• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.6 no.4
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• pp.108-117
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• 1997

A continuum analysis has been performed for the application to the thermo-elasto-plastic behavior in a discontinuous metal matrix composite. an FEM (Finite Element Method) analysis was implemented to obtain the internal field quantities of composite as well as overall composite behavior and an experiment was demonstrated to compare with the numerical simulation . As the procedure, a reasonably optimized FE mesh generation, the appropriate imposition of boundary condition , and the relevant post processing such as elastoplastic thermomchanical analysis were taken into account. For the numerical illustration, an aligned axisymmetric single fiber model with temperature dependent material properties and precipitation hardening effect has been employed to assess field quantities. It was found that the residual stresses are induced substantially by the temperature drop during the thermal treatment and that the FEM results of the vertically and horizontally constrained model give a good agreement with experimental data.with non-woven carbon mat is about 24% higher than that of composite materials without non-woven carbon mat. Transverse tensile strength and torughness also increase by inserting non-woven carbon mat between layers.

• Laser Solutions
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• v.4 no.1
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• pp.21-28
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• 2001

Simulation on the electron beam welding of Al 2219 alloy was carried out by using commercial FEM code MARC, which encounters moving heat sources. Due to axisymmetry of geometry, a half of the cylinder was simulated. A coupled thermo-mechanical analysis was carried out and subroutine for heat flux was substituted in the program. The material properties such as specific heat, heat transfer coefficient and thermal expansion coefficient were given as a function of temperature and the latent heat associated with a given temperature range is considered. As a result, the proper beam power is 60㎸${\times}$60㎃ and welding speed is 1∼1.5 m/min. The residual stress in the heat-affected zone as well as the fusion zone does not increase. It is necessary to use jigs for preventing distortion of cylinder and improving weld quality.

• Laser Solutions
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• v.17 no.3
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• pp.15-18
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• 2014

In this paper, we studied a machining method using a diffractive beam splitter (DBS) and multi- pulse repeated radiation for breathable film. We fabricated micro-grooves on polypropylene (PP) films using multi-pulse radiation and one-shot radiation (radiating pulses at once) and a DBS. In the result, width and depth of the PP film using multi-pulse repeated radiation were more precisely controllable. Therefore, this method can be applicable to in manufacturing breathable film precisely at a high speed.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.22 no.1
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• pp.61-73
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• 2012

The paper presents the novel approach to solve some problems occurred in application of the genetic algorithm to the determination of the optimal tire pattern sequence in order to reduce the tire air-pumping noise which is generated by the repeated compression and expansion of the air cavity between tire pattern and road surface. The genetic algorithm has been used to find the optimal tire pattern sequence having a low level of tire air-pumping noise using the image based air-pumping model. In the genetic algorithm used in the previous researches, there are some problems in the encoding structure and the selection of objective function. The paper proposed single encoding element with five integers, divergent objective function based on evolutionary process and the optimal evolutionary rate based on Shannon entropy to solve the problems. The results of the proposed genetic algorithm with evolutionary process are compared with those of the randomized algorithm without evolutionary process on the two-dimensional normal distribution. It is confirmed that the genetic algorithm is more effective to reduce the peak value of the predicted tire air-pumping noise and the consistency and cohesion of the obtained simulation results are also improved in terms of probability.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1640-1643
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• 2005

This paper presents analysis of dynamic characteristics of a high-speed milling spindle with a drawbar and a built-in motor. The spindle system with a built-in motor can be used to simplify the structure of machine tools, to improve the machining flexibility of machine tools, and to perform the high speed machining. In this system the shaft is usually assumed as a rigid rotor. In this paper, the modal characteristics of drawbar in high-speed milling spindle system due to supporting stiffness between drawbar and shaft and considering the mass and stiffness effects of the built-in motor's rotor are analyzed by numerical method. The result shows enough stiff supports must be provided between shaft and drawbar to prevent occurring drawbar vibration lower than the natural frequency of 1st bending mode of spindle. And considering the mass and stiffness of built-in motor's rotor is important thing to derive more accurate results.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.8
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• pp.687-692
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• 2015

LAM (Laser-Assisted Machining) is an effective method for processing difficult-to-cut workpieces. The focal length of a LAM system is changed by the change of the workpiece shape during laser preheating; this problem is solved by changing the lens of the laser module. Linear- and rotary-type lens changers were developed to change the laser lens of a LAM system. The linear-type lens changer is operated by a motor with a ball-screw, and the rotary type is operated by a stepping motor. The natural frequency and structural stability of the laser lens changers were confirmed by using a finite element analysis; in addition, the functions of the lens changers were verified by measuring the iterative accuracy. The measured results show that the rotary-type lens changer is more accurate than the linear-type changer.

• Transactions of Materials Processing
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• v.14 no.8 s.80
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• pp.718-724
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• 2005

An efficient finite element method has been introduced for analysis of metallic sandwich plates subject to bending moment. A full model 3-point bending FE-analysis shows that the plastic behavior of inner structures appears only at the load point. The unit structures of sandwich plates are defined to numerically calculate the bending stiffness and strength utilizing the recurrent boundary condition for pure bending analysis. The equivalent models with the same bending stiffness and strength of full models are then designed analytically. It is demonstrated that the results of both models are almost the same and the FE-analysis method incorporating the equivalent models can reduce the computation time effectively. The dominant collapse modes are face buckling and face yielding. Since the inner dimpled structures prevent face buckling, sandwich plates with inner dimpled shell structure can absorb more energy than other types of sandwich plates during the bending behavior.

• Transactions of Materials Processing
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• v.18 no.7
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• pp.565-571
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• 2009

This paper is concerned with the analysis on the surface stress profiles of perfectly plastic material in backward extrusion process. Due to heavy surface expansion appeared usually in the backward extrusion process, the tribological conditions along the interface between the material and the punch land are very severe. In the present study, the analyses have focused to reveal the surface conditions at the contact boundary for various punch shapes in terms of surface expansion, contact pressure, and relative movement between punch and workpiece which consists of sliding velocity and distance, respectively. Punch geometries adopted in the analysis include concave, hemispherical, pointed and ICFG recommended shapes. Extensive simulation has been conducted by applying the rigid-plastic finite element method to the backward extrusion process under different punch geometries. The simulation results are summarized in terms of surface expansion, contact pressure, sliding velocity and sliding distance at different reduction in height, deformation patterns, and load-stroke relationship, respectively.

• Transactions of Materials Processing
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• v.18 no.7
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• pp.556-564
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• 2009

Flexible forming process for sheet material using reconfigurable die is introduced based on numerical simulation. In general, this flexible forming process using the reconfigurable die has been utilized for manufacturing of curved thick plates used for hull structures, architectural structures and so on. In this study, numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. The numerical simulation and experimental verification for sheet metal forming process using a flexible forming machine that is more suitable for thick plate forming process are carried out to confirm the appropriateness of the simulation process. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation for smoothing the forming surface which is discrete due to characteristics of the flexile die. In the flexible forming process for sheet metal, effect of a blank holder is also investigated according to blank holding methods. Formability in view of occurrence of dimples is compared with regard to the various punch sizes. Consequently, it is confirmed that the flexible forming for sheet material using urethane pad has enough capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming method.

• Transactions of Materials Processing
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• v.24 no.4
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• pp.293-298
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• 2015

A safety vent is crucial to protect its user from unpredictable explosions caused by increasing internal pressure of the lithium-ion batteries. In order to prevent the explosion of the battery, a safety vent rupture is required when the internal pressure reaches a critical value. In conventional manufacturing, the cap plate and the safety vent are fabricated separately and subsequently welded to each other. In the current study, a manufacturing process including a backward extrusion and coining process is suggested to produce an integral safety vent which also has the benefit of increasing production efficiency. FE simulations were conducted to predict the rupture pressure and to design the safety vent using a ductile fracture criterion and the element deletion method. The critical value, C, in the ductile fracture criterion was obtained from uniaxial tensile tests with an annealed sheet of 1050-H14 aluminum alloy. Rupture tests were preformed to measure the rupture pressure of the safety vent. The results met the required rupture pressure within 8.5±0.5 kgf/cm². The simulation results were compared with experimental results, which showed that the predicted rupture pressures are in good agreement with experimentally measured ones with a maximum error of only 3.9%.