• Journal of the Korean Society for Precision Engineering
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• v.24 no.3 s.192
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• pp.91-99
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• 2007

Fractures of galvannealed coating layer during actual press forming in automotive applications were observed by scanning electron microscopy in order to understand fracture mechanism. Fracture behaviors of galvannealed coating layer in extra deep drawing quality steels and high strength steels have been studied by performing the tests describing the representative plastic deformation in sheet metal forming such as uni-axial tensile test, compression test, bi-axial test and plane strain test. Growth and direction of cracks were deeply related to the plastic deformation modes and history. The material properties of galvannealed coating layer were investigated by nano-indentation test equipped with Berkovich diamond indentor for the specimens. Hardness and elastic modulus of the coating layer were higher than bared steels and that was the reason for crack of coating layer. Flat friction test and drawbead friction test were performed to observe the effect of the surface morphology on the frictional characteristics. The micro-plasto hydrodynamic lubrication were appeared and played an important role in reducing the coefficient of friction.

• Journal of Sensor Science and Technology
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• v.22 no.5
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• pp.333-337
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• 2013

This study proposes a simply fabricated micro stator for higher output power than previously reported micro stators. The stator has been fabricated by inserting enamel coil in silicon mold formed by micro etching process. The most merits of the proposed micro stator are the simple fabrication process and high output power. Previously reported micro stators have high resistance because the micro coil is fabricated by relatively thin-film-based deposition process such as sputtering and electroplating. In addition, the previously reported micro coil has many electrical contact points for forming the coil structure. These characteristics of the micro stator can lead to low performance in output power. However, the proposed micro stator adopts commercially available enamel coil without any contact point. Therefore, the enamel coil of the proposed micro stator has low junction resistance due to the good electrical quality compared with the deposited or electroplated metal coil. Power generation tests were performed and the fabricated stator can produce 5.4 mW in 4000 RPM, $1{\Omega}$ and 0.3 mm gap. The proposed micro stator can produce larger output power than the previously reported stator spite of low RPM and the larger gap between the permanent magnet and the stator.

• Journal of Power System Engineering
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• v.20 no.5
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• pp.5-13
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• 2016

This study is on wear damage of the material for a molding machine that be used at finally cutting of metal beam made in roll forming process of vehicle bump beam process line. SKD11 steel was used with the material for cutting mold jig. In the cutting mold jig, Ti diffusion heat treatment after vacuum heat treatment was carried out for upgrade of surface hardness and anti-wear. Also, the heat treatments by various methods were performed to compare the wear damage degree against above the existing heat treatment. Wear loss and friction coefficient were obtained from wear test. And, micro Vickers hardness values were compared with damaged parts or not of cutting mold jig. Micro Vickers hardness value appeared higher at the undamaged part by Ti diffusion heat treatment. The micro Vickers hardness well followed a two-parameter Weibull probability distribution.

• Interaction and multiscale mechanics
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• v.4 no.2
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• pp.107-122
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• 2011

Mechanical behavior in nano-sized structures differs from those in macro sized structures due to surface effect. As the ratio of surface to volume increases, surface effect is not negligible and causes size-dependent mechanical behavior. In order to identify this size effect, atomistic simulations are required; however, it has many limitations because too much computational resource and time are needed. To overcome the restrictions of the atomistic simulations and graft the well-established continuum theories, the continuum model considering surface effect, which is based on the bridging technique between atomistic and continuum simulations, is introduced. Because it reflects the size effect, it is possible to carry out a variety of analysis which is intractable in the atomistic simulations. As a part of the application examples, the homogenization method is applied to micro/nano thin films with porosity and the homogenized elastic coefficients of the nano scale thickness porous films are computed in this paper.

• Transactions of Materials Processing
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• v.23 no.4
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• pp.206-210
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• 2014

The metal lead frame, a semiconductor component, has product tolerances in micro units as compared to products made with a larger size mold. Therefore, small deflections of the mold and of the press as well as the press molding process itself have a strong influence on accuracy of the product. Hence, it is necessary for the process design to consider the structural response of the mold and the press during deformation. In the current study, the mold deflection and pressure on the punch is examined using the finite element modeling (FEM) program ABAQUS. The results from the simulation were verified with the dynamic deformation measurement equipment using digital image correlation (DIC).

• Design & Manufacturing
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• v.17 no.2
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• pp.55-61
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• 2023

With femtosecond (fs) laser pulse irradiation on metals, various types of nano- and micro-scale structures can be naturally induced at the surface through laser-matter interaction. Two notable structures are laser-induced periodic surface structures (LIPSSs) and cone/spike structures, which are known to significantly modify the optical and physical properties of metal surfaces. In this work, we irradiate fs laser pulses onto various types of metals, cold-rolled steel, pickled & oiled steel, Fe-18Cr-8Ni alloy, Zn-Mg-Al alloy coated steel, and pure Cu which can be useful for precise molding and imprinting processes, and adjust the morphological profiles of LIPSSs and cone/spike structures for clear structural coloration and a larger range of surface wettability control, respectively, by changing the fluence of laser and the speed of raster scan. The periods of LIPSSs on metals used in our experiments are nearly independent of laser fluence. Accordingly, the structural coloration of the surface with LIPSSs can be optimized with the morphological profile of LIPSSs, controlled only by the speed of the raster scan once the laser fluence is determined for each metal sample. However, different from LIPSSs, we demonstrate that the morphological profiles of the cone/spike structures, including their size, shape, and density, can be manipulated with both the laser fluence and the raster scan speed to increase a change in the contact angle. By injection molding and imprinting processes, it is expected that fs laser-induced surface structures on metals can be replicated to the plastic surfaces and potentially beneficial to control the optical and wetting properties of the surface of injection molded and imprinted products.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.3
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• pp.581-593
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• 1990

A semi-solid alloy in which solid and liquid phase are co-existing is obtained by strirring of Al7075 molten metal. A semi-solid alloy is dependent on the corresponding temperature within the solid-liquid range, and the process parameters should be controlled accurately to obtain the homogeneous semi-solid alloy. The possibility o homogeneous fiber-reinforce aluminum alloy by addition of $Al_{2}$O$_{3}$ short fibers with vigorous agitation was investigated. The billet of composite materials was fabricated by squeeze casting, and homogeneous dipersion state of fibers in billet of fabricated metal matrix composites was observed. A slurry of semi-solid short fiber metal matrix composites is used in the direct rolling process, and this process showed the fabrication possibility of metal matrix composite sheets. The fabricated sheet was tested regarding vickers hardness, elongation and micro-structure. It has become clear that mashy state processing and working are very useful to obtain parts of composites material closed to near net shape.

• Transactions of the Korean hydrogen and new energy society
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• v.22 no.3
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• pp.340-348
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• 2011

Effects of various inorganic-metal oxide (Zr, Zn, Si, Al and Ca as promoters and stabilizers) additive on the reduction rate of iron oxide and the composition of forming hydrogen using the steam-iron cycle operation was investigated. The reduction rate of redox agent with additive was determined from weight change by TGA. The changes of weight loss and reduction rate according to redox agent with various additive affected the hydrogen purity and cycle stability of the process. The cyclic micro reactor showed that hydrogen purity exceeding 95% could be obtained by the water splitting with Si/Fe, Zn/Fe, Zr/Fe redox agents. The redox agents with these elements had an affect on redox cycle stability as a good stabilizer for forming hydrogen by the steam-iron process.

• Fire Science and Engineering
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• v.16 no.1
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• pp.77-83
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• 2002

The objective of this study is to propose a method to prevent the possible stress corrosion cracking of a horizontal side-wall sprinkler head deflector in the same atmosphere of ammonia gas as it regulated in the UL (Underwriters Laboratory). A corrosion test is carried out for three types of specimen according to post-forming treatment, one of which is annealing, another sand blasting and the other no treatment. The observation of the test specimens with a metal micro-scope says that the tensile residual stress is a major factor causing corrosion cracking, and that a proper heat treatment can remove or reduce the residial stress and prevent a crack from occurring even in a severe corrosive atmosphers.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1373-1378
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• 2007

Metal forming ins the process changing shapes and mechanical properties of the workpiece without initial material reduction through plastic deformation. Above all, because of hot working carried out above recrystallization temperature can be generated large deformation with one blow, it can produce with forging complicated parts or heat resisting super alloy such as Inconel 718 has the worst forgeability. In this paper, we established optimal variation of hot heading precess of the Inconel 718 used in heat resisting component and evaluated mechanical properties hot worked produce. Die material is SKD61 and initial temperature is $300^{\circ}C$. Initial billet temperature and punch velocity changed, relatively. Friction coefficient is 0.3 as lubricated condition of hot working. CAE is carried out suing DEFORM software before making the tryout part, and it is manufactured 150 ton screw press with optimal condition. It is known that forming load was decreased according to decreasing punch velocity.