• Journal of the Korean Society for Precision Engineering
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• v.17 no.8
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• pp.46-52
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• 2000

3D Welding and Milling is a solid freeform fabrication process which is based on the combination of welding as additive and conventional milling as subtractive technique. This hybrid approach enables direct building of metallic parts with high accuracy and surface finish. Although it needs further improvements it shows an application potential in rapid tooling of injection mold inserts as the investigation results show. To optimize the process for higher surface quality and accuracy effectively Taguchi method is applied to the experimental investigation. in this way relationships between process parameters and final product qualities such as tensile strength and surface hardness are found with minimal efforts.

• Journal of Advanced Research in Ocean Engineering
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• v.1 no.2
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• pp.106-114
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• 2015

In the fabrication of offshore oil and gas facilities, the significance of dimension control is growing continuously. But, it is difficult to determine the deformation of the structure during fabrication by simple lab tests due to the large size and the complicated shape. Strain-boundary method (a kind of shrinkage method) based on the shell element was proposed to predict the welding distortion of a structure effectively. Modeling of weld geometry in shell element is still a difficult task. In this paper, a concept of imaginary temperature pair is introduced to handle the effect of geometric factors such as groove shape, plate thickness and pass number, etc. Single pass imaginary temperature pair formula is derived from the relation between the groove area and the FE mesh size. By considering the contribution of each weld layer to the whole weldment, multi-pass imaginary temperature is also derived. Since the temperature difference represents the distortion increment, cumulative distortion curve can be drawn by integrating the temperature difference. This curve will be a useful solution when engineers meet some problems occurred in the shipyard. A typical example is shown about utilization of this curve. Several verifications are conducted to examine the validity of the proposed methodology. The applicability of the model is also demonstrated by applying it to the fabrication process of the heavy ship block. It is expected that the imaginary temperature model can effectively solve the modeling problem in shell element. It is also expected that the cumulative distortion curve derived from the imaginary temperature can offer useful qualitative information about angular distortion without FE analysis.

• Proceedings of the KWS Conference
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• 2008.05a
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• pp.16-16
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• 2008

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.661-667
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• 2002

Welding-induced buckling distortion is one of the most problematic concerns in both design and fabrication of welded thin-plate structures. This paper deals with experimental and numerical results of the welding-induced longitudinal and/or buckling distortion occurring in welding of 6mm-thick AH36 high strength steel plates. Effects of the heat input and the plate size on the distortion were experimentally evaluated for square plates. Bead-on-plate welding was performed with the submerged arc welding process along the middle line of plate specimens. Experimental results showed that the longitudinal distortion made a single curvature in the plate, and the distortion magnitude along the weld centerline was proportional to the heat input and the plate size. The experimental results were used to examine the validity of the numerical simulation procedure for welding-induced distortion where the longitudinal distortion mode and magnitude were numerically quantified. Three-dimensional, large deformation, welding simulations were performed for selected weld models. Numerical results of the distortion mode and magnitude were in a good agreement with experimental ones. Depending on the presence of halting the distortion growth during the cooling cycle of welding, the condition discriminating buckling distortion from longitudinal distortion was established. Eigenvalue analyses were performed to check the buckling instability of tested plates with different sizes subjected to different heat inputs. The perturbation load pattern for the analysis was extracted from longitudinal inherent strain distributions. Critical buckling curve from the eigenvalue analyses revealed that the buckling instability is manifested when plate size or heat input increases.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.4
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• pp.22-28
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• 2008

Friction stir welding(FSW) is an relatively new solid state joining process. A1606l-T6 aluminium alloy has gathered wide acceptance in the fabrication of light weight structures requiring a high strength to weight ratio and good corrosion resistance. This friction stir process(FSP) uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, etc., and tool pin profile playa major role in deciding FSP zone formation in A16061-T6 aluminium alloy. Tow different tool pin profiles have been used to fabricate the joints. The formation of friction stir processed zone has been analysed macroscopically. Tensile properties of the joints have been evaluated and correlated with the friction stir processed zone formation.

• Journal of Electrical Engineering and Technology
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• v.12 no.1
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• pp.126-133
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• 2017

This paper deals with the effects of welding, which is done to fix the stator stack, on a motor in case of fabricating a prototype motor that is manufactured in a small quantity. In the case of a small motor, the stator is designed and fabricated with the segmented core as a way to raise the fill factor of winding wire to the utmost within a limited size. In case of fabrication by welding both inside and outside of the stator in order to fix the segmented-core stator, the effects of stack are ignored, and the eddy current loss occurs. This paper performed the no-load test on an IPM-type BLDC motor for driving the suction fan of a vacuum cleaner, which was manufactured by using a segmented-core stator. As a result of the test, it was found that input power more than expected was supplied. To analyze the effects of welding by using the finite element analysis method and verify them experimentally, a stator was re-manufactured by bonding, and input power supplied during the no-load test was compared.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.3
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• pp.270-278
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• 2009

Friction stir welding is a relatively new solid state joining process. A6061-T6 and A5052-H32 aluminium alloy has gathered wide acceptance in the fabrication of light weight structures requiring a high strength to weight ratio and good corrosion resistance. This friction stir process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, etc., and tool pin profile play a major role in deciding FSP zone formation in A6061-T6 and A5052-H32 aluminium alloy. Three different tool pin profiles have been used to fabricate the dissimilar butt joints. The formation of friction stir processed zone has been analysed macroscopically. Tensile properties of the joints have been evaluated and correlated with the friction stir processed zone formation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1376-1380
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• 2005

In recent automotive industry, vehicle weight can be reduced by one-step forming of tailored blanks welded with two or more sheets of metal blanks. Tailored blank(TB) welding is a production method for blanks involving welding together materials of different quality, thickness, and coating, and has proved popular in fabrication automotive parts. This paper deals with the forming characteristics of mash seam welded tailored blanks. Using these forming characteristics, the bumper beam was developed using the mash seam welded tailored blank with the different thickness. We performed the forming simulation with respect to strain distribution on blank during the stamping of the bumper rail part. Based on these results, we made some stamping tryouts with selected types of blank designs to investigate the formability of tailored blank with different thickness. During the tryouts, we knew that it was important the BHF(Blank Holding Force). We obtained to reducing 10.5% weight and cost with adapting the bumper beam of automotive component using the tailored blank of mash seam welding.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.59-59
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• 2010

Friction stir welding has become a viable and important manufacturing alternative or fabrication component, especially in aerospace and automobile applications involving aluminium alloys. In recent years, there is an increasing interest for FSW of dissimilar metals and alloys, particularly systems which are difficult to weld by conventional, thermal (or fusion) welding. In this study we tried to analyse the complex heat distribution occurring in TIG assisted FSW of dissimilar butt joint (STS304 and Al6061). For this, an analytical model for heat generation by FSW based on contact conditions has been developed. The heat input was calculated considering the coefficient of friction and slip factor between each work piece material with the tool material. The thermal model is used to generate the temperature characteristics curve, which successfully predicts the maximum welding temperature in each alloys. The analysis was carried out using the in-house solver.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.98-103
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• 2008

This paper is to discuss distribution of welding residual stresses of a ferritic low alloy steel nozzle with dissimilar metal weld using Alloy 82/182. Two dimensional (2D) thermo-mechanical finite element analyses are carried out to simulate multi-pass welding process on the basis of the detailed and fabrication data. On performing the welding analysis generally, the characteristics on the heat input and heat transfer of weld are affected on the weld residual stress analyses. Thermal analyses in the welding heat cycle process is very important process in weld residual stress analyses. Therefore, heat is rapidly input to the weld pass material, using internal volumetric heat generation, at a rate which raises the peak weld metal temperature to $2200^{\circ}C$ and the base metal adjacent to the weld to about $1400^{\circ}C$. These are approximately the temperature that the weld metal and surrounding base materials reach during welding. Also, According to the various ways of appling the weld heat source, the predicted residual stress results are compared with measured axial, hoop and radial through-wall profiles in the heat affected zone of test component. Also, those results are compared with those of full 3-dimensional simulation.