• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.9
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• pp.1299-1304
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• 2010

We examined the working fracture behavior of a silicon-steel strip caused by deformation deviation by performing a pilot rolling test. The deformation deviation resulted in the edges (or center portion) of the strip being stretched and the other parts being compressed in the rolling direction; this was because of different degrees of deformation in these parts. We designed roll grooves shape to reflect the role of roll bending, which generates waviness in the strip in an actual cold rolling process, into the pilot rolling test. The material used in the rolling test was highsilicon steel (about 3%). The results of the test showed that the type of fracture in the strip specimen varied with the magnitude of the deformation deviation. The tensile stress produced at the strip edges because of the center waviness in the rolling direction was a crucial factor that resulted in edge cracking and a zigzag-shaped fracture at the center.

• Transactions of Materials Processing
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• v.22 no.5
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• pp.243-249
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• 2013

The multi-point forming (MPF) process for three-dimensional curved sheet metal has been developed as an alternative to the conventional die forming process since MPF allows the manufacturing of various shapes using one die set and reduce the cost of production. However, the MPF process cannot provide high quality products yet due to defects occurring in the sheet such as dimples and wrinkles. It can also lead to economic loss because of long tool setup time and additional machining required outside of the sheet formed area. In this study, a new sheet metal forming method, called flexible roll forming (FRF), is proposed to solve the problems of existing processes for three-dimensional curved sheet metal. This progressive process utilizes adjusting rods, as well as upper and lower flexible rollers as forming tools. In contrast with the existing processes, FRF can reduce the additional production costs because of the possible blank size for the part longitudinal direction, which is unrestricted. In this research, methods and procedures of the flexible roll forming technology are described. Numerical forming simulations of representative three-dimensional curved sheet products are also carried out to demonstrate the feasibility of this technology.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.103-109
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• 2014

Flexibly-reconfigurable roll forming (FRRF), which is a sheet forming process for multi-curved sheet metal, may solve both the economic and technical problems incurred in using a conventional die forming process. In the FRRF process, the multi-curved sheet metal is formed by different strain distributions on the sheet metal, and the reconfigurable rollers are used as tools during the forming. Therefore, a thorough investigation focused on the reconfigurable rollers is required for the realization of the FRRF process prior to the fabrication of FRRF machine. In the current study, a series of finite element simulations were conducted to study the load distributions experienced by the reconfigurable roller. In order to verify the shape design variables, the effect of the metal thickness on the curvatures of sheet is also presented.

• Aerospace Engineering and Technology
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• v.7 no.2
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• pp.88-94
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• 2008

In this study, triaxial velocity is analyzed for COMS(Communication, Ocean and Meteorological Satellite) configuration, which is generated when thrusters are used to dump wheel momentum. Since COMS is designed to periodically change the thruster set in order to uniformly decrease the performance of thrusters, triaxial velocity would be different during the change of thruster set. So, the triaxial velocity generated due to the change of thruster set is optimized.

• Transactions of Materials Processing
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• v.23 no.6
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• pp.369-375
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• 2014

Flexible roll forming allows profiles to have variable cross-sections. However, the profile may have some shape errors, such as, warping which is a major defect. The shape error is induced by geometrical deviations in both the concave zone and the convex zone. In the current study, flexible roll forming was modeled with FE simulations to analyze the shape error and the longitudinal strain distribution along the flange section over the profile. A distribution of analytically calculated longitudinal strains was used to develop relationships between the shape error and the longitudinal strain distribution as a function of the defined shape parameters for the profile. The FE simulations showed that the shape error is primarily affected by the deviations between the distribution of analytically calculated longitudinal strain and the longitudinal strain distribution of the profile. The results show that the shape error can be controlled by designing the shape parameters to control the geometrical deviations at the flange section in the transition zones.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.36 no.1
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• pp.48-56
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• 2008

Nowadays, CMG(Control Moment Gyros) becomes one of the essential actuators for satellite attitude control. The method to define the key requirements of CMG is suggested to avoid CMG's singularity problem for the limited envelope of angular momentum of 2H. Furthermore, the analysis and simulation are carried out to provide a necessary guideline when three CMGs are used for spacecraft control purpose. An improved configuration of redundant four CMG cluster, slightly different from the conventional configuration, is proposed not only to avoid the CMG singularity problem, but to improve agility about roll or pitch-axis.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.38 no.1
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• pp.42-47
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• 2010

This paper considers a fault tolerant control problem for a spacecraft using wheels which are momentum exchanging devices. The control of a satellite with only two healthy wheels has been studied and its result has been presented. Two different configurations have been considered. When the yaw rate cannot be controlled directly by any control input, the desired yaw rate can be obtained by using the roll rate as a pseudo control. As a result, all three angular speeds have been stabilized, and two attitude angles including pitch and yaw have been controlled to converge to the desired values.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2006.05a
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• pp.387-390
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• 2006

Conventional spinning, shear forming and flow forming techniques are being utilized increasingly due to the great flexibility provided for producing complicated parts, enabling customers to optimize designs and reduce weight and cost, all of which are vital, especially in automotive industries, space shuttle, a munitions industry. The deformation mechanism of conventional spinning and shear forming is studied in this paper through analysis. The forming loads of a spin formed dome in an Al launch vehicle fuel tank was studied analysis and a simple FE model to predict the forming loads of the dome was proposed. The analysis is carried out to study the effects of feed rates and thickness reduction on material flow.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2011.11a
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• pp.31-37
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• 2011

Detail flow structure in a large solid rocket motor with two inhibitors has been investigated using 3D Large Eddy Simulation and Proper Orthogonal Decomposition(POD) analysis. Vortex shedding frequencies periodically occurred by inhibitors are coupled with flow acoustics induced by the impinging of vorticity on nozzle head. As a result of 3D analysis, it was observed that the nozzle exit flow causes roll-torques from the vortex being decomposed in unbalanced shape for the impinging of vorticity on the nozzle head.

• Transactions of Materials Processing
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• v.25 no.2
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• pp.102-108
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• 2016

The aim of the current study was to develop an advanced prediction model for the slab width spread during hot rough rolling. Rough rolling consists of both vertical rolling using a set of profiled edger rolls and horizontal rolling using a set of plain work rolls. FE-simulations were performed to investigate the influences of process variables such as initial slab width, initial thickness, sizing draft, edger roll draft and work roll draft on the final slab width variation. From a statistical analysis of the simulation results, an advanced model, which can predict the slab width spread during the edger rolling and horizontal rolling, was developed. The experimental hot rolling trials showed that the newly developed model provided fairly accurate predictions on the slab width spread during hot rough rolling process using a profiled edger rolls.