• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.266-267
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• 2007

Sandwich sheet with inner structure is expected to find many applications because of high stiffness to mass ratio. In order to simulate forming of sandwich sheet with pyramid core, an effective simulation method is required. Compared to the expensive model using solid elements, cost effective model using simplified elements such as shells and beams is developed. By comparing two models in terms of the cost and accuracy for unit cell deformation, a developed model shows some advantages over the model using solid elements. Evolution of two kind of forming limits, face buckling and core buckling are successfully expressed by developed model. Developed model is also applied in the simulation of square cup drawing and L-type bending. The corresponding experiments are carried out. Deformation shape and wrinkling behavior are compared and discussed. It is found that simulation results using a developed model are in good agreement with experiments.

• Transactions of Materials Processing
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• v.14 no.8 s.80
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• pp.718-724
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• 2005

An efficient finite element method has been introduced for analysis of metallic sandwich plates subject to bending moment. A full model 3-point bending FE-analysis shows that the plastic behavior of inner structures appears only at the load point. The unit structures of sandwich plates are defined to numerically calculate the bending stiffness and strength utilizing the recurrent boundary condition for pure bending analysis. The equivalent models with the same bending stiffness and strength of full models are then designed analytically. It is demonstrated that the results of both models are almost the same and the FE-analysis method incorporating the equivalent models can reduce the computation time effectively. The dominant collapse modes are face buckling and face yielding. Since the inner dimpled structures prevent face buckling, sandwich plates with inner dimpled shell structure can absorb more energy than other types of sandwich plates during the bending behavior.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1690-1695
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• 2007

Lightweight metallic truss structures with open, periodic cell are currently being investigated because of their multi-functionality such as thermal management and load bearing. The Kagome truss PCM has been proved that it has higher resistance to plastic buckling, more plastic deformation energy and lower anisotropy than other truss PCMs. The subject of this paper is an examination of the failure mechanism of Wire woven Bulk Kagome(WBK). To address this issue, the out-of-plane compressive responses of the WBK has been measured and compared with theoretical and finite element (FE) predictions. For the experiment, 2 multi-layered WBK are fabricated and 3 specimens are prepared. For the theoretical analysis, the brazed joints of each wire in WBK are modeled as the pin-joint. Then, the peak stress of compressive behavior and elastic modulus are calculated based on the equilibrium equation and energy method. The mechanical structure with five by five cells on the plane are constructed is modeled using the commercial code, PATRAN 2005. and the analysis is achieved by the commercial FE code ABAQUS version 6.5 under the incremental theory of plasticity.

• Journal of Welding and Joining
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• v.27 no.3
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• pp.92-96
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• 2009

Metallic sandwich plate has many good properties such as high specific stiffness, high specific strength, good impact absorptivity, effective thermal insulation and soundproofing. In our study, a new bonding method, 3-layer roll projection welding, is introduced to fabricate the metallic sandwich plate. The new method uses a pair of roll electrodes like the seam welding, and projection welding is made at two internal interfaces of the 3-layer weldment consisting of a structured inner sheet and a pair of skin sheets. During the welding process, skin sheet temperature are measured to produce metallic sandwich plate with uniform and good quality. But it is difficult to observe or measure the temperature at the welding points during welding process because the welding points exist at the internal interfaces. Therefore FEM numerical analysis using ABAQUS is conducted to estimate the generated heat at the welding points with different welding conditions.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.76-83
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• 2010

Metallic sandwich panels with pyramidal truss structures are high-stiffness and high-strength materials with low weight. In particular, bulk structures have enough space for additional multi-functionalities. In this work, in order to fabricate 3-D structures efficiently, Layered Manufacturing Method (LMM) which was composed of three steps, including crimping process, stacking process and bonding process using rapid infrared brazing, was proposed. The joining time was drastically reduced by employing infrared brazing of which heating rate and cooling rate were faster than those of conventional furnace brazing. By controlling the initial cooling rate slowly, the bonding strength was improved up to the level of strength by conventional vacuum brazing. The observation of infrared brazed specimens by optical microscope and SEM showed no defect on the joining sections. The experiments of 1-layered pyramidal structures and 2-layered pyramidal structures subject to 3-point bending were conducted to determine structural advantages of multilayered structures. From the results, the multi-layered structure has superior mechanical properties to the single-layered structure.

• Composites Research
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• v.26 no.1
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• pp.42-47
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• 2013

In this study, an economical and effective processing technique to form multiple dimples on the surface of a composite part, which are known to be useful to improve aerodynamic performance and heat dissipation. Forming dimples on the surface using molds is an expensive processing because forming multiple tiny positive spheres on the surface of the mold requires much time and effort. In this study, plates with multiple round holes are utilized as a core to form dimples on the carbon/epoxy composite skin covering the core. A vacuum bagging process is used to apply pressure on the surface while curing. Composite parts which have multiple dimples on the surface can be utilized in the field which needs high aerodynamic performance and heat dissipation ability such as high speed sports car bodies.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.2 s.257
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• pp.245-252
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• 2007

Since the new millennium, truss PCMs(Periodic Cellular Metals) have drawn attention because of their superior specific stiffness, strength and multi-functionality. Prior studies have focused on the structural design and optimization. Kagome truss PCM has been proved to have the higher resistance to plastic buckling, more plastic deformation energy and lower anisotropy than other truss PCMs. In this study, we introduce a new idea to fabricate multi-layered Kagome truss PCM from continuous wires which can gain high strength as in piano wires and can be controlled to be defect free owing to drawing process. The relative density, the stiffness and the strength under bending and compressive load are estimated through elementary mechanics and compared with the results from experiments and FEA. The failure mechanisms are analyzed, and also mechanical performance and production are discussed.

• Journal of Welding and Joining
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• v.23 no.6
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• pp.49-54
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• 2005

Inner Structured and Bonded(ISB) panel, a kind of metallic sandwich panel, consists of two thin skin plates bonded to a micro-patterned inner structure. Its overall thickness is $1\~3mm$and it has attractive properties such as ultra-lightweight, high efficiency in stiffness-to-weight and strength-to-weight ratio. In many previous studies, resistance welding, brazing and adhesive bonding are studied for joining the panel. However these methods did not consider productivity, but focused on structural characteristics of joined panels, so that the joining process is very complicated and expensive. In this paper, a new joining process with resistance welding is developed. Curved surface electrodes are used to consider the productivity and the stopper is used between electrodes during welding time to maintain the shape of inner structure. Welding time, gap of electrodes and distance between welding points are selected as the process parameters. By measuring the tensile load with respect to the variation of welding time and gap of electrodes, proper welding conditions are studied. Welding time is proper between 1.5-2.5cycle. If welding time is too long, then inner structures are damaged by overheating. Gap of electrode should be shorter than threshold value fur joint strength, when total thickness of inner structure and skin plate is 3.3mm, the threshold distance is 3.0mm.

• Journal of Aerospace System Engineering
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• v.14 no.3
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• pp.69-77
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• 2020

Airframe structure development of the 35 kg class 'Disaster and Public Safety Multicopter' UAV is described in this paper. To reduce the airframe weight, T-700 grade CFRP composite material was used, and the fuselage was designed with the semi-monocoque structure and plate installed with the control and communication devices designed in a sandwich structure. The specimen tests for the laminated plate and pipe were conducted to verify the strength and stiffness of the designed parts. The stacking sequence of composite materials was determined by the static strength and vibration analysis, and landing gear strut was designed by the nonlinear analysis with decent speed and ground clearance requirements. The static strength test was performed to evaluate the structural integrity and to verify the landing gear behavior.