• Composites Research
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• v.22 no.2
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• pp.30-36
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• 2009

In this paper, we propose the design method for the composite torque link of a landing gear for a helicopter. The composite torque link has to be light weighted and very stiff to keep the shock absorber in the landing gear of helicopter. The configuration and structural shape has to be designed in consideration of the RTM (Resin Transfer Molding) manufacturing process which is adopted to minimize the manufacturing cost. The mechanical properties are obtained through the coupon tests with the specimens made by the same manufacturing process for the composite structure. The optimal design process was performed through iterative modifications of the models which were verified by stress analysis using FEM. The composite torque link has lug-shaped parts and is very thick, so 3D Layered solid elements of ABAQUS were used to get the stress field including the stress components in thickness direction and non-linear static analysis using contact B.C. of rigid-deform condition was used to get the optimal design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.426-430
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• 2008

Hot shear-welding is a process of bonding two plates together by using shearing stress in a controlled manner. This study dealt with the hot shear-welding process of two aluminum plates. These two plates were piles up in the shear-welding mold. Due to the shearing stress, these two plates were cut off longitudinally, and meantime they were welded together. During this process the control of the surplus material flow is very important, and it can be realized by designing the overlapping length and the shape of the cavity. The commercial software Deform-3D was employed to predict the effect of these two factors. The overlapping length and the shape of the cavity that presents the optimum design was then developed to get a good shear-welding process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.370-373
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• 2008

Small size gas turbine disk requires good mechanical strength and creep properties at high temperature. In this study, Waspaloy was used as a superalloy to satisfy these specifications. The control of microstructure was needed to satisfy material properties at high temperature. In order to do this, we studied forging conditions and material analysis. Therefore die and preform design conducted so that hot forged gas turbine disk could have a good microstructure. The die and preform shapes are designed with consideration of the predefined hydraulic press capacity and the microstructure of forging product. Also we carried out the hot compression test for Waspaloy in various test conditions. From these results, we obtained the forging conditions as material temperature, die velocity etc. To verify these forging conditions, we conducted FE simulations by means of the DEFORM 2D-HT. In this study, the hot closed die and preform designs were completed to offer high temperature material properties of a small size gas turbine.

• International Journal of Precision Engineering and Manufacturing
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• v.7 no.1
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• pp.3-8
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• 2006

This paper deals with an automated computer-aided process planning and die design system by which designer can determine operation sequences even if they have a little experience in process planning and die design for axisymmetric products. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM softwares, DEFORM and ANSYS, to form a useful package. The system can provide a flexible process based on either the reduction in the number of forming sequences by combining the possible two processes in sequence, or the reduction of deviation of the distribution on the level of the required forming loads by controlling the forming ratios. Especially in die design module optimal design technique and horizontal split of die insert were investigated for determining appropriate dimensions of components of multi-former die set. Results obtained, using the modules, enable the design and manufacture of a die set for a multi-former to be more efficiently performed.

• Proceedings of the KSME Conference
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• 2007.05b
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• pp.1916-1919
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• 2007

We have been setting up experiments on propagation of shock waves generated by the pulsed laser ablation. One side of a thin metal foil is subjected to laser ablation as a shock wave propagates through the foil. The shock wave, which penetrates through the foil is reflected by an acoustic impedance which causes the metal foil to high-strain rate deform. This short time physics is captured on an ICCD camera. The focus of our research is applying shock wave and deformation of the thin foil from the ablation to accelerating micro-particles to a very high speed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.399-402
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• 2009

The Clad sheet is made roll-bonding process of the one or more material with the different property. Good formability is an essential property in order to deform a clad metal sheet to a part or component. In this study, the mechanical properties and formability of a Mg-Al-SUS clad sheet are investigated. The clad sheet was deformed at elevated temperatures because of its poor formability at room temperature. Tensile tests of the each material and clad sheet were performed at various temperatures and at various strain rates. The limited draw ration (LDR) was obtained using a deep drawing test to measure the formability of the clad sheet. A finite element (FE) analysis was performed to predict formability of the cup drawing product, one_layer model and three_layer model.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.254-258
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• 2009

In this paper, the low frequency vibration forming system is developed for micro-patterns formation on the metal substrate. many researchers have studied about micro-forming technologies such as micro deep drawing, press forming, forging, extrusion etc. for the formation of precise micro-patterns on the surface of metal substrates, multi-step forming process must be used to improve qualifies of the deformed patterns. Since the low frequency vibration forming system could easily deform the surface of metal substrates, several steps of multi-step forming process should be removed by using the low frequency vibration forming system. In order to find optimal process conditions, we have carried out low frequency vibration forming process with varying the vibration frequency from 110Hz to 500Hz.

• Proceedings of the KIEE Conference
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• 2001.11a
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• pp.84-86
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• 2001

Acrylonitrile Butadiene Rubber (NBR) has been used as a transformer gasket material because the transformer gaskets should have high resistivity to oil and should not swell and deform when it contact to insulating oils. Serious cracks were observed in the gaskets being used and ozone test was performed on new, specimens. Cracks were also observed on specimens. So we have performed the following tests on the anti-oxidants containing new gaskets according in accordance with KEPCO purchase specifications; ozone resistance, oil resistance, mechanical properties before and after aging.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.75-81
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• 2014

Progressive dies are used for metal stamping during which multiple operations are performed in a sequence. Material is fed automatically from a coil into the press and advances from one die station to the next with each press stroke. Transfer dies are used in high-volume manufacturing for round, deep-drawn, and medium-to-large parts. Several different operations may be incorporated within a transfer die such as blanking, bending, piercing, trimming, and deep drawing. The main challenge in the current study is how to deform a seat cushion panel meeting the design specifications without any defects. A complex automation die manufacturing technology for the automotive seat cushion panel, mixing both semi-progressive die and transfer die for continuous production, was developed.

• Transactions of Materials Processing
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• v.21 no.7
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• pp.447-452
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• 2012

This paper is concerned with forming of Al-Zn-Mg-Sc aluminum alloy bolts, focusing on the effects of heat treatment and age-hardening on the formability and ductile damage evolution. Both experimental and finite element studies were performed. From the experiments, it is observed that the heat treatment or the normalization of Al-Zn-Mg-Sc aluminum alloy increases its formability dramatically resulting in successful bolt forming, while the effects of age-hardening at room temperature on the stress-strain relationship and formability are not very critical. Deformation characteristics such as distribution of effective stress and strain, material flow, and ductile damage evolution during bolt forming are examined using a commercial finite element package, Deform-2D. It should be noted that the extrusion load predicted by the finite element method matches well the experiment results. The finite element predictions on the deformation characteristics support the experimental observations such as fracture of bolt head flange, material flow, and distribution of hardness.