• Transactions of Materials Processing
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• v.29 no.2
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• pp.113-117
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• 2020

Various parameters are involved in the frictional behavior of steel sheet during stamping. We performed various tests in order to investigate the influence of tool surface texture directionality upon the resulting friction in sheet forming processes. Four different tools were manufactured which gave us a range of roughness for both parallel and transverse texture directions. Each of the tools was examined in flat type friction tests under identical test conditions. The tool with the transverse surface texture produces significantly lower levels of friction than the tool with parallel texture direction. Considering the lubrication mechanism associated with transverse texture, one can imagine the lubricant being constantly supplied from the reservoir of the micro valley to the point of contact and hence producing the lower levels of friction seen.

• Korean Journal of Materials Research
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• v.31 no.7
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• pp.409-419
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• 2021

The effect of solidification rate on micro-segregation in investment casting of IN738LC superalloy was studied. In Ni-based superalloys, the micro-segregation of solute atoms is formed due to limited diffusion during cast and solidification. The microstructure of cast Ni-based superalloys is largely divided into dendrite core of initial solidification and interdendrite of final solidification. In particular, mosaic shaped eutectic γ/γ' and carbides are formed in the interdendrite of the final solidification region in some cases. The micro-segregation phenomena formed in regions of dendrite core and interdendrite including eutectic γ/γ' and carbides were analyzed using OM, SEM/EDS and micro Vickers hardness. As a result of analysis, the lack of (Cr, W) and the accumulation of Ti were measured in the eutectic γ/γ', and the accumulation of (Cr, Mo) and the lack of Ti were measured in the interdendrite between dendrite and eutectic. Carbides formed in interdendritic region were composed of (Ti, W, Mo, C). The segregation applied to each microstructure is mainly due to the formation of γ' with Ni₃(Al,Ti) composition. The Ni accumulation accompanied by Cr depletion, and the Ti accumulated in the eutectic region as a γ' forming elements. The Mo tends to diffuse out from the dendrite core to the interdendrite, and the W diffuse out from the interdendrite to the dendrite core. Therefore, the accumulation of Mo in the interdendrite and the deficiency of W occur in the eutectic region located in the interdendrite. Heat treatment makes the degree of the micro-segregation decrease due to the diffusion during solid solution. This study could be applied to the heat treatment technology for the micro-segregation control in cast Ni-based superalloys.

• Proceedings of the KSME Conference
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• 2001.06a
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• pp.471-476
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• 2001

Milli-structure components ate classified as a component group whose size is between macro and micro scales, that is, about less than 20mm and larger than 1mm. The forming of these components has a typical phenomenon of bulk deformation with thin sheets because of the forming size. In this study, milli-structure rectangular cup drawing is analyzed and measured using the finite element method and experiment. Generally, milli-structure containers or cases like cellular phone vibrator consist of rectangular-shaped drawing to save installation space. A systematic approach is established for the design and the experiment of the forming processes for rectangular milli-structure cases. To verify the simulation results, the experimental investigations were also carried out on a real industrial product. The numerical analysis by FEM shows good agreement with the experimental results in view of the deformation shape of the product.

• Elastomers and Composites
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• v.44 no.4
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• pp.384-390
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• 2009

Roll-to-roll forming process is one of important metal processing technology because the process is simple and economical. These days, with these merits, roll-to-roll forming process is tried to be employed in manufacturing the circuit board, barrier ribs and solar cell plate. The solar cell plate may have millions of patterns, and the analysis of forming considering all the patterns is impossible due to the computational costs. In this study, analyses are carried out for various numbers of patterns and the results are compared. It is shown that the analyses results with four row patterns and twelve row patterns are same. So, it is considered that the analysis can be carried out for only four rows of pattern for the design of incremental roll-to-roll forming process. Also formability is analysed for various number of mesh, protrusion shapes and forming temperature.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.12
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• pp.167-176
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• 2001

The effects of heat treatments and testing temperatures on the mechanical properties of Invar materials were investigated through experiments, which call influence the formability in metal forming fields. Annealing temperatures were changed from $900^{\circ}C$ to $1200^{\circ}C$ with an increment of $100^{\circ}C$ under two different furnace atmosphere(vacuum and H$_2$gas). Microstructure and hardness tests were performed for annealed specimens at room temperature(RT) and tensile tests were also performed by changing annealing temperatures as well as testing temperatures from RT to $300^{\circ}C$. The grain size of annealed materials increased with increasing annealing temperature, while micro-hardness distributions showed almost same hardness values regardless of annealing temperatures. Strength ratio (tensile/yield strength), which influences the forming characteristics of sheet metal, remained almost constant for various experimental conditions in case of unannealed specimens. However, it showed increasing tendency with increasing both annealing and testing temperatures, particularly at the testing temperature higher than $200^{\circ}C$. Therefore it can be concluded that press formability of fully-annealed Invar material can be improved by warm forming technique.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.329-332
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• 2005

Cross rolling process is one of incremental forming processes to form an axi-symmetric shaped metal component. It can be classified into two types according to the shape of dies, which are a drum type (roll type) and a plate type (straight type). It can also be classified into a wedge type and a ramp type processes according to deformation characteristics of a material. The ramp type die is applied to plate type cross rolling process in cold forming process for forming of teeth of gear or bolt, while the wedge type die is generally utilized to drum type and plate type cross rolling processes in hot forming process. A shape of the ramp type die is usually same as final shape of a product at every section of a progressing direction, while the shape of the wedge type die has different shapes in a progressing direction. In this paper, a rolling of neck part in a ball stud component has been carried out using the plate type cross rolling process with a ramp shaped die. Forming characteristics have been performed using finite element analysis in order to obtain a proper preform for the ramp type plate cross rolling process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.397-400
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• 2004

The direct extrusion with porthole die can produce condenser tube which has the competitive power in costs and qualities compared with the existing conform extrusion. In general, porthole die extrusion has a great advantage in the forming that produces the hollow sections difficult to produce by conventional extrusion with a mandrel on the stem. Especially, condenser tube manufactured by porthole die belongs to sophisticated part and demands tighter dimension tolerance and higher surface finish than any other part. In order to confirm the general of porthole die extrusion, we perform the 3D FE analysis of hot porthole extrusion in non-steady state by using DEFORM 3D and investigate a pattern of elastic deformation for porthole die through the stress analysis using ANSYS 5.5 during extrusion process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.448-452
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• 2005

Punching/blanking/shearing is among the oldest and most frequently used sheet metal forming process. We have developed the shear device for burrless cutting using the micro wire. Since the burr minimization and fine shear plane, this paper is a study on the effect of the shear angle and clearance of the cutter-cutter. And, we confirm the tendency of the shear plane. It is impossible to completely remove the burr in the shearing process. In order to minimize the burr size and fine shear plane, we have accomplished the various experiment conditions such as the shear angle and clearance. Despite the quality of shear plane is not good enough yet, it is possible to make the burr minimization and fine shear plane by the optimization of process parameters.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.1
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• pp.109-118
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• 2003

The recent trend towards miniaturization causes an increased demand for parts with very small dimensions. Milli-structure components are classified as a component group whose size is between macro- and micro-scale. The manufacturing process of these components of thin sheet metal forming has a microscopic properties in addition to a typical phenomenon of bulk deformation because of the forming size. Also, the material properties and the deformation behavior change with miniaturization, which means that, a coarse grained materials show a higher resistance against deformation, when the grain size is in the range of the sheet thickness. In this study, a new numerical approach is proposed to simulate intergranular milli-structure in forming by the finite element method. The grain element and grain boundary element are introduced to simulate the milli-structure in the bending. The grain element is used to analyze the deformation of individual grain while the grain boundary element is for the investigation on the movement of the grain boundary. Also, the result of the finite element analysis is confirmed by a series of milli-sized forming experiments.

• Korean Journal of Metals and Materials
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• v.48 no.1
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• pp.90-100
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• 2010

Micro-conductive patterns were microfabricated on an insulating substrate ($SiO_2$) surface by a selective electroless nickel plating process in order to investigate the formation of seed layers. To fabricate micro-conductive patterns, a thin layer of metal (Cu.Cr) was deposited in the desired micropattern using laser-induced forward transfer (LIFT). and above this layer, a second layer was plated by selective electroless plating. The LIFT process. which was carried out in multi-scan mode, was used to fabricate micro-conductive patterns via electroless nickel plating. This method helps to improve the deposition process for forming seed patterns on the insulating substrate surface and the electrical conductivity of the resulting patterns. This study analyzes the effect of seed pattern formation by LIFT and key parameters in electroless nickel plating during micro-conductive pattern fabrication. The effects of the process variables on the cross-sectional shape and surface quality of the deposited patterns are examined using field emission scanning electron microscopy (FE-SEM) and an optical microscope.