• 한국기계가공학회지
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• 제9권2호
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• pp.47-52
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• 2010

Miniaturization and lightweight are increasingly the recent trend in the manufacture of electric appliances and machine parts. So technology of micro joining for joining materials is indispensable. This paper gives a description of an experimental study of the ultrasonic welding of metals. In ultrasonic metal welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely, without producing significant amount of heat. Ultrasonic metal welder consists of Transducer, Booster, and Horn that are designed very accurately to get the natural frequencies and vibration mode. In this study, The horn was designed and analyzed the natural frequency by the modal analysis and harmonic analysis. And using a fiber optic sensor, we measured the amplitude and analyzed the Fast Fourier Transformed result. Using the horn, Ultrasonic metal welding between Ni sheet and Ni sheet of 0.1mm thickness was accomplished under the optimal conditions of static pressure 0.15MPa, vibration amplitude 45% and welding time of 0.28s. This result can be used for ultrasonic metal welding in manufacturing industry.

• 한국생산제조학회지
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• 제26권4호
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• pp.425-429
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• 2017

During ultrasonic welding, plastic deformation, elastic hysteresis, and friction generate heat at the contact portions of the two materials to be welded, theoretically analyzing and experimentally measuring the temperature at the welded part are very important for identifying the heat affected zone. However, the welding temperature during ultrasonic welding wherein welding is performed in less than a second is a challenge. We investigated the effects of welding conditions such as welding time, welding pressure, and the ultrasonic vibration amplitude of horns on the temperature of welded surface of a Ni sheet of thickness 0.1 mm. We used a horn with a resonance frequency of 40 kHz and an ultrasonic welder. The temperature was measured using a intrared sensor, and its characteristics were investigated. Experimental results showed that increase in welding time and pressure and ultrasonic vibration amplitude of horns generally caused the increase in surface temperature of the weld.

• Journal of Welding and Joining
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• 제13권4호
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• pp.85-102
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• 1995

Weld quality of GMA welding processes is closely related to arc stability. Although many researches on arc stability have been performed, real-time estimation of arc stability has not been attempted. For instance, Mita proposed a off-line statistical method in which short circuiting and arcing time, and voltage and current wave forms were sampled to assess arc stability. But this method is not suitable to assess arc stability for GMA welder which employ inverter power source due to its controlled current and voltage wave forms. In this paper, the relationship between are stability and wire feed rate fluctuation is analyzed to propose new criterion for inverter power source. When arc voltage and arc current and arcing time are analyzed, we can assess arc stability only for short circuit transfer mode. When wire feed rate is analyzed, we can estimate arc stability udner the condition of spray transfer mode as well. Hence, the wire feed rate is chosen for monitoring process variable to cover possible metal transfer modes in GMAW. Through this research, it has been identified that arc stability in GMA welding processes is closely related to wire fed rate. When inverter power source is used, conventional statistical method of estimating arc stability, such as Mita index, is no longer valid due to its controlled voltage and current wave forms. Arc stability has been also examined in phase plane diagram.

• 대한전기학회:학술대회논문집
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• 대한전기학회 1999년도 하계학술대회 논문집 F
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• pp.2578-2580
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• 1999

In this paper, an embedded micro processor based resistance spot welding controller is introduced which has been recently developed by Hyosung Co. Ltd. The performance of rapid and constant high current control is tested experimentally. This paper shows configurations of measuring system for high current and realtime RMS conversion techniques of sampled discrete data. A digital proportional control is adopted for this system and the result shows that this new product is working well at wide range of welding current and the performance is improved compared with some other commercially available controllers that are widely used in our industries. User friendly MMI system and a computer network system to monitor each welding processes are also presented.

• 한국지능시스템학회논문지
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• 제9권4호
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• pp.426-435
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• 1999

A high impedance fault(HIF) is one of the serious problems facing the electric utility industry today. Because of the high impedance of a downed conductor under some conditions these faults are not easily detected by over-current based protection devices and can cause fires and personal hazard. In this paper a new method for detection of HIF which uses adaptive neuro-fuzzy inference system (ANFIS) is proposed. Since arcing fault current shows different changes during high and low voltage portion of conductor voltage waveform we firstly divided one cycle of fault current into equal spanned four data windows according to the mangnitude of conductor voltage. Fast fourier transform(FFT) is applied to each data window and the frequency spectrum of current waveform are chosen asinputs of ANFIS after input selection method is preprocessed. Using staged fault and normal data ANFIS is trained to discriminate between normal and HIF status by hybrid learning algorithm. This algorithm adapted gradient descent and least square method and shows rapid convergence speed and improved convergence error. The proposed method represent good performance when applied to staged fault data and HIFLL(high impedance like load)such as arc-welder.

• 한국기계가공학회지
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• 제11권1호
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• pp.76-81
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• 2012

Ultrasonic metal welding is one of the welding methods which welds metal by applying high frequency vibrational energy into specific area at constant pressure, avaliable in room temperature and low temperature. Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each parts' shape, length and mass can affect driving frequency and vibration mode. This paper focused to horn design, its length L was set to 62mm by calculating vibration equation. By performing modal analysis with various shape variable b times integer, when length of b is 30mm the output was 39,599Hz at 10th mode. Also by performing harmonic response analysis, the frequency response result was 39,533Hz, which was similar to modal analysis result. In order to observe the designed horn's performance, about 4,000 voltage data was obtained from a light sensor and was analyzed by FFT analysis using Origin Tool. The result RMS amplitude was approximately 8.5${\mu}m$ at 40,000Hz, and maximum amplitude was 12.3${\mu}m$. Therefore, it was verified that the ultrasonic metal welding horn was optimally designed.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 제5회 압연심포지엄 신 시장 개척을 위한 압연기술
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• pp.109-118
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• 2004

No.2 PCM (Pickling and tandem cold rolling mill) at Pohang works was revamped in 2003. The purpose of this project is to produce carbon and stainless steel using conventional carbon production process, rolling and annealing. This paper introduces the applied facilities and technologies of PCM which are used in production of carbon and stainless steel. To realize the main purpose of this project, POSCO have developed laser weld technology in normal carbon and special steel (stainless, high carbon and high silicon). And this report describes the method which is developed to get down the surface defect of stainless 400 series. After revamping, No.2 PCM can have competitive power in this field and can supply the special steel using carbon rolling process.

• 한국생산제조학회지
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• 제21권6호
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• pp.910-914
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• 2012

In constructing all kinds of equipment and steel structures, discontinuous areas such as weld defects formed in a welded structure tend to generate cracks that will result in damage. In this study, ATOS high-strength steel welding becomes important in butt welding where the tensile strength of the steel is over 80kg/$mm^2$. Structural discontinuities such as joints are more susceptible cracks in part due to their repeated loading and fatigue crack growth. The quality of parts produced depend or the shielded amounts of steel and on the skill of the welders in making strong welds. It is true that there are many factors that can be used to generate a lot of research in this area. However geometry and load conditions due to the combined effects with many issues could be solved through this study. Butt welding material at a plate thickness of 12t in ATOS 80 high-strength steel with a 4 pass, 20l/min, 24V/200A welder is good at making specimens with the quality shown in radiographic testing.

• 한국기계가공학회지
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• 제12권2호
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• pp.55-61
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• 2013

The horn is a key part of the ultrasonic welder. As the shape, mass and material of a horn have effects on the resonant frequency and the vibration mode in ultrasonic welding, a horn has to be designed and manufactured accurately. In this study, 40kHz band horn was designed and manufactured through the vibration mode and finite element analysis. A result of modal analysis showed that the natural frequency of the horn was 39,794Hz, and the frequency response by a harmonic response analysis was 39,800Hz - close to the intended frequency, 40kHz. In addition, weldability of the developed horn was estimated by welding of two Ni sheets and tensile-shear test of welded samples. It was shown the developed horn could be used in metal sheet welding.

• 한국전산구조공학회논문집
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• 제14권3호
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• pp.277-286
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• 2001

자동차 경량화를 지향하는 초경량차체 기술 중에서 합체박판기술을 이용한 수 있는 일련의 최적설계 기법을 제안하고 기존의 자동차 도어 내판에 적용하여 경량화를 수행하였다. 먼저, 내판에 부착되는 보강재를 제거한 후 취약해진 강성을 보강하기 위한 파트 선정을 위해 위상 최적설계를 수행하여 대략적인 파트 분포를 결정하였다. 그 다음 상세설계 단계로서 각 파트의 두께는 치수 최적설계를 이용하여 정하고, 형상 최적설계로 최종 용접선을 결정하였다. 이러한 일련의 최적화를 위해 상용 소프트웨어인 GENESIS가 사용되었다.