• 한국산학기술학회논문지
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• 제19권9호
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• pp.1-6
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• 2018

하이드로포밍 기술은 지난 20년간 자동차부품의 적용을 중심으로 비약적인 발전을 해 왔다. 이 기술은 자동차 산업응용분야에 많은 장점을 가지고 있는데 이는 더 나은 구조적 강건성, 부품수 감소에 기인한 비용절감, 재료절약, 무게감소, 낮은 스프링백현상, 개선된 강도, 내구성 향상, 설계 유연성 등이다. 하이드로포밍 부품의 성형성 검토를 위하여 다양한 컴퓨터 시뮬레이션 기술 등이 발달해 왔으며 이를 통해 성형 가능성을 검토하는 것과 동시에 성형을 위하여 벤딩 공정, 프리포밍공정, 다이클로징 공정 등의 효율적인 공정을 수립하여 하이드로포밍 부품들을 설계하고 있다. 이에 본 연구에서는 하이드로포밍 부품 설계 시 고려사항 중 성형량, 부품의 단면길이(하이드로포밍 프레스 용량에 맞는), 최소 곡률(하이드로포밍 압력에 따른 곡률 영향 평가) 등을 제시하고 실제 자동차용 리어 서브-프레임 부품의 단면분석을 실시함으로써 하이드로포밍 성형을 위한 설계 방안을 제시하고자 한다. 아울러 하이드로포밍 공정인자 중 프리벤딩, 축피딩, 유압 압력, 프레스 하중, 마찰 등의 효과를 분석하여 이들 공정이 직접적인 하이드로포밍 성형에 필요인자 인지 등을 고찰하였다.

• Steel and Composite Structures
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• 제34권5호
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• 소성∙가공
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• 제18권2호
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• pp.150-155
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• 2009

A shaft for laser printers has to be produced with high dimensional accuracy of a few micrometers. Most companies produce the shaft, therefore, by machining. These days, forging process is tried to be employed in manufacturing the shaft for productivity. In this study, the dimensional inaccuracy of straightness is studied and the underfill is not focused because the shaft shape is simple and the load capacity of press is sufficient. The straightness and concentricity of the shaft is important for the operation of a laser printer. Many design parameters such as preform shapes, tooling dimensions, forging load, and billet geometries may affect on the dimensional accuracy. In the forging process of shafts, a billet which is cut from wires is used. The billet, therefore, may be a little bit curved but not always straight. The elastic recovery is considered to cause the dimensional inaccuracy. Therefore, the effect of the forging load on the elastic recovery and straightness is investigated through the finite element analyses using DEFORM-3D and ABAQUS.

• 소성∙가공
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• 제23권6호
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• pp.376-379
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• 2014

During roll forming a sheet metal is continuously and progressively formed into a product of the required cross-section and longitudinal shape. An example product is a circular tube with a required diameter, wall-thickness and straightness. Roll forming occurs by passing the sheet through a series of forming rolls that are arranged in tandem. Each pair of forming rolls in the roll forming line plays a particular role in obtaining the required cross-section and longitudinal shape in the product. In recent years, that process is often applied to car body parts by automotive industries. In the current study, an optimal model design and proper roll-pass sequences as well as the number of forming rolls and bending angles were used to produce a sill side. The effects of the process parameters on the final shape formed by roll forming defects were evaluated.

• 대한기계학회논문집A
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• 제21권11호
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• pp.1827-1836
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• 1997

In this paper, the clamping type forging of helical gears has been investigated. Clamping type forging is an operation in which the product is constrained to extrude sideways through an orifice in the container wall. Punch is cylindrical shaped. The punch compresses a cylindrical bilet placed in a die insetr. As a consequence the material flows in a direction perpendicular to that of punch movement. The forging has been analysed by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, an involute curve has been introduce to re4present tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, helix angle, friction factor and initial height of billet on the forging of helical gears. Some firgiing experiments were catrried out with aluminium alloy to show the validity of the analysis. Good agreement was found between the predicted values of the forging load and obtained from the experimental results.

• 소성∙가공
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• 제12권8호
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• pp.702-709
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• 2003

In the automotive industry hydroforming of sheet metal pairs have received special attention because materials for various sheet metal components of vehicles have changed into the high strength steel, aluminum, and titanium blank having low formability. Uniform deformation over the whole region is a main advantage in the sheet hydroforming process. Because upper and lower parts could be produced simultaneously with one tool, hydroforming of sheet metal pairs is competitive in reducing the lead-time and development cost. In this paper, the multi-stage hydroforming process of sheet pair is proposed in order to increase the formability of a structural part like the oil pan shape. The upper die for forming oil pan shape is divided into two parts which can move separately. By the finite element simulation, the design parameters such as geometry of the tool and detailed specification of hydraulic pump were calculated and verified. For the strict comparison of the proposed process, the blank holding force is kept to a constant value during deformation by hydraulic valve. The deformed shape and strain distribution of the manufactured parts with the proposed process are compared with the results of simulation. In the multi-stage hydroforming process, maximum thickness strain was improved by more than 30 percent.

• 소성∙가공
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• 제26권6호
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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.

• 열처리공학회지
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• 제9권3호
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• pp.177-186
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• 1996

Surface alloying of Ti alloy by $CO_2$ laser is able to produce few hundred micrometers thick TiN or TiC surface-alloyed layer with high hardness on the substrate by injecting reaction gas($N_2$ or $CH_4$). Laser surface alloying by means of process control is in many applications essential in order to obtain predictable hardening layer. This research has been investigated the effect of such parameters on TiN and TiC gas alloying of Ti-6Al-4V alloy by $CO_2$ laser. The maximum surface hardness of TiN layer was obtained 1750Hv on the conditions of 0.8kW laser power, 0.8m/min scanning speed and 100% $N_2$ atmosphere. However, the maximum hardness of TiC formation layer after laser treatment was about 630Hv. As scanning speed was increased, the hardness and depth of these layers were decreased at constant laser power.

• 한국산학기술학회논문지
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• 제5권5호
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• pp.442-446
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• 2004

스웨이징(swaging)제조 공정의 컴퓨터 시뮬레이션에 관한 연구를 수행하기 위하여 상용 소프트웨어를 사용하였다. 시행오차를 통하여 획득한 경험에 기반을 두어 튜브 스웨이징 공정의 시뮬레이션이 이루어졌으며, 변형 경화 지수(strain hardening exponent) n과 소성계수(plastic modulus) K는 튜브재료의 실제 인장 측정 시험을 통하여 얻어졌다. 두 종류의 서로 다른 다이와 튜브 형상을 사용하여 비교하였다. 전처리는 HyperMesh(r), 해석은 LS-DYNA(r), 후처리는 LS-TAURUS(r)를의 상용 소프트웨어를 사용하였으며, 본 연구에서 얻어진 결과들을 문헌에서 이용 가능한 결과들과 비교하였다.

• ETRI Journal
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• 제41권3호
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• pp.396-407
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• 2019

Laser-assisted bonding (LAB) is an advanced technology in which a homogenized laser beam is selectively applied to a chip. Previous researches have demonstrated the feasibility of using a single-tier LAB process for 3D through-silicon via (TSV) integration with nonconductive paste (NCP), where each TSV die is bonded one at a time. A collective LAB process, where several TSV dies can be stacked simultaneously, is developed to improve the productivity while maintaining the reliability of the solder joints. A single-tier LAB process for 3D TSV integration with NCP is introduced for two different values of laser power, namely 100 W and 150 W. For the 100 W case, a maximum of three dies can be collectively stacked, whereas for the 150 W case, a total of six tiers can be simultaneously bonded. For the 100 W case, the intermetallic compound microstructure is a typical Cu-Sn phase system, whereas for the 150 W case, it is asymmetrical owing to a thermogradient across the solder joint. The collective LAB process can be realized through proper design of the bonding parameters such as laser power, time, and number of stacked dies.