• Transactions of Materials Processing
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• v.25 no.6
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• pp.390-395
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• 2016

GDI fuel rail is component of GDI system which directly fuel with high pressure in the engine combustion chamber. And it is required to high strength and dimensional accuracy. Multi roll-die drawing process consists of the idle roll-die and drawing die in tandem. In the course of drawing with roll-die, deformation takes place between the idle roller pair or pairs. The friction force decreases with the idle roll-die, enabling the reductions to be risen in one step. In this study, the caliber of 4-roll was designed into pass schedule that made the draw force at the exit of the drawing die be equal. In order to compensate for over-filling area, the roll caliber was modified using the result of FE-analysis. The results of FE-analysis and experiment show that the proposed design method can be used to effectively design the multi roll-die process, leading to an accurate shape and correct dimensions of the final within an allowable tolerance of ${\pm}0.08mm$. Furthermore, the productivity was evaluated by comparing with multi roll-die drawing process and conventional multi shape drawing process. The result was confirmed that it has an efficiency of about 2 times than conventional process in terms of time.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.103-109
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• 2014

Flexibly-reconfigurable roll forming (FRRF), which is a sheet forming process for multi-curved sheet metal, may solve both the economic and technical problems incurred in using a conventional die forming process. In the FRRF process, the multi-curved sheet metal is formed by different strain distributions on the sheet metal, and the reconfigurable rollers are used as tools during the forming. Therefore, a thorough investigation focused on the reconfigurable rollers is required for the realization of the FRRF process prior to the fabrication of FRRF machine. In the current study, a series of finite element simulations were conducted to study the load distributions experienced by the reconfigurable roller. In order to verify the shape design variables, the effect of the metal thickness on the curvatures of sheet is also presented.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.8
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• pp.847-854
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• 2007

The battery electrode of a mobile phone is made of layered polymer coated on aluminum foils and the hot rolling process is applied to increase the density per volume of an electrode for a high capacity battery. The flatness of batteries surfaces should be less than $2{\mu}m$. To satisfy the required flatness, the deformation of roll surface due to bending and heating of the roll should be minimized. Complicated hot oil paths of $100^{\circ}C$ inside the roll are required for heating the polymer layers. FEA was used to calculate thermal deformations and temperatures distributions of the roller. Based on FEA, a modified surface curvature called a crown roll was suggested and this gave the area of 30% improved flatness compared with a flat roll. The flat roll satisfied the flatness of $2{\mu}m$ in the length of 340 mm and the crown roll resulted in the longer length of 460 mm. Experiments to measure the temperature distribution and thermal strain were performed and compared with FEA. There were only 6% difference between two results.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.10
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• pp.1141-1145
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• 2011

Recently, there are many issues about R2R printing technique for mass production of electronic devices. Among the various Roll-to-roll based printing techniques such as gravure, off-set, flexo and so on, "Gravure off-set printing technique" has an advantage of higher printing resolution. The printing unit of gravure off-set printing technique usually consists of plate roll, blanket roll and impressure roll whose. Linear velocities should be synchronized each other for fine pattern printing. However, roller's manufacturing error and printing variations such as pringting pressure, printing speed, roll stroke and so on actually affected their synchronization anf thus the quality of fine fattern. In this paper, we analyzed the effective of synchronization error on printing quality. Also, this paper reviews the relative motion with each roll. And, this paper studys the synchronization error about its generation problem.

• Journal of the Semiconductor & Display Technology
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• v.9 no.2
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• pp.91-96
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• 2010

In recent years there have been considerable attentions on nanoimprint lithography (NIL) by the display device and semiconductor industry due to its potential abilities that enable cost-effective and high-throughput nanofabrication. Although one of the current major research trends of NIL is large-area patterning, the technical difficulties to keep the uniformity of the residual layer become severer as the imprinting area increases more and more. In this paper we consider the roll-to-plate type imprinting process. In the process a glass mold, which is placed upon the 2nd generation TFT-LCD glass sized substrate(370${\yen}$470 mm), is rolled by a rubber roller to achieve a uniform residual layer. The pressure distribution on the glass mold by rolling of the rubber roller is crucial information to analyze mold deformation, transferred pattern quality, uniformity of residual layer and so forth. In this paper the quantitative pressure distribution induced by rolling of the rubber roller was calculated with finite element analysis under the assumption of Neo-Hookean hyperelastic constitutive relation. Additionally the numerical results were verified by the experiments.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.6
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• pp.81-89
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• 2009

Dancer systems are typical equipment for attenuation of tension disturbances. Lately, demands for high speed roll-to-roll machines are rising but it is prior to attenuate the tension variation on the web entering into the printing zone to achieve the speed increment. Maintaining a constant tension before the first printing cylinder is the key of high speed, high quality printing. Dancer has been researched in two ways, whether it is controlled or not. The first one is active dancer and the other one is passive dancer. In the active dancer, a position of idle roll of dancer is measured and the roll is moved by external hydraulic cylinder to control tension disturbances. While the passive one composed with spring, damper and idle roll has no external actuator to position the idle roll. The tension disturbance causes movement of dancer roll and the displacement of the roll regulates the tension variation. On the other hand a composite type of dancer is applied for roll-to-roll printing machines. It has same apparatus as passive dancer. The displacement of roll is measured and front(or rear) driven roller is controlled to position the roll. In this paper, it is presented an analysis of pendulum dancer including position feedback PI control and logic for PI gain tuning in roll-to-roll machines. Pole-zero map and root locus with varying system parameters gives a design method for control of the dancer.

• Journal of the Korean Graphic Arts Communication Society
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• v.18 no.2
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• pp.83-101
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• 2000

In this experiment butadiene rubber(BR)/acrylonitrile butadiene rubber(NBR) blends was prepared and then the applicability of BR/NBR blends as printing rubber roller was examined. With the aid of open 2-roll mill, BR, NBR and another chemical additives were compounded. Then rubber vulcanizates were manufactured by hot press and maximum torque, Mooney viscosity, mechanical properties and oil resistance of the test specimens were measured. With prolonged oil aged treating time, BR/NBR blends became soft and so the hardness of blends decreased. It could be explained by the swelling of rubber matrix with oil penetration in to rubber molecules. The undesirable low value of oil resistance of BR was significantly improved by blending BR with NBR.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2002.05a
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• pp.39-39
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• 2002

In order to improve wear and fatigue resistance of the structural materials, especially cold work roller for 304 stainless steel, an eco-super-finishing and surface hardening treatment using ultrasonic vibration energy was developed and applied to the SKD-ll roller. The eco-super-finishing machine was designed and fabricated by DesignMecha Co, by its own technology. It was observed that the surface roughness, hardness and residual stress were changed from $Ra{\;}={\;}O.25\mu\textrm{m}$, Hv=710 and ${\sigma}$={\;}+400{\;}MPa{\;}to{\;}Ra{\;}={\;}0.165\mu\textrm{m}$, Hv = 1200 and ${\sigma}=-610$ MPa after 20 KHz micro-cold forging, which means almost equal to the 300 % improvement of life-time.

• Tribology and Lubricants
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• v.26 no.1
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• pp.52-55
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• 2010

This study investigates the friction of the roll stands in the high performance multi- holes slate fin machine which pin is using in heat transfer of radiator, oil cooler, inter cooler, condenser and evaporator. The roll stand part is very important to maintain the high performance fin machine. This multi-holes form roll type is the first time in our country so it will be helpful to increases the export and product of heat transfer. It was include the technical of form rolling system which was self development. Then it will be improve the electric home appliances, future motor vehicle device and industrial machine.

• Journal of the Korean Society of Fisheries and Ocean Technology
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• v.27 no.2
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• pp.125-131
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• 1991

Electrolyte matrix fabrication process can be classifed as hot pressing, tape casting, callendering, electrophoretic deposition. however, these have limits in practice. Hot pressing is cumbersome method, because of careful heating and cooling. Furthermore, the perfected tile is so fragile that it is difficult to fit in a cell. Therefore this method is not adequate for mass production of the electrolyte matrix. Using electrophoretic deposition method, a very thin matrix can be made, but many attempts of the electrolyte embeding were found to be failure. Tape casting and callendering methods are employed in most of the matrix fabrication for the present. But these methods require lots of water as a solvent, so that coating of the LiAlO sub(2) with electrolyte is difficult. Recently, hot roll milling method has been developed and the perfected matrix was proved to be free from crack. The method, however, needs a roller to make a matrix and a perfected matrix is carefully striped off from the cooled roller. Therefore, this method requires a long time due to the cooling process. The author proposes a cold rolling process. On this method, heated slurry of the LiAlO sub(2) mixed with binder, is rolled with a cold roller. The heated slurry dose not adhere to the roller, since contacted hot slurry is rapidly solidified. Therefore fabrication speed is increased, without getting rid of merits of the hot rolling process.