• 한국정밀공학회지
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• 제13권9호
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• pp.77-83
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• 1996

This paper describes forging of trochoidal gears, which are being widely used in timing belt pulley, pump pulley etc., as a series of development of the simulator for non-axisymmetric elements. Kinematically admissible velocity fields for forging of trochoidal gear were proposed and the loads were calculated by numerical method. When the simulation was carried out, half pith of gear was divided into 6 deformation regions which have different velicity fields by assumptions and boundary conditions. The neutral surface was introduced into forging of trochoidal gears with flat punch and, for each step, it is assumed as a circle with its radius r$_{n}$. The experimental set-up was installed in 200 ton hydraulic press for forging. The billets, of A1 2218 aluminum alloy, were slightly phosphate-coated. It was shown that thd theoretical solutions, as upper bound, are useful to predict the forging load for forging of trochoidal gears, because thdt give estimates that are substantially higher than experimental loads.s.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2000년도 추계학술대회 논문집
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• pp.591-594
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• 2000

This paper describes a research work of developing a computer-aided design of product with bending and piercing for progressive working. An approach to the system for progressive working is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of four main modules, which are input and shape treatment, flat pattern layout, strip layout and die layout module. Based on knowledge-based rules, the system is designed by considering several factors such as radius and angle of bend, material and thickness of product, complexities of blank geometry and punch profile, bending sequence, and availability of press. Strip layout drawing generated by the piercing processes with punch profiles divided into for external area is simulated in 3-D graphic forms, including bending sequences for the product with piercing and bending. Results obtained using the modules enable the manufacturer for progressive working of electronic products to be more efficient in this field.

• 한국정밀공학회지
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• 제15권6호
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• pp.22-32
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• 1998

This paper describes a research work of developing a computer-aided design of irregularly shaped-sheet metal product with bending and piercing operation for progressive working. An approach to the CAD system is based on the knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of five main modules, which are input and shape treatment, flat pattern-layout, production feasibility check, blank-layout, and strip-layout module. Based on knowledge-based rules, the system is designed by considering several factors, such as radius and angle of bend, material and thickness of product, complexities of blank geometry and punch profile, and availability of press. This system is capable of unfolding a formed sheet metal part to give flat pattern and automatically account for the adjustment of bend allowances to match tooling requirements by checking dimensions and the best utilization ratio of blank-layout within bending production feasibility area which is beyond ${\pm}30^{\circ}$ degrees intersecting angle between grain flow and bending edge line and which is suitable to progressive bending operation. Also the strip-layout drawing generated by a bending and a piercing operation according to punch profiles divided into automatically for external area of irregularly shaped-sheet metal product is displayed in graphic forms.

• 한국산학기술학회논문지
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• 제18권1호
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• pp.107-114
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• 2017

터보차저는 배기가스로 구동되는 엔진 과급기를 말하며, 배기에너지를 이용하여 배기통로에 연결된 터빈의 회전력을 변화시켜, 혼합 가스의 충전효율을 높여 출력과 연비를 향상 시키는 부품이다. 이러한 목적에 따라 과급을 조절해주는 것이 중요하며, 핵심 부품 중 노즐 슬라이드 조인트가 있다. 소재는 현재 오스테나이트 계 스테인리스강으로 높은 내열성과 내식성 등의 우수한 기계적 성질을 이용하고 있다. 그러나 절삭성이 나쁘기 때문에 절삭가공에 의해 복잡한 형상의 제품을 만드는데 어려운 점이 많다. 현재 노즐 슬라이드 조인트의 가공방법은 금속분말 사출성형후 치수정밀도를 위해 절삭가공을 행하고 있다. 따라서 본 연구에서는 Nitronic 60을 이용하여 터보차저 과급유량을 조절해주는 노즐 슬라이드 조인트의 제작 공정에서 절삭가공이 필요 없는 정형가공 공정을 제안하기 위하여, 기계적 특징에 영향과 연관이 있는 소결온도, 제품의 응력 및 변형률, 형상과 관련이 있는 모따기 펀치각도 및 펀치의 곡률반경을 설계변수로 선정하였다. 그에 따라 유한요소해석과 실험계획법인 다구찌법 및 SN비를 이용하여 가장 좋은 공정 조건을 제안하였다. 최종제품과 유한요소해석 결과의 상대밀도 및 정수압을 비교하여 경향이 일치함을 알 수 있었다. 따라서 다구찌법을 이용한 금속분말의 성형공정 설계에 유용하게 적용할 수 있을 것으로 판단된다.

• 소성∙가공
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• 제21권3호
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• pp.202-206
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• 2012

Marking is a process that engraves letters or a pattern onto the surface of sheet metal. During marking, it is important to set the proper working conditions for clarity of the letters. In this study a simple case for forming circular protrusions by half-piercing and embossing was initially attempted to determine the working conditions which gave good results with respect to shape accuracy. Corner-radius and flatness of circular protrusions made under several experimental conditions were measured and compared. It is shown that the precision of protrusions by half-piercing is superior to that of embossing, and the clearance between punch and die exerts a strong influence on the shape accuracy rather than the penetration percentage into the thickness of the sheet metal. The marking dies for "SNUT" letters, as an example, by applying the above results were manufactured with four different clearances. The working variables for the experiment were clearance and marking depth. For the very shallow depth of 0.1mm the letters were not clearly read. Letters marked under other conditions were easily distinguished with increasing marking depth. It was confirmed that the half-piercing technique with proper values of the working variables gives good quality for the marking of sheet metal.

• Computers and Concrete
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• 제26권2호
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• pp.107-114
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• 2020

In this study, a two dimensional model of receding contact problem has been analyzed using finite element method (FEM) based software ANSYS and ABAQUS. For this aim finite element modeling of elastic layer and two homogeneous, isotropic and symmetrical elastic quarter planes pressed by means of a rigid circular punch has been presented. Mass forces and friction are neglected in the solution. Since the problem is examined for the plane state, the thickness along the z-axis direction is taken as a unit. In order to check the accuracy of the present models, the obtained results are compared with the available results of the open literature as well as the results of two software are compared using Root Mean Square Error (RMSE) and good agreements are found. Numerical analyses are performed considering different values of the external load, rigid circular radius, quarter planes span length and material properties. The contact lengths and contact stresses of these values are examined, and their results are presented. Consequently, it is concluded that the considered non-dimensional quantities have noteworthy influence on the contact lengths and contact stress distributions, additionally if FEM analysis is used correctly, it can be an efficient alternative method to the analytical solutions that need time.

• 대한기계학회논문집A
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• 제25권4호
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• pp.629-636
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• 2001

In order to investigate the possibility of impact punching in brittle materials, an experimental setup was developed. In the setup, a long bar as a punch was used to apply the impact load to the specimen plate and measure the applied impact force during the impact punching process. Impact punching tests with various shape of punches were performed in soda-lime glass and silicon wafer under a different level of contact pressure. The damage appearance after the impact punching was examined according to the applied contact pressure. The minimum contact pressure required for a complete punching in glass specimens without development of radial cracks around the punched hole was sought at each condition. The minimum contact pressure increased with increasing the thickness of specimens and decreasing the end radius of punches. The profile of impact forces was measured during the impact punching experiment, and it could explain well the behavior of the punching process in brittle material plates. The measured impact force increased with increasing the contact pressure applied to the plates.

• 소성∙가공
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• 제26권6호
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• pp.341-347
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• 2017

Flexibly-reconfigurable roll forming (FRRF) is a novel sheet metal forming technology conducive to produce multi-curvature surfaces by controlling strain distribution along longitudinal direction. Reconfigurable rollers could be arranged to implement a kind of punch die set. By utilizing these reconfigurable rollers, desired curved surface can be formed. In FRRF process, three-dimensional surface is formed from two-dimensional curve. Thus, it is difficult to predict the forming result. In this study, a regression analysis was suggested to construct a predictive model for a longitudinal curvature of FRRF process. To facilitate investigation, input parameters affecting the longitudinal curvature of FRRF were determined as maximum compression value, curvature radius in the transverse direction, and initial blank width. Three-factor three-level full factorial experimental design was utilized and 27 experiments using FRRF apparatus were performed to obtain sample data of the regression model. Regression analysis was carried out using experimental results as sample data. The model used for regression analysis was a quadratic nonlinear regression model. Determination factor and root mean square root error were calculated to confirm the conformity of this model. Through goodness of fit test, this regression predictive model was verified.

• 대한기계학회논문집A
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• 제28권2호
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• pp.149-157
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• 2004

Implicit finite element analysis of the flat surface-straight edge hemming process is performed by using a commercial code ABAQUS/Standard. Methods of finite element modeling for springback simulation and contact pair definition are discussed. An optimal mesh system is chosen through the error analysis that is based on the smoothing of discontinuity in the state variables. This study has focused on the investigation of the influence of process parameters in flanging, pre-hemming and main hemming on final hem quality, which can be defined by turn-down, warp and roll-in. The parameters adopted in this parametric study are flange length, flange angle, flanging die corner radius, face angle and insertion angle of pre-hemming punch, and over-stroke of pre-hemming and main hemming punches.

• 한국산학기술학회논문지
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• 제10권7호
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• pp.1453-1458
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• 2009

본 논문은 중공을 가진 판재 두 매를 결합하기 위하여 중공 주위를 따라 기존 레이저 용접법 대신 기계적 프레스 결합법을 적용하는 것에 관한 연구이다. 이를 통해 레이저 용접을 적용했을 때 불가피하게 발생하는 열 변형을 효과적으로 없앨 수 있다. 유한요소해석을 통하여 중공형 판재를 기계적으로 결합시킬 수 있는 금형 설계 방법을 제안하였다. 기계적 결합력을 최대화시키는 데 관련 있는 다섯 가지 설계인자를 선택하여 다꾸치 실험법을 적용한 결과 성형 깊이와 펀치모서리 반경이 가장 크게 영향을 미치는 인자로 나타났다.