• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.94-100
• /
• 2002

During the last years, great progress has been made in the fields of welding power sources and filler materials for the MIG-welding of magnesium alloys. This advice resulted in a better welding process, md, therefore, in highly improved welding results. Furthermore the gap between short-circuiting- and spray-arc-trunsfer could be closed by the triggered short-circuiting- and the short-circuiting-arc with pulse overlay. A crucial contribution to the welding process is the energy input into the filler material. Many problems result from the physical properties of magnesium, for instance its narrow interval between melting point 600$^{\circ}C$ and vaporization point 1100$^{\circ}C$. The energy input into the filler material has to be regulated in such a way that the wire will melt but not vaporize. For th is reason, special characteristics of power sources hue been examined and optimized with the help of high-speed-photographs of the welding process with particular consideration of the drop detachment. An important improvement of the weld seam profile has been achieved by using filler material of only 1.2 mm in diameter. The experiments hue been made with 2.5 mm thick extruded profiles of AZ31 and AZ6l. The results of tensile testing showed strength values of 80 to 100% of the base metal. B ending angles up to 60$^{\circ}$ have been reached. The fatigue strength under reversed bending of the examined magnesium alloys after welding reaches 50% of the strength of the base metal. When the seam reinforcement is ground of the fatigue strength can be raised up to 75% of the base metal.

• Composites Research
• /
• v.22 no.6
• /
• pp.32-38
• /
• 2009

In this study, the energy absorption capabilities and failure modes of four different kinds of circular tubes made of carbon, Kevlar and carbon-Kevlar hybrid composites with epoxy resin have been evaluated. In order to achieve these goals, these tubes were fabricated with unidirectional prepregs and compressive tests were conducted for the tubes under 10mm/min loading speed. From the test results, carbon/epoxy tubes were collapsed by brittle fracturing mode and showed the best energy absorption capabilities, while Kevlar/epoxy tubes were crushed by local buckling mode and worst. The hybrid [$90_C/0_K$] tubes were failed in a local bucking mode and showed good post crushing integrity, whereas [$90_K/0_C$] tubes were failed in a lamina bending mode and bad post crushing integrity.

• Design & Manufacturing
• /
• v.17 no.3
• /
• pp.15-20
• /
• 2023

In the fine blanking process, which is a press operation known for producing parts with narrow clearances and high precision through the application of high pressure, die roll often occurs during the shearing process when the punch penetrates the material. This die roll phenomenon can significantly reduce the functional surface of the parts, leading to decreased product performance, strength, and fatigue life. In this research, we conducted an in-depth analysis of the factors influencing die roll in the curvature area of the fine blanking process and identified its root causes. Subsequently, we designed and experimentally verified a die roll reduction process specifically tailored for the door latch manufacturing process. Our findings indicate that die roll tends to increase as the curvature radius decreases, primarily due to the heightened bending moment resulting from reduced shape width-length. Additionally, die roll is triggered by the absorption of initial punch energy by scrap material during the early shearing phase, resulting in lower speed compared to the product area. To mitigate the occurrence of die roll, we strategically selected the Shaving process and carefully determined the shaving direction and clearance area length. Our experiments demonstrated a promising trend of up to 75% reduction in die roll when applying the Shaving process in the opposite direction of pre-cutting, with the minimum die roll observed at a clearance area length of 0.2 mm. Furthermore, we successfully implemented this approach in the production of door latch products, confirming a significant reduction in die roll. This research contributes valuable insights and practical solutions for addressing die roll issues in fine blanking processes.

• Smart Structures and Systems
• /
• v.33 no.2
• /
• pp.165-175
• /
• 2024

Rotating beams play a crucial role in representing complex mechanical components that are prevalent in vital sectors like energy and transportation industries. These components are susceptible to the initiation and propagation of cracks, posing a substantial risk to their structural integrity. This study presents a two-stage methodology for detecting the location and estimating the size of an open-edge transverse crack in a rotating Euler-Bernoulli beam with a uniform cross-section. Understanding the dynamic behavior of beams is vital for the effective design and evaluation of their operational performance. In this regard, modal parameters such as natural frequencies and eigenmodes are frequently employed to detect and identify damages in mechanical components. In this instance, the Frobenius method has been employed to determine the first two natural frequencies and corresponding eigenmodes associated with flapwise bending vibration. These calculations have been performed by solving the governing differential equation that describes the motion of the beam. Various parameters have been considered, such as rotational speed, beam slenderness, hub radius, and crack size and location. The effect of the crack has been replaced by a rotational spring whose stiffness represents the increase in local flexibility as a result of the damage presence. In the initial phase of the proposed methodology, a damage index utilizing the slope of the beam's eigenmode has been employed to estimate the location of the crack. After detecting the presence of damage, the size of the crack is determined using a Genetic Algorithm optimization technique. The ultimate goal of the proposed methodology is to enable the development of more suitable and reliable maintenance plans.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.21 no.11
• /
• pp.683-692
• /
• 2020

A joint displacement resistance evaluation method for selecting waterproofing materials in railway bridge decks is proposed. The displacement range for an evaluation is determined by finite element method (FEM) analysis of a load case based on an existing high-speed PSC Girder Box railroad bridge structure. The FEM analysis results were used to calculate the minimum joint displacement range to be applied during testing (approximately 1.5 mm). For the evaluation, four commonly used waterproofing membrane types, cementitious slurry coating (CSC), polyurethane coating system (PCS), self-adhesive asphalt sheet (SAS), and composite asphalt sheet (CAS), were tested, with five specimens of each membrane type. The joint displacement width range conditions, including the minimum displacement range obtained from FEM analysis, were set to be the incrementing interval, from 1.5, 3.0, 4.5, and 6.0 mm. The proposal for the evaluation criteria and the specimen test results demonstrated how the evaluation method is important for the sustainability of high-speed railway bridges.

• Journal of the Korean Society for Railway
• /
• v.15 no.1
• /
• pp.48-61
• /
• 2012

It is of great importance to assure the running safety, ride comfort and serviceability in designing the floating slab track for mitigation of train-induced vibration. In this paper, for this, analyzed are the system requirements for the running safety, ride comfort and serviceability, and then, the behavior of train and track at the floating slab track including the transition zone to the conventional concrete slab track according to several main design variables such as system natural frequency, arrangement of spring at transition, spacing of spring isolators, damping ratio and train speed, using the dynamic analysis technique considering the train-track interaction. The results of this study demonstrate that the discontinuity of the support stiffness at the transition results in a drastic increase of the dynamic response such as wheel-rail interaction force, rail bending stress and rail uplift force. Hence, it is efficient to decrease the spacing of springs or to increase the spring constants at the transition to obtain the running safety and serviceability. On the other hand, the vehicle body acceleration as a measure of ride comfort is little affected by the discontinuity of the stiffness at the transition, but by the system tuning frequency; thus, to obtain the ride comfort, it is of great significance to select the appropriate system tuning frequency. In addition, the effects of damping ratio, spacing of springs and train speed on the dynamic behavior of the system have been discussed.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.17 no.10
• /
• pp.331-337
• /
• 2016

Several foundation soil conditions below a homogeneous sand slope were assumed and slope stability analyses were conducted to determine the soil condition, in which a stabilizing pile can be used to increase the factor of safety against sliding. The assumed heights of the sand slope were 5m and 10m. For a 5m slope height, a stabilizing pile can be used in the foundation soil with a $15^{\circ}$ internal friction angle and a cohesion of 10kPa. For a 10m slope height, a stabilizing pile can be used in the foundation soil with a $20^{\circ}$ internal friction angle and a cohesion of 10kPa and a stabilizing pile can be used in the foundation soil with a $0^{\circ}$ internal friction angle and 40kPa, 45kPa and 50kPa of cohesion. According to the analysis results of stabilizing pile-reinforced foundation soil, the length of the stabilizing pile and magnitude of the maximum bending moment were strongly affected by the internal friction angle of the foundation soil. The lengths of stabilizing pile, for an internal friction angle of $0^{\circ}$ were 4.6, 8.0 times greater than those with an internal friction angle of $5^{\circ}$. The magnitude of the maximum bending moment of the stabilizing pile for an internal friction angle of $0^{\circ}$ was 24.6 times greater than that for an internal friction angle of $5^{\circ}$. Practically, a stabilizing pile cannot be used for foundation soil with an internal friction angle of $0^{\circ}$. Considering the results derived from this study, the effects of a stabilizing pile can be maximized for soft foundation soil that is embanked with a slow construction speed.

• Journal of Korean Society of Disaster and Security
• /
• v.14 no.4
• /
• pp.47-60
• /
• 2021

Recently, as the occurrence frequency of sudden floods due to climate variability increased, the damage of aging chuteway slabs of spillway are on the rise. Accordingly, a wide array of field survey, hydraulic experiment and numerical simulation have been conducted to find the cause of damage on chuteway slabs. However, these studies generally reviewed the flow characteristics and distribution of pressure on chuteway slabs. Therefore the derivation of damage on chuteway slabs was relatively insufficient in the literature. In this study, the cavitation erosion and hydraulic jacking were assumed to be the causes of damage on chuteway slabs, and the phenomena were reproduced using 3D numerical models, FLOW-3D and COMSOL Multiphysics. In addition, the cavitation index was calculated and the von Mises stress by uplift pressure distribution was compared with tensile and bending strength of concrete to evaluate the possibility of cavitation erosion and hydraulic jacking. As a result of numerical simulation on cavitation erosion and hydraulic jacking under various flow conditions with complete opening gate, the cavitation index in the downstream of spillway was less than 0.3, and the von Mises stress on concrete was 4.6 to 5.0 MPa. When von Mises stress was compared with tensile and bending strength of concrete, the fatigue failure caused by continuous pressure fluctuation occurred on chuteway slabs. Therefore, the cavitation erosion and hydraulic jacking caused by high speed flow were one of the main causes of damage to the chuteway slabs in spillway. However, this study has limitations in that the various shape conditions of damage(cavity and crack) and flow conditions were not considered and Fluid-Structure Interaction (FSI) was not simulated. If these limitations are supplemented and reviewed, it is expected to derive more efficient utilization of the maintenance plan on spillway in the future.

• 한국신재생에너지학회:학술대회논문집
• /
• 2010.06a
• /
• pp.58.1-58.1
• /
• 2010

In solar cell module manufacturing, single solar cells has to be joined electrically to strings. Copper stripes coated with tin-silver-copper alloy are joined on screen printed silver of solar cells which is called busbar. The bus bar collects the electrons generated in solar cell and it is connected to the next cell in the conventional module manufacturing by a metal stringer using conventional hot air or infrared lamp soldering systems. For thin solar cells, both soldering methods have disadvantages, which heats up the whole cell to high temperatures. Because of the different thermal expansion coefficient, mechanical stresses are induced in the solar cell. Recently, the trend of solar cell is toward thinner thickness below 180um and thus the risk of breakage of solar cells is increasing. This has led to the demand for new joining processes with high productivity and reduced error rates. In our project, we have developed a new method to solder solar cells with a laser heating source. The soldering process using diode laser with wavelength of 980nm was examined. The diode laser used has a maximum power of 60W and a scanner system is used to solder dimension of 6" solar cell and the beam travel speed is optimized. For clamping copper stripe to solar cell, zirconia(ZrO)coated iron pin-spring system is used to clamp both joining parts during a scanner system is traveled. The hot plate temperature that solar cell is positioned during lasersoldering process is optimized. Also, conventional solder joints after $180^{\circ}C$ peel tests are compared to the laser soldering methods. Microstructures in welded zone shows that the diffusion zone between solar cell and metal stripes is better formed than inIR soldering method. It is analyzed that the laser solder joints show no damages to the silicon wafer and no cracks beneath the contact. Peel strength between 4N and 5N are measured, with much shorter joining time than IR solder joints and it is shown that the use of laser soldering reduced the degree of bending of solar cell much less than IR soldering.

• Journal of the Korean Society of Fisheries and Ocean Technology
• /
• v.25 no.2
• /
• pp.87-104
• /
• 1989

Recently, with the tendency of more lightening, high-strength and high-speed in the marine industries such as marine structures, ships and chemical plants, the use of the aluminium Alloy is rapidly enlarge and there occurs much interest in the study of corrosion fatigue crack characteristics. In this paper, the initiation of surface crack and the propagation characteristics on the base metal and weld zone of 5086-H116 Aluminium Alloy Plate which is one of the Al-Mg serious alloy(A5000serious) used most when building the special vessels, were investigated by the plane bending corrosion fatigue under the environments of marine, air and applying cathodic protection. The effects of various specific resistances on the initiation, propagation behavior of corrosion fatigue crack and corrosion fatigue life in the base metal and heat affected zone were examined and its corrosion sensitivity was quantitatively obtained. The effects of corrosion on the crack depth in relation to the uniform surface crack length were also investigated. Also, the structural, mechanical and electro-chemical characteristics of the metal at the weld zone were inspected to verify the reasons of crack propagation behavior in the corrosion fatigue fracture. In addition, the effect of cathodic protection in the fracture surface of weld zone was examined fractographically by Scanning Electron Microscope(S.E.M.). The main results obtained are as follows; (1) The initial corrosion fatigue crack sensitibity under specific resistance of 25Ω.cm% show 2.22 in the base metal and 19.6 in the HEZ, and the sensitivity decreases as specific resistance increases (2) By removing reinforcement of weldment, the initiation and propagation of corrosion crack in the HAZ are delayed, and corrosion fatigue life increases. (3) As specific resistance decreases, the sensitivity difference of corrosion fatigue life in the base metal and HAZ is more susceptible than that of intial corrosion fatigue crack. (4) Experimental constant, m(Paris' rule) in the marine environment is in the range of about 3.69 to 4.26, and as specific resistance increases, thje magnitude of experimental constant, also increases and the effect by corrosion decreases. (5) Comparing surface crack length with crack depth, the crack depth toward the thickness of specimen in air is more deeply propagated than that in corrosion environment. (6) The propagation particulars of corrosion fatigue crack for HAZ under initial stress intensity factor range of $\Delta$k sub(li) =27.2kgf.mm super(-3/2) and stress ratio of R=0 shows the retardative phenomenon of crack propagation by the plastic deformation at crack tip. (7) Number of stress cycles to corrosion fatigue crack initiation of the base metal and the welding heat affected zone are delayed by the cathodic protection under the natural sea water. The cathodic protection effect for corrosion fatigue crack initiation is eminent when the protection potential is -1100 mV(SCE). (8) When the protection potential E=-1100 mV(SCE), the corrosion fatigue crack propagation of welding heat affected zone is more rapid than that of the case without protection, because of the microfissure caused by welding heat cycle.