• 대한기계학회논문집A
• /
• 제38권8호
• /
• pp.899-904
• /
• 2014

자유벌징에 있어서 성형 높이를 최대화하기 위하여 블랭크의 두께 분포를 최적화 하였으며, 등가정하중을 이용한 구조최적화법을 사용하였다. 두께형상은 부드러운 곡선으로 나타내기 위하여 베지어곡선을 사용하였고 제어점의 위치가 설계변수이며, 최대 변형률을 일정 값으로 제한하였다. 사용된 소재는 인코넬 718 이며 최적화된 두께분포로 가공된 블랭크를 이용한 자유벌징 시험을 수행하여 평판형 블랭크를 사용한 결과보다 22% 더 높은 성형 높이를 얻었다. 최적화결과에서 예측된 변형형상, 정점에서의 변형 경향, 두께분포가 실험에서 얻은 결과와 유사하여 최적화 과정의 유효성을 입증하였고, 최적화 결과가 실제 구현될 수 있음을 검증하였다.

• 소성∙가공
• /
• 제26권5호
• /
• pp.271-276
• /
• 2017

A tee is the most common pipefitting used to combine or divide fluid flow. Tees can connect pipes of different diameters or change the direction of a pipe run. To manufacture tee type of stainless steel pipe, combinations of punch piercing and burr forming have been widely used in the industry. However, such method is considerably time consuming with regard to performing empirical work necessary to attain process conditions to prevent upper end tearing of the tee product and meet target tee height. Numerous experiments have shown that the piercing profile is the main cause of defects mentioned above. Furthermore, the mold design is formed through trial and error according to pipe diameters and changes in requirements. Thus, the objective of this study was to perform piercing and burring process analysis via finite element analysis using DYNAFORM to resolve problems mentioned above. An optimization design method was used to determine the piercing punch profile. Three radii of the piercing punch (i.e., large, small, and joined radii) were selected as design variables to minimize thinning of a tee pipe. Based on results of correlation and multiple regression analyses, we developed a predictive approximation model to satisfy requirements for both thickness reduction and target height. The new piercing punch profile was then applied to actual tee forming using the developed prediction equation. Model results were found to be in good agreement with experimental results.

• 한국구조물진단유지관리공학회 논문집
• /
• 제22권1호
• /
• pp.56-63
• /
• 2018

이 연구에서는 연성중심의 보강을 위하여 벽체의 양단부에서 경계요소를 형성하는 내진 보강공법이 적용된 벽체의 반복 휨 거동을 평가하였다. 벽체 경계요소에서 구속효과를 위한 횡보강은 프리스트레스트 와이어로프를 사용하였다. 주요 변수는 제시된 단면 확대공법의 보강 높이로 하였다. 최소 보강 높이는 보강 벽체와 기존 벽체의 모멘트 분포의 비교로부터 결정하였다. 실험결과, 제시된 보강방법은 벽체의 휨 강성 및 연성향상에 매우 효율적이었는데, 최대내력 시 강성과 최대내력의 80%지점에서 산정한 일손상지수는 무보강 벽체에 비해 각각 평균 46%와 210% 증가하였다. 보강높이가 벽체의 일손상지수 증가에 미치는 영향은 보강높이가 $2.0l_w$ 이상일 때 중요하지 않았다. 보강된 벽체의 휨 내력은 ACI 318-14에서 제안하는 등가응력블록을 통한 예측 값보다 22% 이상 높았다.

• Design & Manufacturing
• /
• 제15권4호
• /
• pp.24-31
• /
• 2021

In this study, an artificial neural network model was constructed to convert CAE analysis data into similar experimental data. In the analysis and experiment, the injection molding data for 50 conditions were acquired through the design of experiment and random selection method. The injection molding conditions and the weight, height, and diameter of the product derived from CAE results were used as the input parameters for learning of the convert model. Also the product qualities of experimental results were used as the output parameters for learning of the convert model. The accuracy of the convert model showed RMSE values of 0.06g, 0.03mm, and 0.03mm in weight, height, and diameter, respectively. As the next step, additional randomly selected conditions were created and CAE analysis was performed. Then, the additional CAE analysis data were converted to similar experimental data through the conversion model. An artificial neural network model was constructed to predict the quality of injection molded product by using converted similar experimental data and injection molding experiment data. The injection molding conditions were used as input parameters for learning of the predicted model and weight, height, and diameter of the product were used as output parameters for learning. As a result of evaluating the performance of the prediction model, the predicted weight, height, and diameter showed RMSE values of 0.11g, 0.03mm, and 0.05mm and in terms of quality criteria of the target product, all of them showed accurate results satisfying the criteria range.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2009년도 추계학술대회 논문집
• /
• pp.332-337
• /
• 2009

Recently, boss and rib test based on backward extrusion process was proposed to quantitative evaluate the interfacial friction condition in bulk forming process. In this test, the tube-shaped punch with hole pressurizes the workpiece so that the boss and rib are formed along the hole and outer surface of the punch. It was experimentally and numerically revealed that the height of boss is higher than that of the rib under the severe friction condition. This work is focused on the effect of the punch design and friction condition on deformation pattern in boss and rib test. From the boss and rib test simulations, it was found that there is slight variation in both the heights of boss and rib according to the length of punch land, nose radius, and face angle. However the hole diameter of the punch and the clearance between the punch and die have a significant influence on the heights of the boss and rib. In addition, the effect of flow stress was also investigated on the deformation patterns through FE simulations.

• Journal of Advanced Marine Engineering and Technology
• /
• 제33권4호
• /
• pp.509-516
• /
• 2009

This paper is the study on improving the coefficient of utilization of material in deep drawing process. Cylindrical cup drawing process is widely used in sheet metal forming process. The blank shape is one of the important things in sheet metal forming process. It is produced for the bridge of blank in a blanking process. The coefficient of utilization of material is much effected by this bridge of blank. This study offered a new process method to reduce the loss of material. The new blank shape offered and manufactured by new process method is investigated by a finite element method and the experiment. Then the wrinkling, the punch load, the thickness distribution is observed. This result is different from the result of circular blank process. And it is got that the Max strain, the wrinkle and the height of the wrinkle are effected by the holding force and the punch load. As a result, if the processing optimum condition is found, the loss of material will be reduced. It is necessary to research systematically about determining the optimum value of process variables.

• 한국정밀공학회지
• /
• 제19권4호
• /
• pp.179-186
• /
• 2002

This paper is the study on improving the coefficient of utilization of material in deep drawing process. Cylindrical cup drawing process is widely used in sheet metal forming process. The blank shape is one of the important things in sheet metal forming process. It is produced for the bridge of blank in a blanking process. The coefficient of utilization of material is much effected by this bridge of blank. This study offered a new process method to reduce the loss of material. The new blank shape offered and manufactured by new process method is investigated by a finite element method and the experiment. Then the wrinkling, the punch load, the thickness distribution is observed. This result is different from the result of circular blank process. And it is got that the Max strain, the wrinkle and the height of the wrinkle are effected by the holding farce and the punch load. As a result. if the processing optimum condition is found, the loss of material will be reduced. It is necessary to research systematically about determining the optimum vague of process variables.

• 소성∙가공
• /
• 제23권3호
• /
• pp.171-177
• /
• 2014

The current collector for the molten carbonate fuel cell (MCFC) which has sheared protrusions is manufactured by the three-stage forming process that integrates slitting, preforming and final forming. Due to the repetition of sheared protrusions, an effective simulation method is required to predict the mechanical behavior. In the current study, a sheet with sheared protrusions was assumed to be an orthotropic plate, which has the same length, width and height. FEM simulations were conducted to evaluate the homogenized properties of the current collector, which has 4 (longitudinal direction) x 4 (transverse direction) sheared protrusions. The simulation model was constructed using hexahedral mesh coarsening. From the verification examples, it was found that the proposed simulation method was efficient within reasonable accuracy. The calculated homogenized properties can be applied to the design of a stack for molten carbonate fuel cells and the prediction of mechanical behavior for other applications.

• 한국소성가공학회:학술대회논문집
• /
• 한국소성가공학회 2006년도 제5회 박판성형 SYMPOSIUM
• /
• pp.55-60
• /
• 2006

Draw-bead is applied to control the material flow in a stamping process and improve the product quality by controlling the draw-bead restraining force (DBRF). Actual die design depends mostly on the trial-and-error method without calculating the optimum DBRF. Die design with the predicted value of DBRF can be utilized at the tryout stage effectively reducing the cost of the product development. For the prediction of DBRF, a simulation-based prediction model of the circular draw-bead is developed using the Box-Behnken design with selected shape parameters such as the bead height, the shoulder radius and the sheet thickness. The value of DBRF obtained from each design case by analysis is approximated by a second order regression equation. This equation can be utilized to the calculation of the restraining force and the determination of the draw-bead shape as a prediction model. For the evaluation of the prediction model, the optimum design of DBRF in sheet metal forming is carried out using response surface methodology. The suitable type of the draw-bead is suggested based on the optimum values of DBRF. The prediction model of the circular draw-bead proposes the design method of the draw-bead shape. The present procedure provides a guideline in the tool design stage for sheet metal forming to reduce the cost of the product development.

• 한국전기전자재료학회논문지
• /
• 제27권4호
• /
• pp.209-216
• /
• 2014

The screen printed technique is one of the electrode forming technologies for crystalline silicon solar cell. It has the advantage that can raise the production efficiency due to simple process. The electrode technology is the core process because the electrode feature is given a substantial factor (for solar cell efficiency). In this paper, we tried to change conditions such as squeegee angle $55{\sim}75^{\circ}$, snap off 0.5~1.75 mm, printing pressure 0.6~0.3 MPa and 1.6~2.0 mm finger spacing. As a result, the screen printing process showed an improved performance with an increased height higher finger height. Optimization of fabrication process has achieved 17.48% efficiency at screen mesh of 1.6 mm finger spacing.