• 한국기계가공학회지
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• 제6권2호
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• pp.52-58
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• 2007

This study shows a numerical method to predict automobile type air conditioner tube connector in the forming process. The simulation approach with 3-D FEM program(ABAQUS) for forming process, forming process simulation is in good agrement with it in tendency. Finally, we compared the forming result with simulation. The result of research showed thai forming process technology is promising to produce automobile type air conditioner tube connector.

• 한국기계가공학회지
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• 제17권5호
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• pp.45-51
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• 2018

Roll forming refers to the production of long plate-molded products, such as panels, pipes, tubes, channels, and frames, by continuously causing the bending deformation to thin plates using rotating rolls. As the roll forming method has advantages in terms of mass production because of its excellent productivity, the size of the roll forming industry has been continuously increasing and the roll forming method is increasingly being used in diverse industrial fields as a very important processing method. Furthermore, as the roll forming method mainly depends on the continuous bending deformation of the plate materials, the time and the cost of the heterogeneous materials developed in the process are relatively large when considered from the viewpoint of plastic working because many processes are continuously implemented. The existing studies on roll forming manufacturing have reported the loss of large amounts of time and materials when the raw materials or product types were changed; further, they have stated that the use of this method can hardly guarantee the uniformity of the formed shapes and the consistency in terms of size and cannot detect all the defects occurring during the mass production and related to the dimensions. Therefore, in this research, a real-time process data-based smart roll forming method that can be applied to multiple products was studied. As a result, a roll forming system was implemented that remembers and automatically sets the changes in the finely adjusted values of the supplied quantities of individual heterogeneous materials so that the equipment setting changing time for heterogeneous material replacements or changes in the products being produced can be shortened. It also secures the uniformity of the products so that more competitive and precise slide-rail products can be mass-produced with improvements in the quality, price, and productivity of the products.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.379-382
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• 2007

The MEMS (Micro Electro Mechanical Systems) process is used in a micro/nano pattern manufacturing method. This method is based on the lithography technology. But the MEMS process has some problems such as complicated process, long processing time and high production costs. Many researchers are doing research in substitute manufacturing method to work out a solution to these problems. In this paper, we apply a dieless incremental forming technology to a substitute method of MEMS process. This dieless forming technology is using in the commercial scale sheet forming such as a prototype of automobile sheet parts. 5-axes CNC (Computerized Numeric Control) method are applied in this system to get a micro-scale dieless forming results. These 5-axes system are composed of precision AC servo motor stages (4-axes) and PZT actuator (1-axis). A PZT actuator is used in a precision actuating axis because it can be operated in the nano scale stroke resolution. This micro dieless incremental forming system has the advantage of minimization in manipulating distance and working space. As equipment and tools become smaller in size, minute inertia force and high natural frequency can be obtained. Therefore, high precision forming performance can be obtained. This allows the factory to quickly provide the customer with goods because the manufacturing system and process are reduced. To construct this micro manufacturing system, many technologies are necessary such as high stiffness frame, high precision actuating part, structural analysis, high precision tools and system control. To achieve the optimal forming quality, the micro dieless forming system is designed and made with high stiffness characteristic.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.978-981
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• 2005

In order to manufacture a doubly curved sheet metal effectively, a flexible incremental roll forming process has been developed by adopting the advantages of the incremental forming process and the roll forming process by combining inherent flexibility of the incremental forming process and continuous deformation of the roll forming process. The forming method has been further enhanced to form general quadrilateral blanks (including a square, a rectangle, a symmetrical trapezoid and an asymmetrical trapezoid, etc.) into doubly curved shapes by controlling the forming paths developed by various experiments.

• 한국추진공학회:학술대회논문집
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• 한국추진공학회 2008년 영문 학술대회
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• pp.799-803
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• 2008

The possibility of manufacturing titanium hollow cylinder tank for ramjet engine was demonstrated with superplastic forming of subscale article. An innovative manufacturing method to produce complex configuration from titanium multi-sheets by low hydrostatic pressure was presented. Finite element analysis on superplastic blow forming process has been carried out in order to improve the forming process when manufacturing subscale hollow cylinder structure using Ti-6Al-4V multi-sheets. The simulation focused on the reduction of forming time and obtaining finally required shape throughout investigating the deformation mode of sheet according to the forming conditions and die geometry. From pre-sized titanium sheets, near net shape of hollow cylinder tank is obtained by superplastic blow forming conducted using gas pressure of 15bar at 1148K. The result shows that the manufacturing method with superplastic forming of multi-sheets of titanium alloy has been successful for near net shape forming of subscale hollow cylinder tank of ramjet engine.

• 한국생산제조학회지
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• 제22권5호
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• pp.800-805
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• 2013

Incremental forming of sheet metal is a modern method of forming sheet metal, where parts can be formed without the use of dedicated dies. Existing experimental configurations for incremental forming can be broadly classified into two categories, i.e., negative and positive forming. In this paper, forming qualities such as shape accuracy and surface roughness of Al 1050 material were discussed for different forming methods. The formed and the corresponding opposing surfaces were measured with a three-dimensional scanner and a surface roughness tester. It was found that in terms of shape accuracy, the best opposing surface was obtained with positive forming, whereas the worst formed surface was obtained with negative forming; furthermore, the opposing surface is always better than the formed surface, regardless of the forming method used.

• 한국추진공학회지
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• 제11권1호
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• pp.27-33
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• 2007

각이 있는 얇은 콘 제품을 생산하기 위한 가공법으로는 전단 스피닝에 의한 성형방법이 많이 이용되고 있으며 이는 다른 가공방법에 비해 성형에 필요한 힘이 적게 들고 전단 스피닝에 의해 가공된 제품의 기계적인 강도가 우수하며 표면 품질이 우수하기 때문이다. 따라서 전단 스피닝 기술은 산업현장에서 폭 넓게 이용되고 있다. 특히 전단 스피닝과 유동성형은 자동차, 항공, 방위산업에 자주 이용되고 있다. 본 논문에서는 전단 스피닝에 대한 유한요소해석을 통해 가공깊이와 롤의 리드각이 성형력에 미치는 영향을 살펴보았다. 다양한 가공깊이와 롤의 리드각 조건에서 축 및 반경방향의 성형력을 구하였다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.386-389
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• 2008

Forming limit diagram is created by graphical illustration indicating major and minor strain. In order to provide the criterion for forming safety, FLC(forming limit curve) need to be fitted to the diagram. However, the standard method for the strain measurement and FLC plotting are not fixed yet, which results in inconvenience in digitalized analysis. In this study, new construction method for FLC was suggested in order to minimize operator dependency. For this purpose, major and minor strain were measured automatically and analyzed. Then, a second order equation is adopted to fit the FLC. Optimized by response surface method was performed to ensure particular characteristics of the FLC.

• 대한기계학회논문집A
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• 제25권8호
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• pp.1213-1219
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• 2001

In this paper, modeling of the multi-pass roll forming process with the finite element method and defect prediction in roll forming process are presented. In the roll forming process, there occurs the defect of scratch. It appears on tubes because of the friction between the strip and the roll, the unexpected sliding velocity and the contact pressure when fabricating the tubes. The surface of the product will be not uniform due to the defect. The scratch can be predicted with the simulation modeling of the finite element method, and can be avoided by modifying the design.

• 한국기계가공학회지
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• 제6권4호
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• pp.36-43
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• 2007

Dieless CNC forming is an innovative technology which can form various materials with complex shape by numerically controlled incremental forming process. In order to apply the technology to industrial parts, however, many problems such as spring-back, rising of material, and trimming difficulty must be solved. In this paper a new dieless CNC forming method to improve forming quality is proposed, which consists of how to modify its original shape in CAD and how to generate its CNC tool path in CAM. The effectiveness of the proposed procedures is tested with a brake dust shield of a vehicle. The results shows that the method proposed enhances the forming quality up to 48% compared to traditional method.