• Transactions of Materials Processing
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• v.25 no.6
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• pp.379-389
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• 2016

As a stator for steam turbine diaphragm, hollow-type nozzle stator to substitute for conventional solid one is introduced in this study. This hollowed stator can be separated into two parts such as upper and lower plates with large and curved surface area. This study focuses on thick plate forming process for the upper plate of the hollow-partitioned nozzle stator. First, to reduce forming defects such as under-cut and localized thinning of the deformed plate, and to avoid tool interruption between forming punch and lower die, tool design including the position determination of forming surfaces is performed. Uni-axial tensile tests are carried out using SUS409L steel plate with initial thickness of 5.00mm, and plastic strain ratio (r-value) is also obtained. Due to the asymmetric curved configuration of the upper plate, it is hard to adopt a series of blank holder or draw-bead, so the initial plate during this thick plate forming experiences unstable and non-uniform contact. To easy this forming difficulty and find suitable tool geometry without sliding behavior of the workpiece in the die cavity, two geometric parameters with respect to each shoulder angle of the lower die and the upper punch are adopted. FE models with consideration of 21 combinations for the geometric parameters are built-up, and numerical simulations are performed. From the simulated and predicted results, it is shown that the geometric parameter combinations with ($30^{\circ}$, $90^{\circ}$) and ($45^{\circ}$, $90^{\circ}$) for the shoulder angle of the lower die and the upper punch are suitably applied to this upper plate forming of the hollow-partitioned nozzle stator used for the turbine diaphragm.

• Journal of the Korea Society of Computer and Information
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• v.26 no.10
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• pp.45-51
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• 2021

In this paper, we propose a 3D design method of the vacuum forming method of the front part to improve the lightness and production efficiency of agricultural electric vehicles. For agricultural electric vehicles, lightness and production efficiency are more important than the strength of materials for collision protection. In this paper, we propose a vacuum forming design method that can replace complex machining processes such as laser machining, bending, and painting. The main purpose of this research is to improve product stability, productivity and convenience through 3D design of the front part and development of vacuum forming mold technology. Research procedure follows the 3D modeling of the front part using CATIA, finite element analysis for the structural stability using ABAQUS, manufacturing prototype for the investigation of the dimensions using 3D scanner and actual driving test under agricultural electric vehicle usage environment. The results verifies the proposed 3D design method of the vacuum forming method and are expected to be widely used by agricultural workers through the simplification of the production process of agricultural electric vehicles.

• Transactions of Materials Processing
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• v.27 no.6
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• pp.370-378
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• 2018

Cold forging, carried out at room temperature, leads to high dimensional accuracy and excellent surface integrity as compared to other forging methods such as warm and hot forgings. In the cold forging process, WC-Co (Tungsten Carbide-Cobalt) alloy is the mainly used material as a core dies because of its superior hardness and strength as compared to other structural materials. For cold forging, die life is the most significant factor because it is directly related to the manufacturing cost due to periodic die replacement in mass production. To investigate die life of WC-Co alloy for cold forging, mechanical properties such as strength and fatigue are essentially necessary. Generally, uniaxial tensile test and fatigue test are the most efficient and simplest testing method. However, uniaxial tension is not efficiently application to WC-Co alloy because of its sensitivity to alignment of the specimen due to its brittleness and difficulty in thread machining. In this study, shape of specimen, tools, and testing methods, which are appropriate for uniaxial tensile test for WC-Co alloy, are proposed. The test results such as Young's modulus, tensile strength and stress-strain curves are compared to those in previous literature to validate the proposed testing methods. Based on the validation of test results it was concluded that the newly developed testing method is applicable to other cemented carbides like Titanium carbides with high strength and brittleness, and also can be utilized to carry out fatigue tests for further investigation on die life of cold forging.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.3
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• pp.82-87
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• 2019

Recently, plastic materials have become more diversified, and the development of materials with excellent mechanical properties and plasticity has enabled wider application, miniaturization, and refinement of injection molded products. As a result, the utilization of these products in household goods, electronics, automotive parts, and aircraft parts is increasing in almost all industries. Injection molded parts are often used externally on finished commercial products. This means that the injection mold industry is very important to the value of these products. For this reason, the industry is performing research on the precision and efficiency of the injection molding process. In this study, we investigated the applicability of the core in core cooling method to the problem of product deformation due to temperature variation in existing injection mold designs. We also characterized the cooling performance of an injection mold when using this cooling method.

• Transactions of Materials Processing
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• v.30 no.3
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• pp.142-148
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• 2021

In hot forging analysis, the interfacial heat transfer coefficient (IHTC) is a very important factor defining the heat flow between the die and the material. In particular, in the hot forging analysis of aluminum 6xxx series alloy, which are used in automobile parts, differences in load and microstructure occur due to changes in surface temperature according to the IHTC. This IHTC is not a constant value but changes depends on pressure. This study derived the IHTC under low load using aluminum 6082 alloy. An experiment was performed by fabricating a compression die, and a heat transfer analysis was performed based on the experimental data. The heat transfer analysis used DEFORM-2D, a commercial finite element analysis program. To derive the IHTC, heat transfer analysis was performed for the IHTC in the range of 10 to 50 kW/m²℃ at intervals of 10kW/m²℃. The heat transfer analysis results according to the IHTC and the actual experimental values were compared to derive the IHTC of the aluminum 6082 alloy under low load.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.3
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• pp.12-21
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• 2022

Directed energy deposition (DED) was adopted as a metal additive manufacturing method to develop a mold for the hot stamping process. The test piece was machined from Heatvar laminate material, and results were obtained through microstructure and defect observations, as well as hardness, tensile strength, and joint strength tests. 1) Spherical pores and irregular-shaped cavities were observed as lamination defects, and columnar dendrites formed in the structure, which tended to become coarse upon heat treatment. 2) The hardness of the heat-treated material (480HV) was slightly lower than that of the non-heat-treated material (500HV). 3) In the tensile test, the maximum tensile stress and strain of the heat-treated material were 1392 MPa and 15%, respectively, which were slightly higher than the values of 1381 MPa and 13%, respectively, for the non-heat-treated material. 4) In the case of the early final fracture in the tensile test, in most cases, pores or irregularly shaped cavities were observed at the fracture surface or near the surface. 5) In the joint strength test, most of the specimens finally fractured in the laminated metal area, and the fracture surface was intragranular. In addition, dimples formed over the entire area on the fracture surface of the fractured specimen after sufficient elongation.

• Transactions of Materials Processing
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• v.31 no.2
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• pp.51-56
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• 2022

In this study, finite element analyses were performed by applying a stress ring and split die design to relieve the tensile stress acting on the die due to high surface pressure during warm-closed forging. The applied material was a yield-ratio-control-steel (YRCS). It was used without quenching or tempering after forging. In the case of stress rings design, the number of stress rings and the tolerance for shrink fit were different. Vertical and horizontal splits were applied for insert die split design. Case 5 die with three stress rings, 0.2 % shrink fit tolerance, and vertical split was selected as an effective die design for tensile stress reduction. Based on die stress reduction analyses, Case 5 die for warm-closed forging was produced and smooth forgeability was secured, making it possible to manufacture forging product of yoke with the required geometry. In addition, controlled cooling using warm forging heat was applied to secure mechanical properties of yokes. When oil cooling was used for direct controlled cooling after warm-closed forging, a relatively uniform Rockwell hardness distribution and high mechanical properties could be obtained.

• Transactions of Materials Processing
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• v.31 no.3
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• pp.129-135
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• 2022

The purpose of this study was to quantitatively evaluate the influence of hardness of tool materials on wear resistance in the sheet metal forming process. Punches used in the wear test were made of STD-11 and K340 tool material, and the tempering temperature was set to 530℃ and 500℃, respectively, to control the hardness of the tool materials. The punches mimic the shape of stamping tool of automotive body component to reflect its plastic deformation, and are designed to concentrate wear on the curvature region of punches. Progressive die and coil sheet were used to save time, cost, and raw sheet materials. By quantitatively measuring the wear depth of the punches, the wear behavior and mechanism of the punches were investigated, and characteristics of hardness and wear resistance according to tool materials and tempering temperatures were evaluated. Testing results indicate that the punch made of K340 tool steel with higher hardness had better wear resistance than that of STD-11 tool steel, and the hardness and wear resistance of tool steel were significantly impacted by the tempering temperature.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1991.04a
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• pp.356-362
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• 1991

자동차, 항공기, 선박등과 같은 산업제품과 전화기, TV브라운관과 같은 가전제품, 심미적 기능을 갖는 제품등과 같은 일상용품등은 많은 부분이 자유곡면(sculptured surface)으로 이루어져 있다. 이러한 해석적으로 정의 하기 어려운 제품 또는 그것을 생산하는데필요한 금형을 가공하는데 있어서 기존에는 석고 모형이나 목형을 이용한 모방 절삭을 하였다. 그러나 근래에는 자유곡면으로이루어진 제품을 설계하고 가공하는데 있어서 CAD/CAM system을 이용하고 있다. 제품의 곡면을 표현하거나 이들을 NC가공하기 위해서는 곡면을 나타내는 형상 정보가 필요 하고 이들 형상정보로 곡면모델링을 하여공구 경로를 구한다. 그러므로 이들 형상정보를 허용한도내에서 적절히 정하여 실제형상에 가까운 곡면을 형성하여야 한다. CAD/CAM 기술의 발달에 따라 다양한 형태의 곡면을 형성하는 기능을 가진 system이 많이 출현되었고 점토, 석고 또는 나무등으로 만든 physical model로 부터 얻어진 형상정보에 의해 surface fitting을 함으로서 자유곡면을 표현하는 방법이 많이 사용되고 있다. 어떠한 곡면을 표현할때는 곡면의 특성을 잘 표현하면서 전체적으로 smooth 한 것이 바람직하다. 그러므로 곡면의 형태를 설계자가 쉽게 이해할 수 있고 적은 수의 patch로도 복잡한 형상을 나타내야 하며 또한 국부적으로 수정이 용이하여야한다. 본 논문에서는 자유곡면을 나타낼 수 있는 수학적 표현 방법에 관하여 논하고, 해석적 곡면으로 부터 형상정보를 얻어 곡면 모델링을 한 후의 Ferguson곡면, UBS와 NUBS의 차이점을 분석하고, 이들 곡면과 해석적 곡면으로부터 얻은 실제곡면과의 오차를 측정하여 실제형상에 가까운 모델링 곡면을 찾고자 하였다.. 라. MCl(M:K$^{+}$, $Na^{+}$, NH$_{4}$$^{+}$ 및 H$^{+}$) 수용액 메디움에서의 Cd(II), Mg(II) 및 Zn(II)의 Dowex 1-X8, Cl$^{-}$ 수지에 대한 흡착은 역시 어떤 메디움에서도 Cd(II) 흡착이 제일 크며, 다음이 Zn(II) 이고 착이온을 형성않는 Mg(II)이 제일 작았다. 한편 메디움 종류별 D값의 크기순위는 H$^{+}$>K$^{+}$> $Na^{+}$>NH$_{4}$$^{+}$이였다. 메디움의 종류에 따라 D값의 차이가 나는 것은 금속이온의 착이온 형성과 금속이온의 용액내에서의 이온종의 상태와 관련이 있다고 생각된다. 마. MCl(M:K$^{+}$, $Na^{+}$, NH$_{4}$$^{+}$ 및 H$^{+}$)과 MNO$_{3}$ 용리액에 의한 Cd(II), Mg(II) 및 Zn(II)의 용리는 예상한 바와 같이 MCl에서 작은 Dv 값을 갖는데, 이것은 CdCl$_{4}$$^{2-}$ 착이온을 형성하거나 ZnCl$_{4}$$^{2-}$ , ZnCl$_{3}$$^{-}$같은 이온과 MgCl$^{+}$, MgCl$_{2}$같은 이온종을 형성하기 때문인것 같다. 한편 어떠한 용리액에서던지 N

• Proceedings of the Korean Vacuum Society Conference
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• 2016.02a
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• pp.141.2-141.2
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• 2016

디스플레이, 센서 등 전자소자는 소형화 단계를 지나 인체 부착형 소자로의 발전을 요구하고 있다. 인체 부착을 위해서는 민감한 피부에 장시간 부착시 무해성과 탈부착의 자유로움이 요구되기에 기존의 화학물질을 활용한 접착 방식에서 개코도마뱀 또는 딱정벌레 발바닥에서 영감을 얻은 자연모사형 건식 접착 방식에 대한 연구가 활발하게 진행되고 있다. 폴리머를 이용하여 자연모사형 마이크로/나노구조 형성은 기계적으로 가공된 금형 몰딩과 후처리를 통한 매우 복잡한 공정이 요구된다. 본 연구에서는 이러한 복잡한 공정을 단순화하기 위해서 폴리머 소재에 플라즈마를 활용한 나노구조를 형성하는 방법을 소개하고자 하며, 건식 접착용 폴리머 소재(PMMA, PDMS)에 따른 표면구조 변화와 표면에너지 변화에 대한 연구를 수행하였다. 플라즈마 표면처리를 위해서 본 연구실에서 자체 개발한 선형이온소스를 활용하였으며 입사에너지, 노출시간, 사용가스에 따른 표면형상 변화를 주사전자현미경을 활용하여 관찰하였다. 또한 처리조건에 따른 표면에너지 변화를 확인하기 위해 물접촉각 변화를 측정하였다. PMMA는 입사에너지, 노출시간이 증가함에 따라 쉽게 나노기둥구조가 형성되었으나, 과도한 입사에너지 또는 노출시간에서는 표면구조가 에칭되면서 무너지는 것이 관찰되었다. 또한 PDMS는 동일한 조건에서 주름구조 형태를 보였으며 노출시간이 증가할수록 주름구조의 간격이 늘어남을 확인하였다. 본 연구 결과를 통해 나노 구조를 쉽게 제어할 수 있는 PMMA가 피부 부착형 접착 패치에 응용이 가능할 것으로 기대된다.