• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1285-1288
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• 2005

Screw rotors, the key parts of screw compressors, are used in compressing air and refrigerant due to their high productivity, compact size, low noise and maintenance. In general, a screw compressor is composed of a pair of rotors of complex geometric shape. The manufacturing cost of the screw rotors is high because the complicated helical shapes of the screw rotors are manufactured usually by the dedicated machine tools. In this study, rotor profile is divided into three parts for the efficient machining. The formed tools are designed and shared for the respective split region. By cutting the screw rotor using the formed tools, this method is more efficient than the end mill in machining rotor. Experimental results show that 4-axis machining using formed tools needs less time and has the accuracy.

• Transactions of Materials Processing
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• v.18 no.7
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• pp.538-543
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• 2009

The cowl cross bar of an automobile is a frame component that is installed inside the cockpit module to provide a guide surface, to which functional components for electricity and air condition are attached. In the recent years, the geometries of cowl cross bars are getting more complex in order to meet the demands of a wide variety of embedded functional components and the reduced weight of frame parts with enhanced mechanical and noise/vibration characteristics. There for, welding processes between tubes with different diameters are widely conducted while the welded parts are experiencing various problems such as undermined appearance, low production efficiency and poor mechanical characteristics. Therefore, this paper seeks to develop an one-piece forming process which eliminate welding process for the cowl cross bar by applying the tube drawing process. However, it was predicted that a conventional tube drawing can not be applied directly to the current part since the area reduction ratio of the drawing process reaches 51.7% which exceeds the general limiting value. Therefore, in this study, a combined drawing process which adds a compressive force to a tensile force of the conventional drawing process was proposed and 2-stage drawing process was designed by using CAE analyses. In addition, drawing tryouts were carried out by using the manufactured combined drawing machine in order to verify the designed process.

• Proceedings of the Korean Institute of Navigation and Port Research Conference
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• 2007.12a
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• pp.25-26
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• 2007

Ship are typically thin-walled structures and consists of stiffened plate structure by purpose of required design load and weight reduction etc. Also, a hull structural characteristics are often used in structures with curvature at deck plating with camber, side shell plating at fore and aft parts and bilge circle parts, It have been believed that these structures can be modelled fundamentally by a part of cylinder. Structural component with curvature subjected to combined loading regimes and complex boundary conditions, which can potentially collapse due to buckling. Hence, for more rational and safe design of ship structures, it is crucial importance to better understand the interaction relationship of the buckling and ultimate strength for cylindrically curved plate under these load components. In this study, the ultimate strength characteristic of curved plate under combined load(lateral pressure load + axial compressive load) are investigated through using FEM series analysis with varying geometric panel properties.

• Journal of Powder Materials
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• v.5 no.2
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• pp.145-153
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• 1998

W-Cu alloy is attractive to thermal managing materials in microelectronic devices because of its good thermal properties. The metal injection molding (MIM) of W-Cu systems can satisfy the need for mass production of the complex shaped W-Cu parts in semiconductor devices. In this study, the application of MIM process of the mechanically alloyed (MA) W-Cu composite powders, which had higher sinterability were investigated. The MA W-Cu powders and reduction treated (RT) powders were injected by using of the multicomponent binder system. The multi-stage debinding cycles were adopted in $N_2$ and $H_2$ atmosphere. The isostatic repressing treatment was carried out in order to improve the relative density of brown parts. The brown part of RT W-Cu composite powder sintered at 110$0^{\circ}C$ had shown the higher sinterability compared to that of MA powder. The relative sintered density of all specimens increased to 96% by sintering at 120$0^{\circ}C$ for 1 hour. The relationship between green density and the sintering behavior of MA W-Cu composite powder was analyzed and discussed on the basis of the nanostructured characteristics of the MA W-Cu composite powder.

• Journal of Korea Foundry Society
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• v.22 no.4
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• pp.192-199
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• 2002

Dimensional defects of castings are mainly due to the stresses and strains caused by a nonuniform temperature distribution and phase transformation during solidification and cooling, and by mechanical constraint between the mold and casting. It is, however, nearly impossible to trace movements of the casting and mold during solidification and cooling by experimental measurements for castings with complex shape. Two and three dimensional deformation analyses of the casting and the mold were performed using commercial finite element code, MARC. It was possible to calculate deformation and temperature distribution in the casting and mold simultaneously. Cooling curves of the casting obtained by calculation were close to that measured in the field since it was possible to treat latent heat evolution of the casting which could be divided into two parts, primary and eutectic parts. Mold bent inward just after pouring due to the temperature gradient across the mold thickness, and mold returned to its previous position with time. Plastic deformation occurred at the part of the casting where solidification was slow.

• Journal of Korea Foundry Society
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• v.32 no.3
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• pp.127-132
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• 2012

Al-Zn-Mg alloys, being high strength aluminum alloys, have attracted attention as a material of automobile parts that require higher mechanical properties and lightness. Automobile parts with complex shapes are manufactured by low-priced casting method, but Al-Zn-Mg alloys are difficult to cast because of its poor hot cracking, feeding, and fluidity. Thus fluidity experiments on Al-Zn-Mg alloys were conducted for the castability evaluation. The effects of Mg and Zn, representative elements of Al-Zn-Mg alloys, on fluidity were observed. Spiral mold was used for fluidity experiments and the lengths of solidified specimens were measured after melting and gravity casting. Correlation between microstructures and fluidity length based on the alloy composition was considered. According to the experimental results, as the amount of Mg and Zn increased, fluidity decreased. Also, it was confirmed that fluidity change by the variation of Mg composition was greater than that of Zn.

• Transactions of Materials Processing
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• v.27 no.2
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• pp.87-92
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• 2018

Auto industries have tried to employ lightweight alloys to improve the fuel efficiency of manufactured vehicles, as the environmental concern becomes an important issue. Even though the aluminum alloy is one of the most appropriate lightweight alloys for auto parts, the low formability of an aluminum alloy has been an obstacle to its application. In order to resolve the low formability problem, a recent study (Lee et al., 2017 [1]) showed that the infrared (IR) local heat treatment can improve the formability with a reduction of heating energy. However, the aforementioned study was limited to only a linear line heating. Since many of the available auto parts as applicable to vehicle manufacturing have a curved line shape, the heating experiments for a curved line should be studied. The possibility of building IR lamps having complex shapes is an advantage of the IR lamp, since it can control the heating shape. This work conducted the IR local heat treatment for the curved line. The experimental results show that the IR local heat treatment can improve the formability of the aluminum alloy for curved line. Additionally, it is shown that the IR local heat treatment also reduces the heating energy when it is compared with the furnace heating which heats a blank as a whole. A numerical simulation with a stress-based forming limit diagram also supports the experimental results.

• Journal of Mechanical Science and Technology
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• v.17 no.9
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• pp.1249-1260
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• 2003

This present work focuses on the influence of nonlinearities associated with impact on the rocking behavior of a rigid body block subjected to a two-dimensional excitation in the horizontal and vertical directions. The nonlinearities in rocking system are found to be strongly dependent on the impact between the block and the base that abruptly reduces the kinetic energy. In this study, the rocking systems of the two types are considered : The first is an undamped rocking system model that disregards the energy dissipation during the impact and the second is a damped rocking system, which incorporates energy dissipation during the impact. The response analysis is carried out by a numerical method using a non-dimensional rocking equation in which the variations in the excitation levels are considered. Chaos responses are observed over a wide range of parameter values, and particularly in the case of large vertical displacements, the chaotic characteristics are observed in the time histories, Poincare sections, the power spectral density and the largest Lyapunov exponents of the rocking responses. Complex behavior characteristics of rocking responses are illustrated by the Poincare sections.

• Composites Research
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• v.31 no.5
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• pp.192-201
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• 2018

The use of 3D printing for rapid tooling and manufacturing has promised to produce components with complex geometries according to computer designs and it is emerging as the next generation key of manufacturing. Due to the intrinsically limited mechanical/electrical properties and functionalities of printed pure polymer parts, there is a critical need to develop 3D printable polymer composites with high performance. This article gives a review on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the various fields.

• Proceedings of the KSME Conference
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• 2002.08a
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• pp.279-282
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• 2002

Recently, gas turbines for power generation adopt multistage DLN(Dry Low NOx) type combustion, where diffusion combustion is applied at low load and, with increase in load, the combustion mode is changed to lean premixed combustion to reduce NOx emissive concentration. However, during the mode changeover from diffusion to premixed flame, unfavorable phenomena, such as flashback, high amplitude combustion oscillations, or thermal damage of combustor parts could frequently occur. In the present study, to apply for the analysis of such unfavorable phenomena, three-dimensional CFD investigations are carried out to compare the detailed flow characteristics and temperature distribution inside the gas turbine combustor before and after combustion mode changeover. The fuel considered here is pure methane gas. A standard $k-{\varepsilon}$ turbulence model with wall function and a P-N type radiation heat transfer model, have been utilized. To analyze the complex geometric effects of combustor parts on combustion characteristics, fuel nozzles, a swirl vane f3r fuel-air mixing, and cooling air holes on the combustor liner wall, are included in this simulation.