• Journal of the Korean Society for Precision Engineering
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• v.23 no.7 s.184
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• pp.30-38
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• 2006

Laser cutting technology is one of flexible rapid manufacturing technologies with various advantageous including a high cutting speed, manufacturing of parts with a complex shape and others. The quality of the cut part and the optimum cutting conditions are highly dependent on the combination of the process parameters. The objective of this research works is to investigate the influence of process parameters, such as power of laser, cutting speed of laser and material thickness, on the surface roughness and the striation formation of the cut section for the case of cutting of CSP 1N sheet using high power Nd:YAG Laser with a continuous wave (CW). In order to find the relationship between process parameters and the surface roughness and the striation formation of the cut section, several experiments are carried out. Through the investigation of the empirical results, it has been shown that the surface roughness is highly related to the striation formation, including the frequency and angle of the striation, of the cut section. From the results of experiments, an optimum cutting speed for each cutting condition has been obtained to improve both the quality of the cut surface and the cutting efficiency.

• Journal of Mechanical Science and Technology
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• v.15 no.9
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• pp.1311-1318
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• 2001

It is necessary to diagnose accurately the characteristics of soot formation and oxidation in a diesel engine. Whereas past measurement techniques for soot concentration give limited information for soot, laser-based two-dimensional imaging diagnostics have a potential to provide temporally and spatially superior resolved measurements of the soot distribution. The technique using laser sheet beam has been applied to an optically accessible diesel engine for the quantitative measurement of soot. The results provided the information for reduction of soot from the diesel engine. Both LIS (Laser Induced Scattering) and LII (Laser Induced Incandescence) techniques were used simultaneously in this study. The images of LIS and LII showed the quantitative distribution of the soot concentration in the diesel engine. In this study, several results were obtained by the simultaneous measurements of LIS and LII technique. The diameter and number density of soot in combustion chamber of the test engine were obtained from ATDC 20 degree to 110 degree. The soot diameter increased about 37% between ATDC 20 degree and 110 degree. The number density of soot, however, decreased significantly between ATDC 40 degree and 70 degree.

• Journal of Welding and Joining
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• v.16 no.2
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• pp.100-110
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• 1998

In this paper, the laser weldability of thin gage steels for automobile application is discussed. Welding was carried out with a high power carbon dioxide laser system, and the laser energy was concentrated through a plano-convex lens. Test results showed that the joint gap in the butt welding proved to be one of the critical conditions for an acceptable weld. In the case where the ratio of the gap clearance to the material thickness was slightly bigger than optimal value, the weld strength was reduced showing weld metal fracture. It was possible to obtained a weld penetration ratio of 0.91 when the vertical offset ratio was controlled to be 0.4 or smaller. Results also demonstrated that the weld strength of the lap joint was influenced by travel speed. At the travel speeds lower than 37 mm/s, the weld strength indicated higher value than that of class A recommendation strength of a resistance spot weld based on the KS code. It was clear that the complicated effect of specimen alignment should be considered so as to make a sound weld with high integrity when the laser process was applied to the long weld line.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.7
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• pp.136-144
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• 2004

Optimal process and system to produce the laser welded tube for one body formed bumper beam are studied. The calculated size of tube is a thickness of 1.4mm, diameter of 105.4mm and length of 2000mm. The tube is shaped from a cold rolled high strength steel sheet(tensile strength: 60kgf/$\textrm{mm}^2$ grade). Two roll bending method is the optimal tube shaping process compared to UO-bending, bending on press brake, multi-step continuous roll forming and 3 roll bending methods. Weld quality monitoring and seam tracking along the butt-joint lengthwise to the tube axis are also studied. The longitudinal butt-joint is welded by the $CO_2$ laser welding system equipped with a seam tracker and plasma sensor. The constructed $CO_2$laser tube welding system can be used for the precision seam tracking and the real-time monitoring of weld quality. Finally, the obtained laser welded tube can be used for one-body formed automobile bumper beam.

• Laser Solutions
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• v.18 no.1
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• pp.1-6
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• 2015

High welding speed and narrow weld seam are favorable for welding of magnesium alloy. Magnesium alloy is recommended for the smart frame because it has several advantages such as low density, high thermal conductivity, EMI shielding capability and good cast ability. This study is for the assembly welding of the magnesium smart frame with high productivity, good performance and low cost. The window for battery on AZ91D frame produced by die-casting was prepared by CNC machining. Corresponding AZ31 blank of 0.2mm thickness was prepared by die-blanking cut. All system set was fixed at the stationary bed but the laser beam was manipulated by scanner up-to 1,000mm/s speed. The weld joint between AZ31 sheet and AZ91D frame was welded by fiber laser on 850~1,000W output power. The joint showed penetration enough but some humping bead. The distortion by the weld heat was almost free because of the quick dissipation of the heat by small beam size and fast welding. Consequently, the thinner magnesium foil was assembled successfully to the magnesium frame of mobile phone.

• Transactions of Materials Processing
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• v.30 no.4
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• pp.179-185
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• 2021

Lithium ion batteries are generally manufactured by laser and etching using aluminum thin sheet. These processes are relatively expensive and have low productivity. In this study, blanking process of aluminum thin sheet for lithium ion battery was employed to replace laser cutting and etching process, all to reduce the production cost and improve productivity. Mechanical properties for aluminum and coating were determined by experimental results and rule of mixture for FE analysis of blanking process. Normalized Cockcroft-Latham criteria was also applied to describe shear behavior and critical damage values were determined by comparison of analytical and experimental result. We performed FE analysis to investigate the effects of clearance and punch-die radius on sheared surface of aluminum thin sheet and to determine optimal process condition. We manufactured the die set using the determined optimal process and conducted an experiment to confirm the feasibility of blanking process. The sheared surface of manufactured product was observed by optical microscope. As a results, the proposed process conditions successfully achieved the dimensional requirement in production of lithium ion battery parts.

• Transactions of Materials Processing
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• v.8 no.5
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• pp.429-436
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• 1999

In sheet metal forming , forming limit diagram is very important to design and analyze of sheet metal forming process. Recently tailor welded blanks of different thickness and different material and strength combinations are used widely in automobile industry to reduce car manufacturing cost. In order to analyze the forming characteristics of tailored welded blanks, we have investigated the forming limit dia-grams for 3 kinds of different material using mash seam and laser welding experimentally and dis-cussed for the characteristics of forming for tailor welded blanks. It is concluded that forming limit dia-gram for the different material combination TWB locates between FLD of the thinner base material sheet and the thicker ones.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.25 no.1
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• pp.71-77
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• 2001

A flow visualization study using the oil film method and the smoke-laser light sheet arrangement is carried out to investigate the three-dimensional flow pattern around the free end surface region of a finite circular cylinder (aspect ratios of 1.25 and 4.25) mounted on a flat plate. The experiment is performed for the cases of two Reynolds numbers: 5.92${\times}$10$^3$and 1.48${\times}$10(sup)5. Various kinds of singular points on the free-end surface are disclosed from the oil surface flow visualization. The smoke-laser light sheet visualization, to aid in understanding the oil streak-line patterns, clearly demonstrates that a pair of tornado-like vortices marched along the downstream together with a pair of side tip vortices. A topological sketch to characterize the surface flow and the four vortices emanating from the top surface is included.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.4
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• pp.101-107
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• 2007

The objective of this research work is to investigate into effects of an auto tracking of the focal distance on the quality of the cut part in the cutting of a low carbon sheet using a high-power CW Nd:YAG laser. An auto-tracking system with a capacitance based distance control loop has been employed to perform a real control of the focal distance. In order to examine the influence of the auto-tracking of a focal distance on the optimum focal distance, the kerfwidth, surface roughness and the formation of the cut section, several linear cutting tests have been carried out using the auto-tracking system. The results of experiments have been shown that the optimum focal distance is 0.9mm. In addition, it has been shown that the variation of kerfwidth and the surface roughness of the cut part with control of the focal distance are reduced 40-80% and 30-55% in comparison with those of the cut part without tracking of the focal distance. From the results of the experiments, it has been found that the real time tracking of the focal distance can improve the part quality.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.32 no.11
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• pp.978-983
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• 2008

An application of innovative laser+GMA hybrid welding process is presented for reducing bead humping defects in high speed welding and increasing side wall fusion in narrow groove welding without torch or wire oscillation. In this hybrid process, the laser heat input is applied adjacent to the weld pool at a relatively low power density to produce a wider, flatter weld bead. In bead on plate in sheet metal gauges, the hybrid process was able to produce hump-free welds from 70ipm (${\sim}1780mm/min$) to over 150ipm (${\sim}3810mm/min$) of the travel speed compared to the un-assisted GMAW process. A square-butt joint in 15mm A572 Gr50 steel welds was investigated. A square butt joint with a gap of 3.2mm was filled with 6 passes. Liquid Nitrogen calorimetry and innovative $CO_2$ laser reflective optics were also developed to demonstrate the concept of hybrid welding.