accuracy, strong body assembly and high productivity. However the welding of blanks with different thickness or/and different strength materials introduces many challenging formability problems for process development and tool design. in this paper the deformation characteristics for deep drawing process of laser-welded blank with different thickness sheets are investigated by experiment as well as by FEM simulation. The blank holding force ratio to avoid the movement of weld line was suggested and compared with the experimental result for cylindrical and rectangular cup drawing process. The optimal location of weld line in laser-welded blank with different thickness sheets is calculated to compensate for the movement of weld line on deep drawing process. In addition the effect of location of weld line on formability is clarified using FEM simulation.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.82-88
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• 2002

Simulation systems allow a close inspection of the relation between welding parameters and the resulting weld seam. These systems are very useful in education of weld staff as well as production and planning. In training the influence of variations of parameters can be investigated without the need for real welding experiments. In the design phase requirements of the welding process can be taken into account without several iteration cycles. By estimating a good parameter set for the given welding task the set up phase for a new production cycle can be reduced

• Journal of computational fluids engineering
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• v.18 no.4
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• pp.61-68
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• 2013

Laser welding is widely used in the industry for the advantage of small heat affected zone and short weld process time. Conduction limit welding can be used to modify the surface characteristic and it is important to identify the heat affecting area correctly for the improvement of manufacturing accuracy. Since time and length scale associated with laser welding process are extremely small, numerical study can be a useful tool. In this study, two-dimensional axi-symmetric version of energy equation with enthalpy method has been used to analyze the effect of laser input conditions on final shape by the laser welding process. The proposed numerical procedure has been benchmarked with several experimental results and compared well. The modified Marangoni and Peclet number have been introduced using controllable input variables. Simple parametric researches have been performed for high Pr number material. The results show that higher Marangoni number increase fluid mixing, thus generating convex type weld pool. On the other hand, the width of the weld pool is proportional to Peclet number.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.1
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• pp.79-87
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• 1996

SMC(Sheet Molding Compound) is made of unsaturated polyester resin and other additives reinforced with randomly distributed chopped fiberglass strands. Because of its higher stiffness per unit mass, SMC was used as a substitute for steel for automotive steel outer panels. Thus, understanding of flow characteristics during fabrication of SMC is of importance since the formation of weld line depends on material flow. In the present study, SMC compression molding simulations in the flat and T-shape molds were accomplished. During simulations, the preferential the preferential flow occurred at the low mold closing speed while plug flow was observed for the higher mold closing speed. When the preferential flow was observed, the weld line was seen at the final stage. For simulations, rigid-viscoplastic finite element method was applied. Self-contact algorithm was also applied in order to predict the formation of the weld line. Simulation results were compared to the experimental results available in the literature.

• Transactions of Materials Processing
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• v.23 no.5
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• pp.282-288
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• 2014

It is difficult to control welding variables during spot welding of non-ferrous metals like aluminum because of the low electrical resistance of the material. It has been suggested that a solid state welding process such as friction stir spot welding or extru-spot welding can be used to spot weld aluminum plates. In the extru-spot welding, there is a need to increase the weld strength by improving the shape of the welding die. The current study shows that the weld strength for an extru-spot welding can be increased by using a pin placed on the inside of the upper electrode in the welding die. In the current study, the deformed shape of the insert rivet and the stress distribution in the welding zone were analyzed by simulation. Extru-rivet spot welding experiments were performed by changing the height of pin on the inside of the upper electrode. From the experimental result, it is shown that the weld strength for an extru-rivet spot welding can be increased by adjusting the height of the pin. The optimal shape of the deformed rivet after the extru-rivet spot welding can be observed from the simulation results. The deformed shape of the insert rivet can also be controlled by the height of pin.

• Journal of Welding and Joining
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• v.9 no.3
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• pp.41-51
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• 1991

The thermomechanical coupling phenomena in the resistance welding process is complicated due to interactions of mechanical, thermal and electrical factors. Although experimental investigations of resistance spot welding have been carried out, but there are a few by computer simulation. so the purpose of this research is to decrease the time and cost much required in experimental investigation by carrying out the analysis of the resistance spot welding process through computer simulation based on the finite element method. The tool used in the computer simulation is the commercial ANSYS program package. A two dimensional axisymetric model is used to simulate the resistance spot welding for two stainless steel sheets of equal thickness and parametric study is carried out for variable welding current, workpieces of unequal thickness and dissimilar materials. The results from the computer simulation are in good agreement with the experimental one. Through these results, such items as stress distribution, temperature profiles, thermal expansion and weld nugget formation are predicted. Reliability and applicability of finite element models have been demonstrated to simulate and to analyze the resistance spot welding process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.6 no.4
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• pp.89-95
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• 1997

Welding technique is widely applied to general industry such as pressure vessel for chemical plant, pipe system, heavy industry, and automobile. There are some points which must be considered when robot system is used in welding automation process for productivity improvement. Welding quality is governed by heat input, and this quantity can be different according to shape, property, and thick of material . For desired heat input , weld input parameters such as welding voltage, current, and welding velocity must be determined with those consideration. Until now these parameters have been determined mainly by experience of operator. In this study, the size of welding zone was predicted by fuzzy rules were constructed from the relation between welding variables and weld pool size. Inverse model method which welding control input for welder is determined with optimum voltage and current by fuzzy controller is validatied by computer simulation.

• Journal of Welding and Joining
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• v.16 no.2
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• pp.40-47
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• 1998

In the present study, depressions of the GMA weld pool due to the impact of droplet are numerically investigated. The numerical simulation is conducted on the basis of the Navier-Stokes equation and the volume of fluid(VOF) functions. The kinetic energy of transferring droplet makes a depression of the weld pool surface. The surface active element affects the depression of the weld pool. The droplets transferred efficiently to the bottom of the weld pool, along with electromagnetic force make the finger shape penetration at the high current GMAW.

• Journal of Welding and Joining
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• v.34 no.5
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• pp.47-53
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• 2016

The aim of this study is to consider effect of weld elastic modulus on simulations of stress concentration and fatigue life for pressure vessel. The investigations include analysis with ADINA and WINLIFE softwares for whole body model about using condition of the boiler vessel. Values of weld elastic modulus were divided by 5 steps in butt weld area of the boiler vessel body. The stress concentration of the butt weld more was increased in case of higher elastic modulus of weld area because of higher difference of material properties between matrix and weld. It was concluded that the fatigue lives were decreased along increasing stress concentration due to high elastic modulus of weld. The matrix microstructure was estimated as pearlitic structure of ${\alpha}$ ferrite and pearlite. And the microstructures of welds along 5 steps of elastic modulus were estimated as bainitic fine pearlite and martensite as increasing elastic modulus.