• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.7-13
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• 2015

The production processes were reviewed through the injection analysis of the shift lever as a core component of an auto lever installed in the automatic transmission of cars. The injection analysis was carried out for the shift lever and rod among the components in a shift lever module. The shift lever and rod are designed for injection molding with the insertion of a tube, a pin cable plate, and a steel rod for securing the strength of the product. The charging time, failure of injection molding, weld line, air trap, and deformation were reviewed according to this insert. Analyses on various gate positions were carried out for reviewing the cultivation and deformation of fiber around major components, such as the generation section of manipulation feeling and assembly section, so that optimal gate conditions might be reviewed and reflected in the mold design. Finally, we plan to compare the analysis results with the production of trial products.

• Korean Journal of Materials Research
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• v.29 no.4
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• pp.258-263
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• 2019

Since the directly bonded interface between TiAl alloy and SCM440 includes lots of cracks and generated intermetallic compounds(IMCs) such as TiC, FeTi, and $Fe_2Ti$, the interfacial strength can be significantly reduced. Therefore, in this study, Cu is selected as an insert metal to improve the lower tensile strength of the joint between TiAl alloy and SCM440 during friction welding. As a result, newly formed IMCs, such as $Cu_2TiAl$, CuTiAl, and $TiCu_2$, are found at the interface between TiAl alloy and Cu layer and the thickness of IMCs layers is found to vary with friction time. In addition, to determine the relationship between the thickness of the IMCs and the strength of the welded interfaces, a tensile test was performed using sub-size specimens obtained from the center to the peripheral region of the friction-welded interface. The results are discussed in terms of changes in the IMCs and the underlying deformation mechanism. Finally, it is found that the friction welding process needs to be idealized because IMCs generated between TiAl alloy and Cu act to not only increase the bonding strength but also form an easy path of fracture propagation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.271-274
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• 2007

Housing and insulation of electrical connectors are made of plastic resin by injection molding process. The metallic inner tube is easily deformed by high pressure during the injection process. In order to prevent deformation of the inner tube, it is desirable to simulate it by structural CAE analysis. However, it takes a long time to calculate the stress- of the part by commercially available injection molding CAE software with sufficient accuracy. In this study, structural analysis in conjunction with injection molding analysis is proposed to improve accuracy of the structural analysis. Pressure distribution on the inner tube is predicted by the injection molding CAE analysis, and then mapped onto the mesh of structural analysis by a mapping algorithm developed in this study. As a result reliable result is obtained in shorter time than the conventional method. The predicted deformation of the inner tube is compared with the actual part after experiment.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.2
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• pp.603-608
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• 2014

In many manufacturing such as the components of airplane and automobile, aluminum alloys(Al2024) which remarkable in low specific gravity and high strength have been utilized effectively. Face milling machining technology for surface roughness quality of workpiece has been applied in these fields. A face milling machining with chamfered throw away type insert tip can produce a perfect flat surface only in theory. But It is impossible because of many unwanted factors, namely, cutting temperature, plastic deformation, dynamic effect, etc. In this paper, experimental investigations are performed to improve surface roughness after high speed machining of Al2024 using qualified face milling cutter body for high speed machining.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.8-15
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• 2021

Cold forging is a method in which molding is performed at room temperature. It has a high material recovery rate and dimensional precision and produces excellent surface quality, and it is mainly used for the production of bolted or housing products. The lifespan of cold forging molds is generally determined by the wear of the mold, plastic deformation of the mold, and fatigue strength. Cold forging molds are frequently damaged due to fatigue destruction rather than wear and plastic deformation in a high-temperature environment as it is molded at room temperature without preheating the raw material and mold. Based on the results analyzed through FEM, an effective mold structure design method was proposed by analyzing the changes in tensile and compressive stresses on molds according to the number of molds and reinforcement rings and comparing the product geometry and mold stress using three existing mold models.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.4
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• pp.419-426
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• 2011

In this study, an experimental and theoretical program were carried out to determine the cutting forces and chip formation at different cutting speeds using a 0.4mm nose radius ceramic insert and -7 rake angle for non heat-treated AISI 4140 (27HRc) and heat-treated AISI 4140 (45 HRc) steel. The results obtained were compared to show the hardness differences between the materials. The secondary deformation zone thicknesses when comparing the two materials show different physical structure but similar size. These results were also discussed in light of the heat treatment and the effects it had on the machining characteristics of the material. In addition, the Oxley Machining Theory was used to predict the cutting forces for these materials and a comparison made. The predicted cutting performances were verified experimentally and showed good agreement with experimental data.

• Transactions of Materials Processing
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• v.22 no.3
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• pp.171-177
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• 2013

Vacuum-assisted thermoforming is one of the critical steps for successful application of film insert molding (FIM) to make parts of complex shape. If the thickness distribution of the formed film is non-uniform, then cracking, deformation, warpage, and wrinkling can easily occur at the injection molding stage. In this study, the simulation of thermoforming was performed to predict the film thickness distribution, and the results were compared with experiments. Uniaxial tensile tests with a constant crosshead speed for various high temperatures were conducted to investigate the stress-strain behavior. An instance of yielding occurred at the film temperature of $90^{\circ}C$, and the film stiffness increased with increasing crosshead speed. Two types of viscoelastic models, G'Sell model, K-BKZ model, were used to describe the measured stress-strain relationship. The predicted film thickness distributions were in good agreement with the experimental results.

• Korean Journal of Applied Biomechanics
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• v.19 no.1
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• pp.13-25
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• 2009

Existing footwear biomechanics studies rely on simplified kinetics and kinematics, plantar pressure and muscle electromyography measurements. Because of the complexity of foot-shoe interface and individualized subject response with different footwear, consistent results regarding the biomechanical performance of footwear or footwear components can yet be achieved. The computational approach can be an efficient and economic alternative to study the biomechanical interactions of foot and footwear. Continuous advancement in numerical techniques as well as computer technology has made the finite element method a versatile and successful tool for biomechanics researchdue to its capability of modelling irregular geometrical structures, complex material properties, and complicated loading and boundary conditions. Finite element analysis offers asystematic and economic alternative in search of more in-depth biomechanical information such as the internal stress and strain distributions of foot and footwear structures. In this paper, the current establishments and applications of the computational approach for footwear design and evaluation are reviewed.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2002.04a
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• pp.19-26
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• 2002

In this paper, the nonlinear structural analysis for the composite structure of the spent nuclear fuel disposal container and the 50cm thick bentonite buffer is carried out to predict the collapse of the container while the sudden rock movement of 10cm is applied on the composite structure. This sudden rock movement is anticipated by the earthquake etc. at a deep underground. Horizontal symmetric rock movement is assumed in this structural analysis. Elastoplastic material model is adopted. Drucker-Prager yield criterion is used for the material yield prediction of the bentonite buffer and von-Mises yield criterion is used for the material yield prediction of the container(cast iron insert, copper outer shell and lid and bottom). Analysis results show that even though very large deformations occur beyond the yield point in the bentonite buffer, the container structure still endures elastic small strains and stresses below the yield strength. Hence, the 50cm thick bentonite buffer can protect the container safely against the 10cm sudden rock movement by earthquake etc.. Analysis results also show that bending deformations occur in the container structure due to the shear deformation of the bentonite buffer. The elastoplastic nonlinear structural analysis for the composite structure of the container and the bentonite buffer is performed using the finite element analysis code, NISA.

• Journal of Korean Association for Spatial Structures
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• v.19 no.2
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• pp.35-42
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• 2019

The purpose of this paper is to evaluate the structural performance of joints between modules with steel plate press forming type non-symmetric cross section. The main experimental variables are direction of load, whether vertical bolts are fastened, and whether the concrete inside the column is filled. A total of three experiments were performed for each variable. Experimental results show that the behavior of the joints dominated by the local buckling deformation of the upper and lower beam flanges of the module joints, and the final failure was the fracture of the column-beam welds. In case of short side direction, it is possible to secure the performance of intermediate moment frame (0.02 rad). In case of long side direction, it is evaluated that the performance of special moment frame (0.04 rad) is secured regardless of whether or not concrete is infilled in the column.