• Journal of the Institute of Electronics Engineers of Korea SC
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• v.47 no.6
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• pp.58-63
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• 2010

In this paper, distributed tension observer for R2R process is proposed. The minimal order observer theory is utilized to design the distributed tension observer. The proposed method estimates the tension of a specific sub-process based on the speed and tension information from its adjacent sub-processes. Utilizing its properties, the proposed method can be applied to decentralized control structure. In order to achieve high estimation accuracy, sliding mode technique is also adopted to the proposed method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.164-167
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• 2003

Profile ring rolling process is simulated by using the general purpose commercial finite element analysis software MSC.Superform Because the deforming region is restricted to the vicinity of the roll gap, only a ring segment spanning the roll gap is analysed in order to save computation time and cost. A profile ring with an external round groove is chosen as an example to be analysed. The rolls with and without groove were analysed to compare the amount of side spread. It is found that the grooves in the rolls reduce the amount of side spread.

• International Journal of Precision Engineering and Manufacturing
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• v.3 no.1
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• pp.26-32
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• 2002

Laser direct patterning of the coated photoresist (PMER-NSG31B) layer was studied to make halftone dots on the gravure printing roll. The selective laser hardening of the photoresist by Ar-ion laser(wavelength: 333.6∼363.8 nm) was controlled by the A/O modulator. The coating thickness in the range of 5∼11㎛ could be obtained by using the up-down directional moving device along the vertically located roll. The width, thickness and hardness of the hardened lines farmed under the laser power of 200∼260mW and irradiation time of 4.4∼6.6 $\mu$ sec/point were investigated after developing. The hardened width increased as the coating thickness increased. Though the hardened thickness was changed due to the effect of the developing solution, the hardened layer showed good resistance to the scratching of 2H pencil. Also, the hardened minimum line width of 10㎛ could be obtained. The change of line width was also found after etching, and the minimum line widths of 6㎛ could be obtained. The hardened lines showed the good resistance to the etching solution. Finally, the experimental data could be applied to make gravure halftone dots using the developed imaging process, successfully.

• Korean Journal of Materials Research
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• v.21 no.12
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• pp.655-659
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• 2011

An ultrafine grained complex aluminum alloy was fabricated by an accumulative roll-bonding (ARB) process using dissimilar aluminum alloys of AA1050 and AA5052 and subsequently annealed. A two-layer stack ARB process was performed up to six cycles without lubricant at an ambient temperature. In the ARB process, the dissimilar aluminum alloys, AA1050 and AA5052, with the same dimensions were stacked on each other after surface treatment, rolled to the thickness reduction of 50%, and then cut in half length by a shearing machine. The same procedure was repeated up to six cycles. A sound complex aluminum alloy sheet was fabricated by the ARB process, and then subsequently annealed for 0.5h at various temperatures ranging from 100 to $350^{\circ}C$. The tensile strength decreased largely with an increasing annealing temperature, especially at temperatures of 150 to $250^{\circ}C$. However, above $250^{\circ}C$ it hardly decreased even when the annealing temperature was increased. On the other hand, the total elongation increased greatly above $250^{\circ}C$. The hardness exhibited inhomogeneous distribution in the thickness direction of the specimens annealed at relatively low temperatures, however it had a homogeneous distribution in specimens annealed at high temperatures.

• Journal of the Society of Naval Architects of Korea
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• v.52 no.6
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• pp.452-459
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• 2015

It is important to use bench test results in the design process of anti-rolling tanks. Traditional bench tester is usually designed to perform only roll motions about a fixed axis and relatively small so that the viscous effects may not be neglected. Novel bench tester which could adjust the motion center to realize the coupled motion of sway and roll has been devised and manufactured therefore, large scaled bench tester could be utilized for designing the passive anti-rolling tanks. The time history of the reference signal from the rotation sensor of the bench tester have been recorded and processed to determine the phase angle to derive the Response Amplitude Operator(RAO) of the stabilized ship. The breadth of ART tank model should be large up to 2 m to diminish viscous scale effect and the vertical position of the tank can be varied with the ship's center of motion. The periods and the amplitude of roll motion can be varied from 1.5 sec to 5 sec and up to ±20°, respectively. The components of the tester was expressed in three dimensional digital mockup (DMU) and assembled together in the CAD space. The final configuration of the bench tester has been determined by confirming the smooth operation of the moving parts without interference through the animation in CAD space. New analytic logic are introduced for the determination of hydrodynamic moment and phase difference due to fluid motion in ART and verified through the test. The developed bench tester is believed to be effective and accurate for the verification of stabilization effect of ART taking into the consideration of the sway effect in the design stage.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.313-316
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• 2008

This work sought to examine the suitability of twin roll strip casting for Ag-27%Cu-25%Zn-3%Sn brazing alloy (BAg-7A) and to investigate the mechanical properties and microstructure of the strip. The effect of aging heat treatment on the properties was also studied,. This new manufacturing process has applications in the production of the brazing alloy. XRD and microstructural analysis of the Ag-27%Cu-25%Zn-3%Sn strip represented eutectic microstructure of a Cu-rich phase and a Ag-rich matrix regardless of heat treatment. The results of mechanical tests showed tensile strength of 470MPa, a significant enhancement, and an 18% elongation of the twin roll casted strip, due mainly to the solid solution strengthening of Zn atoms (${\sim}20%$) in the Cu-rich phases. Tensile results showed gradually decreasing strengths and increasing elongation with aging heat treatment. Microstructural evolution and fractography were also investigated and related to the mechanical properties.

• Transactions of Materials Processing
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• v.25 no.3
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• pp.161-168
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• 2016

Sheet metals are often required to be formed into three dimensional curved shapes for use as skin structures. As a result various sheet metal forming methods, such as press die forming, stretch forming, and line heating have been used over the years in industrial production lines. Although they are extensively used in industry, these methods are not suitable for small quantity batch productions. Studies have been conducted to improve or replace these methods with plausible flexible forming technologies. As a part of these studies, we developed a new and more efficient forming device named flexibly-reconfigurable roll forming (FRRF). The current study presents the process development and experimental verification for the applicability of this device. To improve the efficiency of the FRRF apparatus, several hardware components were invented and a suitable operating program was developed using MFC of visual C++. The ways to make the FRRF apparatus fully functional are also described. Sheet metal was formed into three dimensional shapes using the FRRF apparatus and the final products are presented as evidence for the applicability of the developed device.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.101-105
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• 2005

Hemming process, composed of flanging, pre-hemming and main hemming, is the last one of a series of forming processes conducted on the automotive panels, having a great influence on the outward appearance of them. The hem quality can be quantitatively defined by the hemming defects including turn-down, warp and roll-in. However, it is difficult to evaluate and predict the hem quality through the experimental measurement or the numerical calculation since the size of defects is very small. This study is focused on how to simulate in the finite element analysis (FEA) the same conditions as in the experiment. The FEA result on turn-down, that was obtained from a finite element model including the spring element linked to the flanging pad, had a good correlation with the experimental data. It was found that the radius of curvature of the flange deeply affects the final hem quality and therefore high rigidity of forming tools and tight assembling tolerance are highly recommended. An over-stroke of the main hemming punch is also proposed to reduce the turn-down.

• Korean Journal of Materials Research
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• v.15 no.9
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• pp.555-559
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• 2005

An oxygen free copper severely-deformed by eight cycles (an equivalent strain of $\~6.4$) of accumulative roll-bonding (ARB) was annealed at various temperatures ranging from 100 to $300^{\circ}C$. The annealed copper was characterized by transmission electron microscopy (TEM) and tensile & hardness test. TEM observation revealed that the ultrafine grains developed by the ARB still remained up to $150^{\circ}C$, however above $200^{\circ}C$ they were replaced by equiaxed and coarse grains due to an occurrence of the static recrystallization. Tensile strength and hardness of the copper decreased slightly with the annealing temperature up to $150^{\circ}C$, however they dropped largely above $200^{\circ}C$. Annealing characteristics of the copper were compared with those of a commercially pure aluminum processed by ARB and subsequently annealed.

• Corrosion Science and Technology
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• v.20 no.5
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• pp.315-323
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• 2021

In this study, we examined corrosion behaviors of two types of Pb alloys for a lead acid battery comparatively. One containing 6.6 wt% Sn, 36 mg/kg Bi, and 612.4 mg/kg Ca was prepared by twin-roll continuous casting. The other containing 5.2 wt% Sn, 30.5 mg/kg Ag, and 557 mg/kg Ca was made by twin-belt continuous casting. Potentiodynamic polarization tests were performed to evaluate corrosion resistance. Cyclic voltammetry was done to examine oxidation and reduction reactions occurring on the surface of each alloy in 4.8 M H₂SO₄ solution. Electrochemical test results implied that the Pb alloy prepared with the twin-belt casting method was less stable than that cast with the twin-roll method. Such results might be due to precipitations formed during the casting process. Rolling did not appear to affect the corrosion behavior of the twin-roll samples with Ag < 10 mg/kg, while it reduced the anodic reaction of Ag on the surface of the twin-belt sample with 30.5 mg/kg Ag.