• Composites Research
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• v.15 no.5
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• pp.44-52
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• 2002

To study numerically the mechanical behaviors of advanced composite materials considering the microscopic phenomena as well as the macroscopic properties and behaviors, a multi-scale modeling and analysis by the mathematical homogenization method with the help of the finite element method(FEM) are reviewed. The hierarchical modeling strategy and the formulation are briefly described first to give some idea of the multi-scale framework. The latter half of this article focuses on the verification of the multi-scale analysis by the homogenization method in its applications to real advanced materials. The first example is the verification of the predicted macroscopic(homogenized) properties based on the microstructure of porous ceramics. In spite of the complexity of the random microstructure, the error between the predicted and the measured values was only 1%. Next, two applications to the process simulation of fiber reinforced polymer matrix composites are presented. The permeability characteristics are evaluated for sheared weave fabrics for resin transfer molding(RTM) simulation, and the thermoforming of FRTP sheet is analyzed considering the large deformation of the knit structure during the deep-draw forming was verified by comparison with the experimental results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.4
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• pp.43-49
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• 2004

The production parts have required multiple processes such as drawing, piercing, blanking and notching etc. are performed with a high production rates in progressive die. In order to prevent the defects of process result, the optimization of strip process layout design, die design, die making, and tryout etc. are needed. According to these factors of die development process, it has been required that the theory and practice of metal working process and its phenomena, die structure, machining conditions for die making, die materials, heat treatment of die components, processing know-how and so on. In this study, we designed and analyzed die components through the carrying out of upper relevant matters also simulated the strip process layout of multiple stage drawing by DEFORM. Especially the result of tryout and its analysis became to the feature of this study with a system of PDDC(Progressive Die design by computer).

• Proceedings of the Materials Research Society of Korea Conference
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• 2010.05a
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• pp.40.1-40.1
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• 2010

Recently high strength steel sheets with high formability for automotive parts have been being developed to meet the demands for passenger safety and weight reduction of car body. Among these high strength steels, dual-phase steels are regarded as one of the attractive steels due to their excellent mechanical properties including high strength and ductility. However, to be successfully applied to automotive parts they should be corrosion resistant enough to satisfy the required quality of car maker. This also requires their feasibility for galvannealed production including hot dip galvanizability. In this study has been placed on understanding the effects of heat-treatment(austenizing and isothermal treatment) on the microstructures and mechanical properties of a 0.06C-0.03Si-2.0Mn high strength steel for cold forming. The microstructure and phase distribution were examined with eth aids of SEM, EBSD, TEM etc.. Through the study the production of 590MPa grade DP GA steels with good formability and galvaniability were shown to be possible.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06b
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• pp.19-27
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• 1998

박판금속성형공정을 통하여 컴퓨터를 이용한 계산방법으로 효율적이고 정확하게 해석할 수 있는 박판성형해석시스템인 SAIT_STAMP를 개발하였다. 또한 이를 현업문제에 적용하여 금형의 개발기간과 비용을 줄이고 성형품 품질저하 문제들을 해결하는데 이용하였다. SAIT_STAMP 는 성형해석, 성형후해석 프로그램과 전·후 처리기로 구성이 되어있다. 금형과 재료의 접촉 및 마찰을 고려한 새로운 접촉처리방법을 성형해석에 적용하여 해석속도와 해석정확도를 향상하였고 다단계성형 및 유압성형 등 박판성형에 필요한 대부분의 기능을 개발하여 적용하였다. 성형후해석은 성형해석의 결과를 토대로 스프링백해석을 수행한다. Visual C++을 사용하여 개발된 전·후 처리기는 window 95N/T 환경의 PC에서 수행된다. 개발된 프로그램을 이용하여 현업 문제에 적용 해석하였으며 상용S/W 대비 우수한 결과를 얻었다. 현재 삼성내 9개 관계사에서 설치되어 사용중이며 프로그램의 대외신뢰성확보를 위해 대학과 비경쟁업체에 프로그램을 설치하여 프로그램을 설치하여 프로그램의 시험과 성능향상을 하고 있다.

• Transactions of Materials Processing
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• v.18 no.5
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• pp.371-376
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• 2009

An equivalent drawbead model(EDM) for sheet metal forming analysis, which replaces complex drawbead geometries with drawbead forces in modeling the stamping dies with finite elements, is experimentally verified and applied to the numerical simulation of auto-panel stamping process. The drawbead restraining and opening forces of elliptical drawbead, circular drawbead, square drawbead, and step drawbead are obtained by performing the drawbead pulling test and compared with those of EDM and commercial code models(CCM). Better agreement with experimental measurements is found in EDM than CCM. Furthermore, the excellence of EDM is demonstrated in its application to the auto-body stamping analysis.

• Transactions of Materials Processing
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• v.17 no.3
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• pp.197-202
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• 2008

The control of springback is very important in sheet metal forming since springback affects the dimensional inaccuracy of product. The object of this study is to design the manufacturing process for the improvement of the performance of seat rail by DP780. The influence of process variables such as bend angle and pad force on the springback has been firstly investigated through the comparison between the results of FE-analysis and trial out for initial design based on designer's experience. The process variables of the initial design have been modified in order to improve the dimensional accuracy of seat rail from the prediction of springback by FE-analysis. It was shown from experiment that the improved design satisfied the required specifications such as the dimensional accuracy and the strength of seat rail.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.3
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• pp.119-126
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• 1998

유리섬유 강화 열가소성 복합재료는 고상성형법에 의해 저렴한 가격으로 큰 부피의 제품의 제조에 널리 사용될 수 있어 아주 좋은 전망을 가지고 있다. 그러나 이러한 재료의 성형성이나 재료거동의 특성은 아직 잘 파악되지 않았다. 본 연구의 주안점은 이러한 재료의 단순 굽힘에서의 굽힘성형성을 연구하는데 두었다. 실험에 사용된 재료는 임의의 방향으로 위치한 유리섬유를 중량비로 20 %, 35 %, 40 % 함유한 폴리프로필렌이다 굽힘시험은 75 $^{\circ}C$에서 150 $^{\circ}C$ 사이의 온도에서 25 $^{\circ}C$ 씩 증가하면서 행했고, 편치속도는 2.54 mm/sec와 0.0254 mm/sec에서 행했다. 단순 굽힘시험에서 측정된 굽힘성형성은 해석적 모델로 예측한 결과와 비교하였다. 실험결과와 예측결과가 비교적 잘 일치함을 보였으며, 굽힘성 map으로써 성형 온도와 펀치반경의 좌굴에 대한 효과를 가시화 함은 물론 좋은 성형조건을 선정할 수 있는 좋은 도구로써 나타내었다.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.89-92
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• 1997

Design of a weld line in a tailor welded blank is indispensable for good manufacturing of stamped parts as assigned, since the intial weld line is distorted severely with forming. The initial weld line has to be determined such that desired weld line in a formed part can be obtained. The initial weld line was predicted by inverse finite element analysis from the desired weld line in a formed part. The inverse approach is applied to the cylindrical and square cup drawing with tailor welded blanks. The applications demonstrates that the approach is useful for design of weld line of tailor welded blank.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.448-452
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• 2005

Punching/blanking/shearing is among the oldest and most frequently used sheet metal forming process. We have developed the shear device for burrless cutting using the micro wire. Since the burr minimization and fine shear plane, this paper is a study on the effect of the shear angle and clearance of the cutter-cutter. And, we confirm the tendency of the shear plane. It is impossible to completely remove the burr in the shearing process. In order to minimize the burr size and fine shear plane, we have accomplished the various experiment conditions such as the shear angle and clearance. Despite the quality of shear plane is not good enough yet, it is possible to make the burr minimization and fine shear plane by the optimization of process parameters.

• Transactions of Materials Processing
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• v.19 no.5
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• pp.290-295
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• 2010

Shaving technology is one of the significant metal forming technologies which can make the smooth and fine sheared surface of products after shearing process. The sheared surface on the side wall of the cutting edge is very important because it functions as a basic surface for measuring the dimensions of product. Effective sheared surface after shaving can be influenced by several working variables such as shaving allowance, shaving clearance, type of material and profile of cutting edge. The influence of these variables on shaving characteristics was investigated in this study. A cut-off die to make the simplified gear-shaped products was manufactured. Three kinds of sheet metals (AL5052, SPCC and SAPH440) of 3mm thickness were firstly sheared and then shaved for four shaving allowances and three sharing clearances. It was shown through experiments that the optimum working condition to give the maximum effective sheared surface in shaving was found ; Shaving allowance is 0.2mm and Shaving clearance is 0.01mm.