• Journal of the Society of Naval Architects of Korea
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• v.48 no.6
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• pp.528-538
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• 2011

As a forming method for curved hull plates more efficient than the flame bending, mechanical bending using multi point press forming and die-less forming is discussed in this paper. the mechanical forming is a flexible manufacturing system for automatically forming of hull parts. It is especially suited to varied curved parts. This paper discusses a multiple point pressing machine composed of a pair of reconfigurable punches in order to achieve the rapid forming of curved hull plates using division forming and presents how forming information is obtained from the given design surface. Although the mechanical forming can be efficient in the metal forming, spring back after pressing is a phenomenon which must be carefully considered when quantifying the process variables. If the spring back is not accurately controlled, the fabricated shell plate cannot meet assembly tolerance. This paper describes the principles to calculate the proper stroke of each punch at the divided areas. the strokes are determined by an iterative process of sequential pressing and spring back compensation from an unfolded flat shape to its given design surface. FEA(finite element analysis) is used to simulate the spring back of the plate and the IDA(iterative displacement adjustment) method adjusts the offset of pressing punches from the deformation results and the design surface. The shape deviations of two surfaces due to spring back are compensated by integrated system using FEA and IDA method. For the practical application, It is aimed to develop an integrated system that can automatically perform the compensation process and calculate strokes of punches of the double sides' reconfigurable multiple-press machine and some experimental results obtained with mechanical bending are presented.

• Korean Journal of Computational Design and Engineering
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• v.17 no.3
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• pp.188-197
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• 2012

Recently, aluminum ships are constructed more than ever because of the environmental pollution generated by FRP (Fiber Reinforced Plastic) ships. In particular, FRP ships have been replaced by the Aluminum ships. The forming process of the curved aluminum plate has been performed only by labor works without systematic technique. Therefore, it is difficult to construct the aluminum ship that the design satisfies both required propulsion performance and hull design. Present study introduces a MPSF (Multi Point Stretching Forming) that is a flexible manufacturing technique to form large sheet panels of doubly curvature. The hull pieces are stretch-formed over the MPSD (multi-point stretching die) generated by the punch element matrix. In this study, MPSF is applied to deform the doubly curved surfaces of aluminum ship. The forming system including FEA (finite element analysis) of the processes for stretching the plate were carried out by static implicit analysis is suggested. Residual deformation of the surface is modeled by an elasto-plastic contact phenomena while the forming process is simulated by FEA. Finally, the proposed system is also validated, comparing the deformed shape by MPSF with that of object surfaces.

• Transactions of the Korean Society of Mechanical Engineers
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• v.13 no.6
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• pp.1070-1081
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• 1989

본 논문의 목적은 일반적인 곡면을 갖는 냉간단조 공정을 컴퓨터 시뮬레이션 을 통해 해석하고자 강소성 유한요소법의 프로그램을 개발하고, 이를 축대칭 및 평면 변형 단조성형에 적용하고자 한다. 축대칭 문제로는 산업적으로 이용이 많은 치차 블랭크(gear blank) 형태의 예제를 선택하였고 평면변형으 경우 정밀 단조품의 하나인 터어빈 블레이드(turbine blade)를 평면변형 문제로 보아 해석하였다. 한편 심한 변형을 하는 후방압출과 같은 문제의 수렴성을 향상시키고 공정을 계속적으로 해석하 기 위하여 격자 재구성기법을 도입함으로서 냉간단조 문제의 일반적인 해석을 하도록 한다.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.2
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• pp.89-97
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• 2005

Thin plate correction of forming process that it is nowadays smile change of simple contact surface as it becomes possible that forecast dictionary numerically exactly to analyze comparative big comp displacement real industry spot problems between complicated and abnormal curved line shapes and thin plate and die more reliable and need many efforts yet economical analysis method is required and develops this efficient algorithm. This research analyzes correction of forming and examined possibility and validity of spot application using One-Step Finite Element Method. Its application is being increased especially in the automotive industrial area for the cost reduction, weight saving, and improvement of strength.

• Korean Journal of Agricultural Science
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• v.22 no.1
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• pp.11-23
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• 1995

The CAD/CAM system for the manufacturing automation is the newest technology in mechanical engineering area and becomes the important research subject nowadays. Most of all hardwares and softwares for the CAD/CAM system used in the our manufacturing companies such as automobile company are developed by the foreign country and the purchasing price of them is very expensive but their applicability to a certain area is very limited. This study was conducted to develope a CAD/CAM system for the design and the automatic manufacturing of the iron pattern shaped with 3 - dimensional free curved surface, and to test its applicability to the design and the manufacturing of the rotary blade. The results obtained from the study are as follow; 1. The CAD system which can process graphic procedures from the free curved surface shaped data was developed with personal computer. 2. The CAM main program was developed. This main program could produce CL data from CAD data file by checking the tool interference according to the cutting mode. 3. The sub. program which can simulate the tool trace from the CL data was developed. 4. The post processor for the Deckel FP2NC NC milling machine from CL data file was developed and the sub program could transmit NC program through modem to NC milling machine was developed. 5. The developed CAM system seemed to be applicable to any other system. Because the measuring results of the cross sectional thickness of the plastic model from the manufacturing iron pattern by the system showed that this system could properly check the tool interference. 6. In took 75~90 hours to manufacture two iron patterns of rotary blade. For the sake of convenience in applying to the other systems, this system was developed in BASIC and FORTRAN computer language and minimum portion of machine language as possible.

• Design & Manufacturing
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• v.17 no.4
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• pp.1-7
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• 2023

In the fabrication of curved multi-display glass for automotive use, the surface roughness of the mold is a critical quality factor. However, the difficulty in detecting micro-cutting signals in a micro-machining environment and the absence of a standardized model for predicting micro-cutting forces make it challenging to intuitively infer the correlation between cutting variables and actual surface roughness under machining conditions. Consequently, current practices heavily rely on machining condition optimization through the utilization of cutting models and experimental research for force prediction. To overcome these limitations, this study employs a surface roughness prediction formula instead of a cutting force prediction model and converts the surface roughness prediction formula into experimental data. Additionally, to account for changes in surface roughness during machining runtime, the theory of position variables has been introduced. By leveraging artificial neural network technology, the accuracy of the surface roughness prediction formula model has improved by 98%. Through the application of artificial neural network technology, the surface roughness prediction formula model, with enhanced accuracy, is anticipated to reliably perform the derivation of optimal machining conditions and the prediction of surface roughness in various machining environments at the analytical stage.

• Transactions of Materials Processing
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• v.26 no.6
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• pp.341-347
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• 2017

Flexibly-reconfigurable roll forming (FRRF) is a novel sheet metal forming technology conducive to produce multi-curvature surfaces by controlling strain distribution along longitudinal direction. Reconfigurable rollers could be arranged to implement a kind of punch die set. By utilizing these reconfigurable rollers, desired curved surface can be formed. In FRRF process, three-dimensional surface is formed from two-dimensional curve. Thus, it is difficult to predict the forming result. In this study, a regression analysis was suggested to construct a predictive model for a longitudinal curvature of FRRF process. To facilitate investigation, input parameters affecting the longitudinal curvature of FRRF were determined as maximum compression value, curvature radius in the transverse direction, and initial blank width. Three-factor three-level full factorial experimental design was utilized and 27 experiments using FRRF apparatus were performed to obtain sample data of the regression model. Regression analysis was carried out using experimental results as sample data. The model used for regression analysis was a quadratic nonlinear regression model. Determination factor and root mean square root error were calculated to confirm the conformity of this model. Through goodness of fit test, this regression predictive model was verified.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.625-631
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• 2002

In the previous study, a polishing robot system was developed to automate the polishing process and to cope with the shortage of skilled workers. This polishing robot system has several advantages: reduced time for setting polishing work, decreased labor costs, effective operation, continuous polishing work without an operator, improved machine accuracy, and the ability to polish a free curved surface die. However, still the problem remains that a worker must stay to monitor the polishing process in the poor working conditions for a long time. Nowadays some advanced manufacturing companies need to find a way to check the performance of their production equipments and plants from remote sites. Thus, this study constructed the communication network and developed the monitoring programs (a servo program and a client program) to operate the polishing robot from remote sites. Using these programs, workers are able to monitor and control the polishing robot on the web page, in any place where internet service is possible. To guarantee a stable operation in spite of a variable computer operating environment, the monitoring system is implemented in Java. The experimental results showed that the developed monitoring programs provided a stable communication.

• Design & Manufacturing
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• v.16 no.4
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• pp.17-23
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• 2022

Recently, several studies are being conducted to achieve a curvature of 180° or more for the edge of the display glass. The thermocompression molding process is applied to the manufacture of curved glass, and high hardness G5 graphite is used as the mold material to withstand the impact applied to the mold. G5 graphite has high hardness and strong brittleness, which makes tool wear and surface damage easy during machining. Therefore, the demand for diamond-coated tools with good mechanical properties is increasing in the G5 machining field. In this study, the optimal cutting conditions and machinability of a nanodiamond (NCD) coated ball end mill being developed by a tool manufacturer were analyzed and evaluated. For this purpose, the same test was performed on the microdiamond (MCD) coated ball end mill and compared together. In summary, the machinability of MCD and NCD coated tools showed better cutting performance at a cutting speed of 282 m/min, a feed rate of 1,400 mm/min, and a radial depth of cut of 0.08 to 0.1 mm.

• Journal of Ocean Engineering and Technology
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• v.22 no.6
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• pp.75-82
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• 2008

Flame bending has been extensively used in the shipbuilding industry for hull plate forming In flame bending it is difficult to obtain the desired shape because the residual deformation dependson the complex temperature distribution and the thermal plastic strain. Mechanical bending such as reconfigurable press forming multi-point press forming or die-less forming has been found to improve the automation of hull plateforming because it can more accurately control the desired shape than line heating. Multi-point forming is a process in which external forces are used to form metal work-pieces. Therefore it can be a flexible and efficient forming technique. This paper presents an optimal approach to determining the press-stroke for multi-point press forming of curved shapes. An integrated configuration of Finite element analysis (FEA) and spring-back compensation algorithm is developed to calculate the strokes of the multi-point press. Not only spring-back is modeled by elastic plastic shell elements but also an iterative algorithm to compensate the spring-back is applied to adjust the amount of pressing stroke. An iterative displacement adjustment (IDA) method is applied by integration of the FEA procedure and the spring-back compensation work. Shape deviation between the desired surface and deform￡d plate is minimized by the IDA algorithm.