• Proceedings of the Korean Society of Precision Engineering Conference
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• 한국정밀공학회 2007년도 추계학술대회 논문집
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• pp.343-344
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• 2007

• Transactions of Materials Processing
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• 제9권3호
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• pp.265-273
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• 2000

The conventional and new forging processes of the power steering worm blank are analyzed by the rigid-plastic finite element method. The conventional process contains three stages such as indentation, extrusion and upsetting, which was designed by a forming equipment expert. Process conditions such as reduction in area, semi-die angle and upsetting ratio are considered to prevent internal or geometrical defects. The results of simulation of the conventional forging process are summarized in terms of deformation patterns, load-stroke relationships and die pressures for each forming operation. Based on the simulation results of the current three-stage, the power steering worm blank forging process for improving the conventional process sequence is designed. Die pressures and forming loads of proposed process are within limit value which is proposed by experts and the proposed process is found to be proper for manufacturing the power steering worm blank.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.329-332
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• 2006

$Conform^{TM}$, a continuous extrusion forming process can produce a variety of very long extruded products such as aluminum alloyed wires, strips and profiles, hollow sectioned tubes, coated wires used in the current forming industry. This process has some advantages like as superiority of pre-heating free, availability of high extrusion ratio and continuous forming without stroke limit. But it is still difficult to analyze the realistic model of the process. In this study the analysis using two-dimensional model of $Conform^{TM}$ process together with several parametric investigations on the heat transfer are carried out by FEA code DEFORM $^{TM}2D$. In spite of simple model the results of analysis shows a good guidance to design the real process.

• Journal of the Korean Society for Precision Engineering
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• 제14권10호
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• pp.127-134
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• 1997

열가소성 복합재료는 고상 성형법에 의해 저렴한 가격으로 부피가 튼 제품의 제조에 널리 사용될 수 있어 아주 좋은 전망을 가지고 있다. 그러나, 이러한 재료의 성형성에 대해선 아직 잘 알려지지 않았다. 본 연구의 첫번때 주안점은 2축 인장성형시 성형성에 대한 연구에 두었다. 실험에 사용된 재료는 임의의 방향으로 위치한 유리 섬유를 중량비로 20, 35, 40% 함유한 폴리프로필렌이다. 성형시험은 75 .deg. C 에서 150 .deg. C 사이의 온도에서 행했으며, 펀치 속도는 0.01cm/sec 와 1cm/sec 에서 행했다. 2축 인장성형에서 측정된 한계 변형률(Limiting Strain)은 Marciniak 불완전성 (Imperfection) 이론에 근거한 예견치외 비교되었다. 이론치와 실험치가 잘 일치함을 보였으며, 성형한계선도(Forming Limit Diagram) 로써 결과들을 요약하였다. 성형한계 변형률은 성형온도와 성형속도에 의해 크게 영향을 받는다는 것을 보인다. 이러한 결과들은 적절한 성형조건이 선택된다면 열가소성 복합재료의 인장성형은 실제 상업적으로 이용하기에 충분한 성형성을 갖는다는 것을 보인다.

• Transactions of the Korean Society of Mechanical Engineers A
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• 제36권4호
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• pp.413-420
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• 2012

An aluminum foil-laminated sheet is a laminated steel sheet on which aluminum foil is adhesively bonded. It is usually used on the outer panel of home appliances to provide an aluminum feeling and appearance on the surface of the product. The delamination of aluminum foil is one of the main problems during the stretch forming process. The purpose of this study is was to determine the delamination limit of an aluminum foil-laminated sheet in the stretch forming process. The delamination was dependent on the bonding strength between aluminum foil and steel sheet. The fracture behavior of the interface between the aluminum foil and the steel sheet was described by a cohesive zone model. A finite element was conducted with the cohesive zone model to analyze the relationship between the delamination limit and the bonding strength of the interface. The interface bonding strength was evaluated by lap shear and T-peel test. The delamination limit of the aluminum foil-laminated sheet was determined by using the bonding strength of the steel sheet. The delamination limit was also verified by the Erichsen test.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• 제37권9호
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• pp.939-945
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• 2009

The dome stretching tests and tension tests have been performed to obtain a forming limit curve(FLC) for the copper alloy which is used for manufacturing the regenerative cooling thrust chamber. For experimental investigation of the forming limit curve, we have used in-plane tension specimen to obtain tension-compression strain state as well as out-of-plane specimen to obtain tension-tension strain state through dome stretching test. All specimens were divided into longitudinal and transverse directions according to the orientation of test specimen. The test results showed that in the tension-tension region, copper alloy revealed a maximum major strain of 62.3% and a maximum minor strain of 58.6%. In the tension-compression region, the maximum major strain and the maximum minor strain were measured to be 60.5% and 25.8%, respectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 한국소성가공학회 2001년도 추계학술대회 논문집
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• pp.358-363
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• 2001

In sheet metal forming, material cost and die process number are very important manufacturing process for an economic die-making. In this report on implemention of a computer aided sheet-metal nesting program for nesting of irregular shaped blank on ae coil strip of limit width. The result of the computing in the nesting program reduced material cost and die process number.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 한국소음진동공학회 2014년도 추계학술대회 논문집
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• pp.698-698
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• 2014

According to the analysis of special medical examination and work environment monitoring data, the rate of C1 and D1 on noise hazard exceeded 90% among those of total hazardous factors. The rate of company exceeding noise exposure limit was also more than 90%. The analysis result shows that main ages diagnosed with C1 and D1 was age of 50s. The majority scale company having workers diagnosed with C1 and D1 was the companies employing 5~49 workers. Types of industries which have a large number of companies exceeding noise exposure limit were automobile and trailer manufacturing, metal processing industry and primary metal manufacturing. A large number of work processes exceeding noise exposure limit were forming and processing work, cutting and bending work and grinding. To reduce the number of company exceeding noise exposure limit, the reduction counterplan should be focused on the type of industry and the work process which exceeded noise exposure limit frequently. However, the reduction counterplan is preemptively necessary to the type of industry and the work process which exceeded noise exposure limit consecutively if the purpose of reduction counterplan is not to merely reduce the number of company exceeding noise exposure limit but to abate workers' suffering from noise.

• Transactions of the Korean Society of Mechanical Engineers A
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• 제35권8호
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• pp.889-897
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• 2011

In this work, we investigated the theoretical forming limit models for Zircaloy-4 and Zirlo used for spacer grid of nuclear fuel rods. Tensile and anisotropy tests were performed to obtain stress-strain curves and anisotropic coefficients. The experimental forming limit diagrams (FLD) for two materials were obtained by dome stretching tests following NUMISHEET 96. Theoretical FLD depends on FL models and yield criteria. To obtain the right hand side (RHS) of FLD, we applied the FL models (Swift's diffuse necking, M-K theory, S-R vertex theory) to Zircaloy-4 and Zirlo sheets. Hill's local necking theory was adopted for the left hand side (LHS) of FLD. To consider the anisotropy of sheets, the yield criteria of Hill and Hosford were applied. Comparing the predicted curves with the experimental data, we found that the RHS of FLD for Zircaloy-4 can be described by the Swift model (with the Hill's criterion), while the LHS of the FLD can be explained by Hill model. The FLD for Zirlo can be explained by the S-R model and the Hosford's criterion (a = 8).

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.218-221
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• 2008

Hot Press Forming (HPF), an advanced sheet forming method in which a high strength part can be produced by forming at high temperature and rapid cooling in dies, is one of the most successful forming process in producing components with complex geometric shape, high strength and a minimum of springback. In order to obtain effectively and accurately numerical finite element simulations of the actual HPF process, the flow stress of a boron steel in the austenitic state at elevated temperatures has been investigated with Gleeble system. To evaluate the formability of the thermo- mechanical material characteristics in the HPF process, the FLDo defined at the lowest point in the forming limit diagrams of a boron steel has been investigated. In addition, the simulation results of thermo-mechanical coupled analysis of an automobile one-piece lower-arm part are compared with the experimental ones to confirm the validity of the proposed simulations.