• Journal of Korean Society of Industrial and Systems Engineering
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• v.38 no.4
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• pp.177-183
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• 2015

Incremental sheet metal forming is a manufacturing process to produce thin parts using sheet metals by a series of small incremental deformation. The process rarely needs dedicated dies and molds, thus, preparation time for the process is relatively short as to be compared to conventional metal forming. Spring back in sheet metal working is very common, which causes critical errors in dimensions. Incremental sheet metal forming is not fully investigated yet. Hence, incremental sheet metal forming frequently produces inaccurate parts. This paper proposes a method to minimize dimensional errors to improve shape accuracy of products manufactured by incremental forming. This study conducts experiments using an exclusive incremental forming machine and the material for these experiments are sheets of aluminum AL1015. This research defines a process parameter and selects a few factors for the experiments. The parameters employed in this paper are tool feed rate, tool diameter, step depth, material thickness, forming method, dies applied, and tool path method. In addition, their levels for each factor are determined. The plan of the experiments is designed using orthogonal array $L_8$ ($2^7$) which requires minimum number of experiments. Based on the measurements, dimensional errors are collected both on the tool contacted surfaces and on the non-contacted surfaces. The distances between the formed surfaces and the CAD models are scanned and recorded using a commercial software product. These collected data are statistically analyzed and ANOVAs (analysis of variances) are drawn up. From the ANOVAs, this paper concludes that the process parameters of tool diameter, forming depth, and forming method are the significant factors to reduce the errors on the tool contacted surface. On the other hand, the experimental factors of forming method and dies applied are the significant factors on the non-contacted surface. However, the negative forming method always produces better accuracy than the positive forming method.

• Korean Journal of Metals and Materials
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• v.46 no.12
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• pp.800-808
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• 2008

Heat treatment is an important step for tool manufacture, but unavoidably generates dimensional distortion. This study investigated the continuous dimensional change and the anisotropic behavior of STD11 tool steel during austenitizing and tempering heat treatment especially using quenching dilatometer. Dilatometric results represented that the dimensional change along longitudinal direction was larger than that along transverse direction. Anisotropic phase transformation strain was produced in forged STD11 tool steel during heat treatment. Anisotropic dimensional change increased with increasing austenitizing temperature. After tempering, anisotropic distortion was partially reduced. FactSage thermodynamic equilibrium phase simulation and microstructural observation (FE-SEM, TEM) showed that large ($7{\sim}80{\mu}m$) elongated $M_7C_3$ carbides could be formed along rolling direction. The resolution of elongated carbides during austenitizing was found to be related with the change of martensite transformation temperature after heat treatment. Anisotropic size change of STD11 tool steel was mainly attributed to large elongated carbides produced during rolling process. Using dilatometric and metallographic examination, the possible mechanism of the anisotropic size change was also discussed.

• Korean Journal of Materials Research
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• v.22 no.3
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• pp.123-129
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• 2012

The microstructures and mechanical properties of friction stir welded lap joints of Inconel 600 and SS 400 were evaluated; friction stir welding was carried out at a tool rotation speed of 200 rpm and welding speed of 100 mm/min. Electron back-scattering diffraction and transmission electron microscopy were introduced to analyze the grain boundary characteristics and the precipitates, respectively. Application of friction stir welding was notably effective at reducing the grain size of the stir zone. As a result, the reduced average grain size of Inconel 600 ranged from $20{\mu}m$ in the base material to $8.5{\mu}m$ in the stir zone. The joint interface between Inconel 600 and SS 400 showed a sound weld without voids and cracks, and MC carbides with a size of around 50 nm were partially formed at the Inconel 600 area of lap joint interface. However, the intermetallic compounds that lead to mechanical property degradation of the welds were not formed at the joint interface. Also, a hook, along the Inconel 600 alloy from SS 400, was formed at the advancing side, which directly brought about an increase in the peel strength. In this study, we systematically discussed the evolution of microstructures and mechanical properties of the friction stir lap joint between Inconel 600 and SS 400.

• Korean Journal of Materials Research
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• v.28 no.7
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• pp.405-410
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• 2018

TiN and CrN thin films are among the most used coatings in machine and tool steels. TiN and CrN are deposited by arc ion plating(AIP) method. The AIP method inhibits the reaction by depositing a hard, protective coating on the material surface. In this study, the characteristics of multi-layer(TiN/CrN/TiN(TCT), CrN/TiN/CrN(CTC)) are investigated. For comparison, TiN with the same thickness as the multilayer is formed as a single layer and analyzed. Thin films formed as multilayers are well stacked. The characteristics of micro hardness and corrosion resistance are better than those of single layer TiN. The TiN/CrN peak is confirmed because both TCT and CTC are formed of the same component(TiN, CrN), and the phase is first grown in the (111) direction, which is the growth direction. However, the adhesion and abrasion resistance of the multilayer films are somewhat lower.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.294-297
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• 2007

Due to their low densities and high specific strength and stiffness, magnesium alloy sheets are very attractive lightweight materials for automotive and electrical products. However, the magnesium alloy sheets are usually formed at elevated temperature because of their poor formability at room temperature. To use of the magnesium alloy sheets for an industrial, their mechanical properties at elevated temperature and appropriate forming process conditions have to be developed. In this study, non-isothermal simulations of a square cup drawing from magnesium alloy sheets have been conducted to evaluate a proper forming process conditions such as the tool temperature, the tool shoulder radius, friction between the blank and the tools. According to this study, appropriate forming process conditions of square cup drawing at elevated temperature from magnesium alloy sheets are suggested.

• Tribology and Lubricants
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• v.19 no.3
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• pp.151-158
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• 2003

In metal cutting at the tool-chip interface, friction generates considerable amount of heat. Thus, the knowledge of wear properties of cutting tool material in high temperature has been as one of important factors in need of clarification. The authors presented the wear properties of 5%Co-5%V-1%Nb high speed steel, fabricated by powder metallurgy, in room temperature in previous articles. The objective of this paper is to clarify the effects of temperature on its wear properties. Wear tests in sliding conditions under various temperatures have been conducted using the pin-on-disc type wear test machine. The results indicate that the wear properties of 5%Co-5%V-1%Nb high speed steel in high temperature as well as in room temperature are excellent. It may be deduced that the oxide layer formed on worn surface at high temperature is stable enough to prevent wear due to the high temperature strength of its matrix.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.327-330
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• 2004

Laser aided direct metal deposition (LADMD) process offers the ability to make a metal component directly from 3-D CAD dimensions. A 3-D object can be formed by repeating laser cladding layer by layer. The key of the build-up mechanism is the effective control of powder delivery and laser power to be irradiated into the melt-pool. A feedback control system using optical sensors is introduced to control laser power and powder mass flow rate. Using H13 tool steel and $CO_2$ laser system, comprehensive analysis are executed to test the efficiency of the system. In addition, the dimensional characteristics of directed deposited material are investigated with the parameters of deposition thickness, laser power, traverse speed and powder mass flow rate.

• Transactions of Materials Processing
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• v.16 no.5 s.95
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• pp.401-405
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• 2007

Due to the low densities and high specific strength and stiffness, magnesium alloy sheets are very attractive lightweight materials for automotive and electrical products. However, the magnesium alloy sheets should be usually formed at elevated temperature because of their poor formability at room temperature. For the use of the magnesium alloy sheets for an industrial, their mechanical properties at elevated temperature and appropriate forming process conditions have to be developed. In this study, non-isothermal simulation of a square cup drawing of magnesium alloy sheets have been conducted to evaluate a proper forming process conditions such as the tool temperature, the tool shoulder radius, friction between the blank and the tools. According to this study, appropriate forming process conditions of square cup drawing at elevated temperature from magnesium alloy sheets are suggested.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.3
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• pp.83-91
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• 1999

In this paper, we suggest a virtual machining system that can simulate cutting forces of ball end milling at the stage of part design. Cutting forces, here, are estimated from the machanistic model that uses the concept of specific cutting farce coefficient. To this end, we need undeformed chip thickness which is used for calculating chip load. It is derived from the Z-map data of a CAD model. That is, chip load is the height difference between the cutting tool and the workpiece at an arbitrary position. The tool contact point is referred from the cutter location data. On the other hand, the workpiece height is acquired from the Z-map model of a CAD data. From the experimental verification, we can simulate machining process effectively to the slot and the side cutting of ball end mill.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.1
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• pp.33-39
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• 2007

One of the most important processes is the face milling in processing task. It makes the smooth surface of processed goods. In processing stage, the formation of burr is inevitable. The formed burr decreases a detailed drawing and effects the safety of workers. So, it causes a deburring process for removing and a bottle-neck condition. Therefore, the study which can minimize the generation of burr is needed. In this paper, complex feature, such as line, arc, circle, spline is studied more reality than any other papers. And also, the algorithm which can predict the path of generated burr is established. Moreover, the finality goal is that the system which can produce tool-path minimized has to be developed.