• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.7
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• pp.1340-1347
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• 2002

Finite element simulations are being widely used to increase the efficiency and effectiveness of design of bulk metal forming processes. In such simulations, proper consideration of friction condition is crucial in obtaining reliable results. For this purpose, tip test based on backward extrusion was proposed recently. In this lest, a cylindrical billet is positioned in a shallow groove of a counter punch for centering purpose and formation of a radial tip is induced on the extruded end of the workpiece. In this study, the effect of centering groove on tip test was investigated. The quantitative ratio of the shear friction factors between the punch and die was numerically determined depending on the shape of centering groove. Also, surface expansion and pressure distribution along the punch and die were considered in order to better understand the reason that friction condition at the punch compared to the one of die was more severe.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.5
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• pp.50-56
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• 2014

A technique based on the finite element method (FEM) is used in the simulation of metal cutting process. This offers the advantages of the prediction of the cutting force, the stresses, the temperature, the tool wear, and optimization of the cutting condition, the tool shape and the residual stress of the surface. However, the accuracy and reliability of prediction depend on the flow stress of the workpiece. There are various models which describe the relationship between the flow stress and the strain. The Johnson-Cook model is a well-known material model capable of doing this. Low-alloy steel is developed for a dry storage container for used nuclear fuel. Related to this, a process analysis of the plastic machining capability is necessary. For a plastic processing analysis of machining or forging, there are five parameters that must be input into the Johnson-Cook model in this paper. These are (1) the determination of the strain-hardening modulus and the strain hardening exponent through a room-temperature tensile test, (2) the determination of the thermal softening exponent through a high-temperature tensile test, (3) the determination of the cutting forces through an orthogonal cutting test at various cutting speeds, (4) the determination of the strain-rate hardening modulus comparing the orthogonal cutting test results with FEM results. (5) Finally, to validate the Johnson-Cook material parameters, a comparison of the room-temperature tensile test result with a quasi-static simulation using LS-Dyna is necessary.

• Transactions of Materials Processing
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• v.8 no.1
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• pp.108-115
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• 1999

In this paper, the analysis of cold forging in final state has been performed by using rigid-plastic FEM. For the analysis, the geometry and flow stress of the workpiece are required. One method to obtain the geometry is measurement of that made from experimet. To evaluate the flow stress, average effective strain is calculated from the load-stroke diagram by using energy method. The numerical test performed to show the validity of propose method. The analysis of PFIR, the precision forging of spurgear with inside relif, is performed.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.4 no.3
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• pp.12-24
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• 1995

Various surface grinding experiments using resin bonded diamond abrasive wheels are carried out for tungsten carbide materials in order to minimize the damage on the ground surface and to purse the precise dimension compared to conventional grinding machine. When grinding quality is constant, theoretical grinding effect is changed according to the speed of workpiece. Accordingly, grinding forces, which are Fn, Ft, were analyzed for the machining processes of tungsten-carbide material to obtain optimum grinding conditions. Brief investigation is carried out to decrease the dressing efficiency of resinoid bonded diamond grinding wheel to grind tungsten-carbide. Truing is also carried out to provide a desired shape on a wheel or to correct a dulled profile. High quality in dimensional accuracy and surface are often required as a structural components, therefore 3-points bending test is carried out to check machining damage on the ground surface layer, which in one of sintered brittle material. From this experimental study, some useful machining data and information to determine proper machining condition for grinding of tungsten-carbide materials are obtained.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1997.10a
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• pp.54-58
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• 1997

In this study, study, about Automatic Loader and Unloader system which can directly be used for material handing and tool operating is moving linear transfer system for mainly forming of small electronic unit and other at press line. This system for been installed in a press in order to load and unload a workpiece from a press die. Control method be used Programmable logic control(PLC) unit. other Control equipment of system is Motor drive, Positioning Control and so on. It took data of input from each sensor and send signal of output to actuator by sequence program. We try to Characteristics test of this system has good condition when operating by laser measurement

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.335-340
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• 2004

KS and ISO have proposed several evaluation methods of conventional machine tools. Even though the accuracy of the tools can be evaluated with those methods, there are still no proper evaluation methods of high speed machining. Because it is hard to evaluate characteristics of high speed machining such as decrease of cutting temperature, cutting force, and reduced machining time. Therefore, new evaluation method for high speed machine should be developed. In this paper, several shapes of model have been proposed to evaluate cutting accuracy of high speed machine.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.3
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• pp.294-299
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• 2009

Micro end-milling has been becoming an important machining process to manufacture a number of small products such as micro-devices, bio-chips, micro-patterns and so on. Many related researches have given grand effects to micro end-milling phenomenon, for example, micro end-milling mechanism, cutting force modeling and machinability. This paper strongly concerned actual problem, micro tool deflection, which causes excessive machining errors on the workpiece. Machining error were predicted and measured through a series of test micro cutting and analysis of their SEM images and FEM analysis. Experiments are carried out to validate the approaches.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.389-394
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• 1993

Die making process is classified into design,manufacturing,polishing,assembly, and performance test. Die polishing is not a machining process by cutting edge of tool, but it is finishing by relative cutting movement under the surface contact between grinding particles and workpiece, and this process comprised 30~40% of total manufacturing hours. However, die polishing process is still performed by the skilled workers. Now a days, it is very difficult to secure skilled workers due to the hardworking environment and this situation will be getting worse in the future which has great difficulty of dies and molds industries.This process has the common problem on the elimination of tedious manual polishing among the tool making industries. Therefore this study is aimed at the development of an automatic polishing attachment which could be attached onthe spindle of CNC machine tool and controlled by the NC program data created by CAD/CAM system. As a result, this study will contribute the realization of automatic fine polishing process and improvement of quality level of dies and molds.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1281-1284
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• 2005

In the micro electrochemical machining (ECM), unfavorable oxide/passive layer formation and overall corrosion of electrodes must be prevented. Generally, the stainless steel electrode corrodes, passivates or dissolves in the electrochemical cell according to the electrode potential. Therefore, the electrode must maintain stable potential. The stable electrode potentials of tool and workpiece were determined with the potentiodynamic polarization test and verified experimentally from the point of machining stability and machined surface quality.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.94-99
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• 2002

KS and ISO have proposed several evaluation methods of conventional machine tools. Even though the accuracy of the tools can be evaluated with these methods, there are still no proper evaluation methods of high speed machining. Because it is hard to evaluate characteristics of high speed machining such as decrease of cutting temperature, cutting force, and reduced machining time. Therefore, new evaluation method for high speed machine should be developed. In this paper, several shapes of model have been proposed to evaluate cutting accuracy of high speed machine.