• Journal of the Korean Society for Precision Engineering
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• v.19 no.3
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• pp.152-159
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• 2002

SLA (Stereolithography Apparatus) it a process used to rapidly produce polymer components directly from a computer representation of the part. Though SLA is being recognized as an innovative technology, it still cannot be used to fully practical application since it lacks of dimensional accuracy compared to conventional process. If the shrinkage were perfectly uniform and no distortion took place, excellent part accuracy could still be achieved through and appropriate scaling factor when generating the build file. However, in certain geometries involving intersecting thick and thin sections, nonuniform retrain shrinkage becomes the engine of part distortion. In order to improve the part accuracy of SLA, this paper evaluates how largely each parameter of SLA contributes to the part accuracy and estimates the optimal set of parameter which minimizes the dimension error of the test part, "Slab (100mm$\times$100mm$\times$2mm)"and "scale bar"part. Three control parameters such as critical exposure, generation depth and fill cure depth are used.

• Transactions of Materials Processing
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• v.20 no.2
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• pp.110-117
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• 2011

The purpose of this work is to develop of a press forming process for mobile phone battery cover as an alternative to the current manufacturing process by laser welding. This press forming process consists of a combination of bending, side pressing and side bending operations. The dimensional error for each process was investigated by finite element(FE) analysis and the Taguchi optimization method. The spreading of the cover width in the side pressing process was adjusted by modifying the blank shape with a notch. The over-bending method was adopted to compensate the spring-back which occurs after bending. Forming experiments were performed to verify the reliability of the developed press forming process. In addition, the strength of the product was evaluated to verify the suitability of the battery cover manufactured with this new press forming process. The results of the forming experiments indicate that the dimensional accuracy of the battery cover is within the required tolerance. The strength of the battery cover was evaluated to 547N which is larger than required strength of 400N.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.393-400
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• 2008

Springback is one of the most difficult phenomena to analyze and control in sheet forming. Most of traditional springback control methods rely on experiences of skilled workers in industrial fields. This study focuses on prediction and generation of optimum reconfigurable die surfaces to control shape errors originated by springback. For this purpose, a deformation transfer function(DTF) was combined with finite element analysis of the springback in the 2D sheet forming model of elastic-perfectly plastic materials under the condition without blank holder. The results showed shape errors within 1% of the objective shape, which were comparable with analytically predicted errors. In addition to this theoretical analysis, DTF method was also applied to 2D and 3D sheet forming experiments. The experimental results showed ${\pm}0.5$ mm and ${\pm}1.0$ mm shape error distribution respectively, demonstrating that reconfigurable die surfaces were predicted well by the DTF method. Irrespective of material properties and sheet thickness, the DTF method was applicable not only to FEM simulation but also to 2D and 3D elasto-reconfigurable die forming. Consequently, this study shows that springback can be controlled effectively in the elasto-RDF system by using the DTF method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.8
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• pp.51-59
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• 2019

Flow forming is an eco-friendly and high-efficiency plastic deformation process with fewer chips during a process which is specifically used to manufacture seamless tubular products like tire wheels, rocket motor cases etc. On the development of mortar barrel using Inconel718 tube, some flow formed products had dimensional errors on their thickness. In this study, our purpose is to optimize the process conditions with the smallest dimensional error. In order to find an optimum process condition, 2D axisymmetric FEM simulation analyses with Taguchi method were conducted. Geometric variables (attack angle, flatting angle, roller nose radius) and operating parameters (depth of forming, feed rate) are considered as control factors. Forward flow forming with single roller was first analyzed to determine the effective factors using AFDEX software and attack angle of the roller was identified as the most influential factor. Also, the nose radius of the rollers was confirmed as a significant factor in multi-rollers flow forming system. The effect of rollers offset values are also studied and finally, we proposed optimal conditions to improve the accuracy of flow forming process with Inconel718 tube for mortar barrel manufacturing.

• The Journal of Korean Institute of Electromagnetic Engineering and Science
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• v.29 no.6
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• pp.449-456
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• 2018

Herein, several multibeam forming methods that can be applied to microwave wireless power transmission are presented. Because the conventional multibeam forming methods do not consider an active element pattern(AEP), an intended beam shape will contain a steering angle error when applied to an actual system. To solve this problem, a method of considering the average of the AEP and a method of considering all the AEPs by the modified Fourier series method have been proposed. We confirmed that the proposed method reduces the error with the intended beam shape in the multibeam formation. In addition, for the side lobe level(SLL) and null control, a method of multibeam forming by applying the superposition principle to the Dolph-Tschebyscheff method is proposed. We also confirmed that SLL control can be simultaneously achieved with the multibeam formation.

• Transactions of Materials Processing
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• v.23 no.6
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• pp.351-356
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• 2014

The current study aims to predict the forming limits considering the deformation characteristics of tailor rolled blank(TRB) during hot stamping. The formability of TRB is affected by the TRB line orientation because elongations change due to the intrinsic geometry within the sheet. To evaluate the forming limits, Nakazima tests were conducted at elevated temperatures with different TRB line orientations. Forming limit diagrams(FLD) of TRB can be predicted by an interpolating equation based on the Nakazima test. Predicted FLDs were used in FE-simulations of a rectangular drawing. The predicted limit drawing height was compared with experimental results. The simulation results show good agreement with the experimental ones with an error range of 3%.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.06a
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• pp.163-172
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• 1994

The Aerospace and automobile industries have need to avoid sheet-metal forming problem such as incorrect springback after forming and trimming process, excessive thinning/tearing, wrinking/perkering. It is common practice to use costly trial-and-error experimental methods to develop tooling and manufacturing process parameters. Experimentation should be complemented with computer simulation to reduce cost and leadtime in manufacturing and to influence the design of components. In this study, firstly we solved the springback problem after drawing and trimming process of KFP(F100-229) engine airsealing bearing support part(53H00) forming and studied on the effect of several process parameters on the gap between the formed blank and punch shape using the implicit F.E.M code(ABAQUS). Secondly by the three dimensional dynamic analysis using the explicit. F. E. M code (LS-DYNA3D), we studied on the effect of several process parameters which can be used for avoid tearing and wrinking during the drawing process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.108-111
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• 2002

It is important to predict forming procedure for minimizing trial-and-error in the application of cold forging of gears. In this study, 3-dimensional simulations of cold forging processes of spur and bevel gear were carried out using finite element method to investigate the characteristics of the processes. From the simulation result it was found that incomplete teeth forming of spur gear was occurred with increase of teeth number in forging by forward extrusion. It can be reduced through division of material flows at the initial forming state using forward/backward combined extrusion.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.83-94
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• 1998

An analysis system for sheet metal forming has been developed to improve the design and tryout process by predicting the deformation behaviour more precisely. This analysis system consists of forming analysis, springback analysis and post processor modules. The more accurate prediction of stress history can be achived due to the improved contact algorithm. Successive simulation of several processes can be carried out conveniently without interrupt by the improved data management of the developed system. The error of data transfer between forming analysis and springback analysis is minimized using the proper shell element. Several benchmark test results and practical results are presented to show the effectiveness and reliability of this program.

• Journal of Magnetics
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• v.21 no.2
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• pp.215-221
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• 2016

We conducted a phased electromagnetic forming process analysis (EFPA) over time through a coupling of electromagnetic analysis and structural analysis. The analysis is conducted through a direct linkage between electromagnetic analysis and structural analysis. The analysis process is repeated until the electric current is completely discharged by a formed coil. We calculate the forming force that affects the workpiece using MAXWELL, a commercial electromagnetic finite element analysis program. Then, we simulate plastic behavior by using the calculated forming force data as the forming force input to ANSYS, a commercial structure finite element analysis program. We calculate the forming force data by using the model shape in MAXWELL, a commercial electromagnetic finite element analysis program. We repeat the process until the current is fully discharged by the formed coil. Our results can be used to reduce the error in data transformation with a reduced number of data transformations, because the proposed approach directly links the electromagnetic analysis and the structural analysis after removing the step of the numerical analysis of a graph describing the forming force, unlike the existing electromagnetic forming process. Second, it is possible to simulate a more realistic forming force by keeping a certain distance between nodes using the re-mesh function during the repeated analysis until the current is completely discharged by the formed coil, based on the MAXWELL results. We compare and review the results of the EFPA using the peak value of the forming force that acts on the workpiece (which is the existing analysis method), and the proposed phased EFPA over time approach.