• Design & Manufacturing
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• v.15 no.4
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• pp.51-56
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• 2021

Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.

• Transactions of Materials Processing
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• v.31 no.2
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• pp.103-108
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• 2022

Systematic quality control based on real time data is required for modern factories. This study introduced a method of predicting punch wear in the trimming process of automobile parts. Based on monitoring data of the mass production process using a bolt-type piezo sensor, it was shown that precursor symptoms of die wear could be predicted from the change in load pattern with respect to production volume. The load pattern that changed according to the wear of the die was verified by numerical analysis.

• Journal of Korean Tunnelling and Underground Space Association
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• v.11 no.1
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• pp.47-56
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• 2009

Rock bolts and shotcrete play a crucial role as a main support system in the underground space. Thus, the safety of the underground space may be affected by the defect of rock bolts. In order to evaluate the rock bolt integrity by using non-destructive technique, the transmission method of the guided ultrasonic waves, which are generated by using the piezo disk elements has been successfully performed. The energy generated by the piezo disk elements, however, is not enough for the rock bolts in the field. In addition, the piezo disk elements should be installed at the end of the steel bar during construction of the rock bolts. The purpose of this study is the devolvement of the reflection method, which may generate enough energy, and the application in the field rock bolts. Both laboratory and field tests are carried out. The guided ultrasonic waves with high energy are generated by the hammer impact with the center punch, and the AE sensor is used to measure the reflected guided waves. The received guided waves are analyzed by the wavelet transform. The peak value of the wavelet transform produces the energy velocity, which is used for the evaluation of the rock bolt integrity. The energy velocity increases with an increase in the defect ratio in both laboratory and field rock bolts. This study demonstrates that the hammer-impact reflection method may be a suitable method for the evaluation of the rock bolt in the field.

• Journal of Korean Tunnelling and Underground Space Association
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• v.10 no.3
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• pp.221-232
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• 2008

Rock bolts have been installed into rockmass as a main support system. In order to evaluate the rock bolt integrity using non-destructive technique, the transmission method of the guided ultrasonic wave has been successfully performed. For the transmission method, however, the source for the generation o# guided ultrasonic waves should be installed at the end of the steel bar during construction of the rock bolt in the field. The purpose of this study is to suggest a reflection method that the source and the receiver are installed on the head of the steel bar. The reflection method is compared with the transmission method using non-embedded rock bolts and rock bolts embedded in concrete block. In this experiment, the piezo disc element is used as the source and the AE sensor is used as the receiver. The wavelet transform is applied to determine the energy velocity. The experimental studies show that the reflection method produces almost identical value of the transmission method, and the energy velocity increases with the defect ratio. This study suggests that the reflection method of the guided ultrasonic wave may be a suitable method fur the rock bolt integrity evaluation in the field.

• Journal of Korean Tunnelling and Underground Space Association
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• v.9 no.1
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• pp.75-82
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• 2007

As one of the main support systems, rock bolts play a crucial role in the reinforcement of tunnels. Numerical and experimental studies using a transmission method of ultrasonic guided waves are performed to evaluate the integrity of rock bolts encapsulated by grouting paste. Numerical simulations using "DISPERSE" are carried out for the selection of the optimal experimental setup, i.e. non-destructive testing (NDT) system of the rock bolt. Based on results of the numerical simulation, the calculated frequency range for NDT testing is between 20kHz and 70kHz with the first longitudinal L(1) mode. Laboratory transmission tests are performed by attaching the piezo electric sensor at the tip of the rock bolt before embedding. Both of analytical and experimental results show that the amplitude of signals as well as the wave velocity increases with increase in the defect ratio of grouting paste. The defect in grouting paste means that the space around the rock bolt is not fully filled with the grouting paste. Experimental results also show that the increase of the wave velocity is more sensitive to the defect ratio increase than that of the amplitude. This study demonstrates that the transmission technique of ultrasonic guided waves may be a valuable tool in the evaluation of the rock bolt integrity.

• Journal of the Korean Geotechnical Society
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• v.25 no.12
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• pp.5-12
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• 2009

As rock bolts become one of the main support systems in tunnels and underground structures, the integrity of the rock bolts affects the safety of these structures. The purpose of this study is the evaluation of rock bolt integrity using wavelet transforms of the guided ultrasonic waves by using transmission test in the field. After several rock bolts with various defect ratios are embedded into a large scale concrete block and rock mass, guided waves are generated by a piezo disk element and measured by an acoustic emission (AE) sensor. The captured signals are analyzed in the time-frequency domain using the wavelet transform based on a Gabor wavelet. Peak values in the time-frequency domain represent the interval of travel time of each echo. The energy velocities of the guided waves increase with an increase in the defect ratio. The suitable curing time for the evergy velocity analysis is proposed by the laboratory test, and in-situ tests are performed in two tunnelling sites to verify the applicability of rock bolt integrity tests performed after proposed curing time. This study proves that time-frequency domain analysis is an effective tool for the evaluation of the rock bolt integrity.