• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.6
• /
• pp.1-8
• /
• 2016

As demand for paper cups markedly increases, this has brought about a requirement to develop fast paper cup forming machines. However, the fast manufacturing speed of these machines causes faults to occur more frequently in the final product. To reduce the possibility of producing faulty products, it is necessary to develop technologies to monitor the manufacturing process and diagnose the machine status. In this research, we selected the main driving axis of the forming machine for fault diagnosis. We searched the states of rotational elements related to the driving axis and suggested a fault diagnostic system based on spectrum analysis consisting of a real-time data acquisition device, accelerometers, and a diagnosis algorithm. To evaluate the developed fault diagnostic system, we performed experiments using a test station which resembles the actual paper cup forming machine. As a result, we were able to confirm that the proposed system was sufficiently feasible to diagnose any abnormalities in the operation of the paper cup forming machine.

• Korean Journal of Materials Research
• /
• v.16 no.2
• /
• pp.111-115
• /
• 2006

High-finned tubes have good thermal conductivity and have better cooling efficiency than plain tubes or low-fined tubes due to bigger air contact area. During high-fined tubes are manufactured by roll forming, the main technique is illustrated to optimizing primary material(copper pipe), optimized die matrix designing technique for roll forming, control manufacturing speed to develop productivity etc. In this study, a roll forming system was developed in oder to produce high-finned tube. Also a multi-step roll forming die was designed & built to produce high-finned tube that has over 10 mm fin height. And then, roll forming test using copper pipe was performed to produce high-finned tube. Roll forming process for producing highfinned tube was optimized by analyzing and adjusting misrostructure, hardness, and surface roughness of roll formed high-fined tube.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2011.06a
• /
• pp.203-204
• /
• 2011

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.15 no.1
• /
• pp.95-102
• /
• 2016

Wrinkle, spring-back, and fracture are major defects frequently found in the sheet metal forming process, and the reduction of such defects is difficult as they are affected by uncontrollable factors, such as variations in properties of the incoming material and process parameters. Without any countermeasures against these issues, attempts to reduce defects through optimal design methods often lead to failure. In this research, a new multi-attribute robust design methodology, based on the Mahalanobis Taguchi System (MTS), is presented for reducing the possibilities of wrinkle, spring-back, and fracture. MTS performs experimentation, based on the orthogonal array under various noise conditions, uses the SN ratio of the Mahalanobis distance as a performance metric. The proposed method is illustrated through a robust design of the sheet metal forming process of a cross member of automotive body.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2001.04a
• /
• pp.996-999
• /
• 2001

This study is the election of optimum forming condition for RP system using ADS. Program using ADS reduces the required time for feedback between design and manufacturing of workpiece. When we produce rapid prototype using RP system, we investigate the relationship between Facetres in system variable number of AutoCAD and circularity of rapid prototype, and we will find optimum forming condition in RP system.

• Special Issue of the Society of Naval Architects of Korea
• /
• 2011.09a
• /
• pp.32-35
• /
• 2011

Template has been widely used for hull forming process in most of shipyards. It is used to estimate the curvature of deformed shape in comparison with design shape. SHI (Samsung Heavy Industry) had used AutoKon system for ship manufacturing design in the past. The AutoKon used the global coordinate system of ship (frame, water line and so on) to create template data. It brought the mismatched angles between templates and a curved shell plate. The mismatched angle is measured by forming worker to place template on shell forming stage. However, the mismatched angle is difficult to place template with exactly required angle because the shell plates have various curvature and size. It causes incorrect shape of formed shell plates. The attached angle of template should be 90 degree to place template easily on forming shell plates. Currently, SHI has been applied GSCAD for ship manufacturing design process which is 3D solid modeling system. The GSCAD is the rule-based system which can automate 3D modeling and control the manufacturing data by rule. The rule can easily provide methods to create and automate template object with regular attached angle in comparison with AutoKon system. Therefore, SHI developed new template rule which it can automatically create template object with regular attached angle in GSCAD.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2004.10a
• /
• pp.405-408
• /
• 2004

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2004.10a
• /
• pp.184-187
• /
• 2004

The sheet parts are formed with dies conventionally. But this conventional forming process is not suited to small volume and varied production for the reason of high cost. For the solution of this problem, a new forming process, which is called CNC incremental sheet forming, is being introduced. This process can form sheet parts without die, and is very well suited to small volume and varied production in space flight and automobile. In this paper, dieless CNC forming system based on a machining center is developed. A special device to grasp and pull the blank sheet built in the machining center and tool path generation S/W from STL file of 3-D model are developed. Several sheet parts are incrementally formed to verify the effectiveness of the developed system.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.12 no.6
• /
• pp.69-76
• /
• 2013

This paper presents the development of the FCF method for the manufacturing of final products using numbers related to the minimum amount of work. The utilized product is a drum clutch, which is part of the transmission of an automobile. A double acting press is secured first and a prediction of the forming load on the practical material is made through an experiment with a plasticine model. Also, a finite element simulation using product shape and properties is performed, as well as a press experiment. A double acting press is manufactured that is suitable for a double acting experiment with a conventional hydraulic press(200 tons). A peripheral device for the press is additionally designed for experimental purposes. And, the press has as its essential points the drive speed, stroke control, etc., all of which influence the forming and is modified. Especially, a laser system is used for velocity measurement of two punches. The forming load of a practical material is predicted in order to derive a forming load formula for cold conditions on the basis of approximate similarity theory. Finite element analysis of the relative velocity ratio(RVR), etc., for most suitable flow defect(unfilling, etc.) prevention is achieved as well. The results are verified through a press experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.400-403
• /
• 2008

For the effective manufacture of doubly curved metal plates, a line array roll set (LARS) process is proposed. The suggested process utilizes a pair of upper and lower symmetric roll assemblies. In the process, the initial plate is progressed into the final shape in a stepwise or pathwise manner according to the basic principle of the incremental forming process. The deformation proceeds simultaneously in the longitudinal and transverse directions. Moreover, there is a close correlation between the deformation in the longitudinal direction and that in the transverse direction of the plates. Therefore, the finally formed shape in the incremental forming process is strongly dependent upon process conditions, such as the forming path and the forming increment. The manufacturing of arbitrary doubly curved plates with various curvatures is not an easy task because of such complicated behaviors of the plate; thus, the forming schedules for the desired shape should be carefully and accurately designed. In this study, several experiments with the LARS system were carried out for the fundamental investigation on process design for manufacturing of doubly curved plates.