• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.35-38
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• 2004

In general, tube drawing process is composed of two steps, so called first drawing and second drawing. Drawing cracks are mainly occurred during the 2nd drawing process due to the improper drawing process. In order to analyze the reduction distribution in successive two-step drawing process, tube drawing process was simulated by finite element method. From the finite element analysis, the balance between first and second reduction is proved to be important factor to prevent drawing cracks. Hence the numerical expression was developed for tube drawing process to distribute even strain and criteria curves that can predict the safe drawing region were also proposed using this numerical formula.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.671-677
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• 2004

For the large reduction in tube cross section, the tube drawing process is usually performed by two successive passes, so called first drawing and second drawing. In multi-pass drawing process, the reduction balance is important to prevent drawing cracks. Therefore in this study, the model for uniform reduction distribution in two-pass drawing process has been developed on the basis of cross sectional variation of drawn tube. For the given product geometry the model provides optimal diameter and thickness that can evenly distribute drawing reductions. The capability of model is well confirmed by finite element analysis of tube drawing process. Criteria curves at various limit strains to determine whether the drawn tube would fail during drawing process are also proposed by using newly developed model.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.10
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• pp.1179-1185
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• 2011

Cold and hot-rolled carbon steel sheets are commonly used in railroad cars or commercial vehicles such as the automobile. The sheets used in these applications are mainly fabricated by spot welding, which is a type of electric resistance welding. However, the fatigue strength of a spot-welded joint is lower than that of the base metal because of high stress concentration at the nugget edge of the spot-welded part. In particular, the fatigue strength of the joint is influenced by not only geometrical and mechanical factors but also the welding conditions for the spot-welded joint. Therefore, there is a need for establishing a reasonable criterion for a long-life design for spot-welded structures. In this thesis, ${\Delta}P-N_f$ relation curves have been used to determine a long-life fatigue-design criterion for thin-sheet structures. However, as these curves vary under the influence of welding conditions, mechanical conditions, geometrical factors, etc. It is very difficult to systematically determine a fatigue-design criterion on the basis of these curves. Therefore, in order to eliminate such problems, the welding residual stresses generated during welding and the stress distributions around the weld generated by external forces were numerically and experimentally analyzed on the basis of the results, reassessed fatigue strength of gas welded joints.

• Journal of the Institute of Convergence Signal Processing
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• v.19 no.2
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• pp.61-67
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• 2018

Welding preheating means that the surface of the base material to which the metal is welded before the main welding is heated to a constant temperature. It prevents the cracks of the adjacent influences such as reduction of material hardening degree by controlling the cooling rate, suppression of segregation of impurities, prevention of thermal deformation, and moisture removal. For this reason, it is a necessary operation for high quality welding. Induction heating is an efficient heating method that converts electric energy into heat energy by applying electromagnetic induction phenomenon. Compared with combustion heat generated by gas and liquid, it is clean, stable, and economical as well as rapid heating. It can be heated regardless of the shape, depth and material of the heating body by modifying the shape of the frequency and the coil with a simple structure. In this paper, we implemented a low frequency welding preheating system using induction heating technique and observed the temperature changes of coil resistance, inductance and automotive transmission parts according to the height of each transmission in winding coil for three kinds of automotive transmission parts. We confirmed that the change of current is a very important factor in the low frequency heating.

• Journal of Electrical Engineering and Technology
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• v.13 no.5
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• pp.2059-2066
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• 2018

This study explored the feasibility of utilizing an SWCNT-coated fabric sensor for the development of a wearable motion sensing device. The extent of variation in electric resistance of the sensor material was evaluated by varying the fiber composition of the SWCNT-coated base fabrics, attachment methods, number of layers, and sensor width and length. 32 sensors were fabricated by employing different combinations of these variables. Using a custom-built experimental jig, the amount of voltage change in a fabric sensor as a function of the length was measured as the fabric sensors underwent loading-unloading test with induced strains of 30 %, 40 %, and 50 % at a frequency of 0.5 Hz. First-step analysis revealed the following: characteristics of the strain-voltage curves of the fabric sensors confirmed that 14 out of 32 sensors were evaluated as more suitable for measuring human joint movement, as they yield stable resistance values under tension-release conditions; furthermore, significantly stable resistance values were observed at each level of strain. Secondly, we analyzed the averaged maximum, minimum, and standard deviations at various strain levels. From this analysis, it was determined that the two-layer sensor structure and welding attachment method contributed to the improvement of sensing accuracy.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.32-32
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• 2009

Electric Resistance Welding (ERW) process is the most efficient process to manufacture the linepipe. To develop the high performance ERW linepipe using the high strength and the high alloy steels, the modulation of input power waveform such as sinusoidal waveform is introduced because the conventional ERW technology is not sufficient enough to produce the high quality linepipe due to its strength and high alloy contents (high Ceq). In this article, the material used for the experiment was API X60 with 8.2mm thickness, and ERW simulator at POSCO was used to develop a waveform control system for the power modulation. The frequency of power modulation was varied from 50Hz to 150Hz with the fixed amplitude of ${\pm}2%$ power. The non-modulated power input and the modulated power input cases are conducted to demonstrate the variation of the narrow gap length and the arcing frequency due to power modulation. From results of the non-modulated power input case, the excessive power causes the longer narrow gap length and the low arcing frequency due to the large heat input and the strong electro magnetic force that increase the weld defect. On the contrary, the small narrow gap length and the high arcing frequency reduce the weld defect. After modulating the power input with 50Hz and 100Hz at the fixed power, the arcing frequency increases, but the narrow gap length does not change much. The high arcing frequency prevents the formation of weld defect because the sweeping frequently cleans the oxides on the narrow gap edges. As a result, the manufacturing window can be expanded by the power modulation that provides the stable ERW process for the quality improvement of the linepipe made from the high strength/high alloy steels.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.239-242
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• 2005

In the roll forming, a flat strip is progressively deformed by feeding it through a series of rotating rolls. There are various layouts for the tube toll-forming stages. The process sequences are as follows: leveling, roll-forming, welding, bead removing, seam annealing, cooling, sizing and cutting. Electric resistance welded(ERW) tubes have been widely used for the machinery parts, especially for hydroformed automotive parts. However conventional ERW tubes do not have a high formability because of hardening of welded portion by rapid cooling. Moreover the decrease in thickness of the welded portion during the grinding of the inner and outer bead may reduce the formability of the tube. In case of applying the tubular parts without grinding the bead, the flow of the fluid can be prevented due to the turbulent flow induced by the inner bead. In attempt to determine the optimal bead grinding amount in the roll forming process, in the present paper, the effects of the removal depth and width of the inner beads on the hydroformability are analyzed by the finite element simulation.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.5 s.170
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• pp.152-158
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• 2005

Inner structured and bonded panel, or ISB Panel, as a kind of sandwich type panel, has metallic inner structures which have low relative density, due to their dimensional shape of metal between a pair of metal skin sheets or face sheets. Previous works showed that ISB panels containing inner structures formed as repeated pyramidal shapes saved weight up to $60\%$ in condition of same stiffness comparing with solid sheet. In this work, woven metal is adapted to inner structures replacing pyramidal structures. The test specimens of ISB panel containing woven metal made by multi-point electric resistance welding and 3-point bending test have been carried out. The results of experiments and comparisons of process parameters, stiffness and failure mode are discussed.

• Journal of the Microelectronics and Packaging Society
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• v.30 no.2
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• pp.33-42
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• 2023

Throughout all industries, eco-friendliness is being promoted worldwide with focus on suppressing the environmental impact. With recent international environment policies and regulations supported by government, the electric vehicles demand is expected to increase rapidly. Battery system itself perform an essential role in EVs technology that is arranged in cells, modules, and packs, and each of them are connected mechanically and electrically. A multifaceted approach is necessary for battery pack bonding technologies. In this paper, pros and cons of applicable bonding technologies, such as resistance welding, laser and ultrasonic bonding used in constructing electric vehicle battery packs were compared. Each bonding technique has different advantages and limitations. Therefore, several criteria must be considered when determining which bonding technology is suitable for a battery cell. In particular, the shape and production scale of battery cells are seen as important factors in selecting a bonding method. While dealing with the types and components of battery cells, package bonding technologies and general issues, we will review suitable bonding technologies and suggest future directions.

• Journal of the Korea institute for structural maintenance and inspection
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• v.24 no.6
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• pp.67-76
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• 2020

This paper reports an experimental study to evaluate the flexural behavior of concrete beams reinforced using Fe based shape memory alloy (Fe-SMA) bars. For the experiment, a concrete beam of 200mm×300mm×2,200mm was produced, and a 4% pre-strained Fe-SMA bar was used as a tensile reinforcement. As experimental variables, type of tensile reinforcement (SD400, Fe-SMA), reinforcement ratio (0.2, 0.39, 0.59, 0.78), activation of Fe-SMA (activation, non-activation), and joint method of Fe-SMA bar (Continuous, welding, coupler) were considered. The electric resistance heating method was used to activate the Fe-SMA bar, and a current of 5A/㎟ was supplied until the specimen reached 160℃. After the upward displacement of the specimen due to the camber effect was stabilized, a three-point flexural loading experiment was performed using an actuator of 2,000 kN capacity. As a result of the experiment, it was found that the upward displacement occurred due to the camber effect as the Fe-SMA bar was activated. The specimen that activated the Fe-SMA bar had an initial crack at a higher load than the specimen that did not activate it. However, as with general prestressed concrete, the effect of the prestress by Fe-SMA activation on the ultimate state of the beam was insignificant.