• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.4
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• pp.110-121
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• 2009

It is essential to embed product quality in the design process to win the global competition. Many components found in many products including automobiles and electronic devices are fabricated using sheet metal forming processes. Wrinkle and fracture are two types of defects frequently found in the sheet metal forming process. Reducing such defects is a hard problem as they are affected by many uncontrollable factors. Attempts to solve the problem based on traditional deterministic optimization theories are often led to failures. Furthermore, the wrinkle and fracture are conflicting defects in such a way that reducing one defect leads to increasing the other. Hence, it is a difficult task to reduce both of them at the same time. In this research, a new design method for reducing the rates of conflicting defects under uncontrollable factors is presented by using operating window and a sequential search procedure. A new SN ratio is proposed to overcome the problems of a traditional SN ratio used in the operating window technique. The method is applied to optimizing the robust design of a sheet metal forming process. To show the effectiveness of the proposed method, a comparison is made between the traditional and the proposed methods using simulation software, applied to a design of particular sheet metal forming process problem. The results show that the proposed method always gives a more robust design that is less sensitive to noises than the traditional method.

• Journal of Welding and Joining
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• v.26 no.4
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• pp.79-84
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• 2008

Use of sheet metal structure is increased in various fields such as automobile, aerospace and communication equipment industry. When this structure is welded, welding distortion is generated due to the non-uniformity of temperature distribution. Recently welding distortion becomes a matter of great importance in the structure manufacture industry because it deteriorates the product's quality by bringing about shape error. Accordingly many studies for solving the problems by controlling the welding distortion are being performed. However, it is difficult to remove all kinds of distortion by welding process, though various kinds of methods for reducing distortion are applied to production. Consequently, straightening process is operated if the high precision quality is requested after welding. The local heating method induces compression plastic deformation by thermal expansion in the heating stage and then leaves constriction of length direction in the cooling stage. Accordingly, in the case of sheet metal structure, straightening effect is expected by heating for the part of distortion. This study includes numerical analysis of straightening effect by the local heating method in distortion comes from production of welded sheet metal structure. Particularly straightening effect followed by dimensions of heating area is analyzed according to the numerical analysis. The numerical analysis is performed by constructing 3-dimensional finite element model for 0.4mm stainless steel-sheet metal. Results of this study confirm that straightening effect changes as heating area increases and the optimum value of heating area that proves the maximum straightening effect exists.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.26 no.7
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• pp.539-544
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• 2013

To study the encapsulation method for heat dissipation of high brightness organic light emitting diode (OLED), red emitting OLED of ITO (150 nm) / 2-TNATA (50 nm) / NPB (30 nm) / $Alq_3$ : 1 vol.% Rubrene (30 nm) / $Alq_3$ (30 nm) / LiF (0.7 nm) / Al (200 nm) structure was fabricated, which on $Alq_3$ (150 nm) / LiF (150 nm) as buffer layer and Al as protective layer was deposited to protect the damage of OLED, and subsequently it was encapsulated using attaching film and metal sheet. The current density, luminance and power efficiency was improved according to thickness of Al protective layer. The emission spectrum and the Commission International de L'Eclairage (CIE) coordinate did not have any effects on encapsulation process using attaching film and metal sheet The lifetime of encapsulated OLED using attaching film and metal sheet was 307 hours in 1,200 nm Al thickness, which was increased according to thickness of Al protective layer, and was improved 7% compared with 287 hours, lifetime of encapsulated OLED using attaching film and flat glass. As a result, it showed the improved current density, luminance, power efficiency and the long lifetime, because the encapsulation method using attaching film and metal sheet could radiate the heat on OLED effectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.282-284
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• 2007

The hardening and the constitutive equation based on the crystal plasticity are introduced for the numerical simulation of hemispherical sheet metal forming. For calculating the deformation and the stress of the crystal, Taylor's model of the crystalline aggregate is employed. The hardening is evaluated by using the Taylor factor, the critical resolved shear stress of the slip system, and the sum of the crystallographic shears. During the hemispherical forming process, the texture of the sheet metal is evolved by the plastic deformation of the crystal. By observing the texture evolution of the BCC sheet, the texture evolution of the sheet is traced during the forming process. Deformation texture of the BCC sheet is represented by using the pole figure. The comparison of the strain distribution and punch force in the hemispherical forming process between crystal plasticity and experiment shows the verification of the crystal-based formulation and the accuracy of the hardening and constitutive equation obtained from the crystal plasticity.

• Journal of Mechanical Science and Technology
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• v.16 no.12
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• pp.1687-1692
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• 2002

The problem analyzed here is a sheet metal forming process which requires a drawbead. The drawbead provides the sheet metal enough tension to be deformed plastically along the punch face and consequently, ensures a proper shape of final products by fixing the sheet to the die. Therefore, the optimum design of drawbead is indispensable in obtaining the desired formability. A static-explicit finite element analysis is carried out to provide a perspective tool for designing the drawbead. The finite element formulation is constructed from static equilibrium equation and takes into account the boundary condition that involves a proper contact condition. The deformation behavior of sheet material is formulated by the elastic-plastic constitutive equation. The finite element formulation has been solved based on an existing method that is called the static-explicit method. The main features of the static-explicit method are first that there is no convergence problem. Second, the problem of contact and friction is easily solved by application of very small time interval. During the analysis of drawbead processes, the strain distribution and the drawing force on drawbead can be analyzed. And the effects of bead shape and number of beads on sheet forming processes were investigated. The results of the static explicit analysis of drawbead processes show no convergence problem and comparatively accurate results even though severe high geometric and contact-friction nonlinearity. Moreover, the computational results of a static-explicit finite element analysis can supply very valuable information for designing the drawbead process in which the defects of final sheet product can be removed.

• Journal of Navigation and Port Research
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• v.35 no.7
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• pp.569-573
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• 2011

In this paper, we developed a Smart Heat Radiating Sheet(SHRS) having the absorption ability of more than 15 dB, and thermal conduction rate more than 20 W/mk for port logistics RFID(Radio Frequency IDentification) system by using AMP(Amorphous Metal Powder) and shielding sheet. Firstly, the EM(Electro_Magnetic) wave absorber samples were fabricated by using AMP and CPE (Chlorinated Polyethylene) with different composition ratios of 80 : 20 wt.% and 85 : 15 wt.%, respectively. Secondly, we fabricated the Smart Heat Radiating Sheet using the shielding sheet to attach EM Wave Absorber. As a result, the Smart Heat Radiating Sheet with absorption ability of 16 dB at 433 MHz and thermal conduction rate is 24 W/mk has been developed with the composition ratio of Amorphous Metal Powder : CPE = 85 : 15 wt.% and thickness of 5.5 mm.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.21 no.10
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• pp.938-942
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• 2008

Electrical and optical properties of semitransparent Ag and Al layer were studied, which are used for the electrodes in top-emission organic light-emitting diodes. Sheet resistance and transmittance of visible light through a thin layer were measured and analyzed. Several thin metal layers of Ag and Al were deposited onto a glass substrate up to a thickness of 50 nm using a thermal evaporation. Sheet resistance measurements show that a layer thickness is needed more than 15 nm and 20 nm for Ag and Al, respectively, when a proper sheet resistance is assumed to be less than $50{\Omega}/sq$. From the measurements of transmittance of visible light through a thin-metal layer, metallic behavior was observed when the layer thickness is over 25 nm for both films. Thus, from a study of sheet resistance and transmittance of visible light, a minimum proper thickness of semitransparent metal layer is 20 nm and 25 nm for Ag and Al, respectively.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.29-32
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• 2002

The mechanical joining process of a sheet metal pair has been developed in order to replace the resistance spot welding process in case that joining of mechanically unweldable materials and coated sheet metals with different thickness are needed. Form-joining or clinching, a kind of mechanical joining process, is defined as joining process of a sheet metal pair by geometric constraint imposed by plastic deformation of workpieces without any additive part. It has been reported that the joining strength by commercial form-joining apparatus is 50∼70 percent of that by resistance spot welding. Therefore, a two-step form-joining process with a secondary punch is proposed. The device is designed to improve the joining strength by increasing the geometric constraint of the deformed shape by combining a primary punch, a secondary punch and a female die. In order to verify the improved joining strength by the designed process, the tensile-shear strength, the peel-tension strength and the asymmetric peel-tension strength are compared with those by the TOX process and resistance spot welding.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.643-648
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• 2008

Ultra-thin sheet metal forming techniques are required in precision forming of miniaturized and integrated products. In order to manufacture a good quality and low cost ultra-thin sheet metal products, a highly precise high-speed press is needed. The precision of a press is related with its vibration characteristics during pressing operation. This study evaluated the vibration characteristics of a proposed press design using computer simulation. The analysis compares the static deformation characteristics of the slide and the slide motion for the metal forming of an ultra-thin sheet of thickness less than 0.1mm. Further, in order to minimize the vibrations during high speed pressing operation, revolution balances of the eccentric shaft and the balance weight device is also considered. Finally, modal analysis is used to characterize the natural frequency of vibration of the press.

• Laser Solutions
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• v.11 no.2
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• pp.15-19
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• 2008

Electron beam (EB) weldability of pure grade Nb sheet was studied. One of Nb sheets was as-annealed and the other was cold rolled. Microstructures, Vickers hardness, and transverse weld tensile test were carried out for the base metal, the heat affected zone (HAZ) and weld metal. In the case of the EB welds made using the annealed Nb sheeet, fine equiaxed grains and coarse grains were dominant at the base metal and the HAZ, respectively, and columnar grains were observed at the weld metal. For the EB welds made using the cold rolled Nb sheet, elongated grains in the rolling direction at the base metal, and the microstructures of the weld metal and the HAZ are similar to those of the EB welds made using the annealed Nb sheet, respectively. For both annealed and cold rolled Nb sheet, the width of the HAZs are unusually wide in spite of using high density heat source, i.e. electron beam, and the grain sizes of both HAZs are similar. When tensile test was carried out using the transverse weld specimens, the failure occurred at the HAZ for both EB welds made using Nb sheets annealed and cold rolled, respectively and the tensile strengths of both specimens were 161MPa. Vickers hardness of EB welds made using annealed Nb was 56-57 Hv at both base metal and weld metal, 52-53 Hv at the HAZ. On the other hand, Vickers hardness of EB welds made using cold rolled Nb was 97-99 Hv at the base metal, but the hardness values of weld metal were similar to those obtained at the weld metal of annealed Nb.