• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.1
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• pp.76-81
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• 2012

Ultrasonic metal welding is one of the welding methods which welds metal by applying high frequency vibrational energy into specific area at constant pressure, avaliable in room temperature and low temperature. Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each parts' shape, length and mass can affect driving frequency and vibration mode. This paper focused to horn design, its length L was set to 62mm by calculating vibration equation. By performing modal analysis with various shape variable b times integer, when length of b is 30mm the output was 39,599Hz at 10th mode. Also by performing harmonic response analysis, the frequency response result was 39,533Hz, which was similar to modal analysis result. In order to observe the designed horn's performance, about 4,000 voltage data was obtained from a light sensor and was analyzed by FFT analysis using Origin Tool. The result RMS amplitude was approximately 8.5${\mu}m$ at 40,000Hz, and maximum amplitude was 12.3${\mu}m$. Therefore, it was verified that the ultrasonic metal welding horn was optimally designed.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.42-45
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• 2003

The purpose of this study is the development or the extensive Rapid Prototyping Technique. which can resolve the long-term manufacturing process, shrinkage and deformation occurring rapid prototyping technique. To begin with. the various specimens for tensile were manufactured on the basis of this modeling technology. Then, many kinds of the laminate pieces for the test were made by using the sheet metals lmm and 1.5mm thickness which is composed of the same ingredient. The tensile specimen were manufactured by changing the process variables, Such as electric current, pressure and resistance welding time for the Rapid Prototyping with metal sheet. And then by using the Taguchi method. The interrelation between the specimen and mechanical properties were determined and the system for the optimum process variable organized.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.227-230
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• 2009

The aim of this study was to improve extrudability limit, eliminate welding line and obtain optimum thixoextrusion conditions for manufacturing tubes of 7075 Al wrought alloy. By thixoextrusion, it was possible to improve deformability, control isotropy with extrusion direction, eliminate welding line (seamless) and save cost due to low energy consumption compared with conventional extrusion processes. The welded part was not observed at the welding line area. The grains of thixoextruded tube were homogeneously distributed and equiaxed grains were observed. Therefore, thixoextrusion is the most effective variable for the control of the magnitude of the welding line.

• Journal of Welding and Joining
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• v.32 no.2
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• pp.29-36
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• 2014

Recently, in order to enhance the function and usefulness of products, cladding of dissimilar materials that maximizes the performance of the material is being widely used in all areas of industry as an important process. Clad steel plate, produced by cladding stainless steel plate, an anticorrosive material, on carbon steel plate, is being used to produce pressure vessels. Stainless steel plate has good corrosion resistance, and carbon steel plate has good rigidity and strength; clad steel can satisfy all of these qualities at once. This study aims to find the ${\delta}$-ferrite behavior, mechanical properties, structure change, integrity and reliability of clad steel weld on hot rolled steel plates. For this purpose, multi-layer welding, repair welding and post weld heat treatment were implemented according to welding procedure specifications (WPS). In order to observe the mechanical properties and toughness of clad steel weld zone, post weld heat treatment was carried out according to ASME Sec. VIII Div.1 UW-40 procedure for post weld heat treatment. With heat treatment at $625^{\circ}C$, the hold time was used as the process variable, increased by intervals that were doubled each time, from 80 to 1,280 min. The structure of weld part was typical cast structure; localized primary austenite areas appeared near central vermicular ferrite and fusion line. The heat affected zone showed rough austenite structure created by the weld heat input. Due to annealing effects of heat treatment, the mechanical properties (tensile strength, hardness, impact value) of the heat affected area tended to decrease. From the results of this study, it is possible to conclude the integrity of clad steel welds is not affected much in field welding, repair welding, multi-layer welding, post weld heat treatment, etc.

• Transactions of Materials Processing
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• v.18 no.7
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• pp.538-543
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• 2009

The cowl cross bar of an automobile is a frame component that is installed inside the cockpit module to provide a guide surface, to which functional components for electricity and air condition are attached. In the recent years, the geometries of cowl cross bars are getting more complex in order to meet the demands of a wide variety of embedded functional components and the reduced weight of frame parts with enhanced mechanical and noise/vibration characteristics. There for, welding processes between tubes with different diameters are widely conducted while the welded parts are experiencing various problems such as undermined appearance, low production efficiency and poor mechanical characteristics. Therefore, this paper seeks to develop an one-piece forming process which eliminate welding process for the cowl cross bar by applying the tube drawing process. However, it was predicted that a conventional tube drawing can not be applied directly to the current part since the area reduction ratio of the drawing process reaches 51.7% which exceeds the general limiting value. Therefore, in this study, a combined drawing process which adds a compressive force to a tensile force of the conventional drawing process was proposed and 2-stage drawing process was designed by using CAE analyses. In addition, drawing tryouts were carried out by using the manufactured combined drawing machine in order to verify the designed process.

• Proceedings of the KSR Conference
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• 2009.05b
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• pp.421-426
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• 2009

Recently, the design process for a railway bogie frame in Europe has been carried out according to the norm EN 13749. The activities in the norm EN shall demonstrate that the design of the bogie frame fulfills the acceptances of 4 steps of the program such as structural calculation, static tests, fatigue test and on-tracks tests. At the end of the acceptance program, the on-tracks tests have the aim to measure the real stress history generated in operation and to verify that they are reasonably next to those calculated and measured on the test rig. Therefore, in order to assure the safety of the railway vehicle, it is important to examined the durability of that under load histories measured from on-tracks tests. In this study, under variable amplitude loading based on the actual acceleration history, fatigue analysis of the welding bogie frame is investigated by using durability software. Moreover, the fatigue life of the frame under the loading in the norm EN fatigue test condition is evaluated and compared with the life under variable amplitude loading.

• Journal of Welding and Joining
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• v.13 no.4
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• pp.85-102
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• 1995

Weld quality of GMA welding processes is closely related to arc stability. Although many researches on arc stability have been performed, real-time estimation of arc stability has not been attempted. For instance, Mita proposed a off-line statistical method in which short circuiting and arcing time, and voltage and current wave forms were sampled to assess arc stability. But this method is not suitable to assess arc stability for GMA welder which employ inverter power source due to its controlled current and voltage wave forms. In this paper, the relationship between are stability and wire feed rate fluctuation is analyzed to propose new criterion for inverter power source. When arc voltage and arc current and arcing time are analyzed, we can assess arc stability only for short circuit transfer mode. When wire feed rate is analyzed, we can estimate arc stability udner the condition of spray transfer mode as well. Hence, the wire feed rate is chosen for monitoring process variable to cover possible metal transfer modes in GMAW. Through this research, it has been identified that arc stability in GMA welding processes is closely related to wire fed rate. When inverter power source is used, conventional statistical method of estimating arc stability, such as Mita index, is no longer valid due to its controlled voltage and current wave forms. Arc stability has been also examined in phase plane diagram.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.25 no.3
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• pp.301-311
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• 2015

Objectives: Operators of overhead traveling crane in a ship assembly factory perform work to transmit large vessel blocks to an appropriate working process. Hazardous matters such as metal dusts, carbon monoxide, carbon dioxide, ozone, loud noise and fine particles are generated by variable working activities in the factory. The operators could be exposed to the hazardous matters during the work. In particular, welding fumes comprised of ultra fine particles and heavy metals is extremely hazardous for humans when exposing a pulmonary through respiratory pathway. Occupational lung diseases related to welding fumes are increasingly on an upward tendency. Therefore, the objective of this study is to assess properly unknown occupational exposure to the welding fumes among the operators. Methods: This study intended to clearly determine an equivalence check whether or not chemical constituents and composition of the dusts, which existed in the driver's cab, matched up with generally known welding fumes. Furthermore, computational fluid dynamics program(CFD) was used to identify a ventilation assessment in respect of a contamination distribution of welding fumes in the air. The operators were investigated to assess personal exposure levels of welding fumes and respirable particulate. Results: The dust in an operation room were the same constituents and composition as welding fumes. Welding fumes, which caused by the welding in a floor of the factory, arose with an ascending air current up to a roof and then stayed for a long time. They were considered to be exposed to the welding fumes in the operation room. The personal exposure levels of welding fumes and respirable particulate were 0.159(n=8, range=0.073-0.410) $mg/m^3$ and 0.138(n=8, range=0.087-0.178) $mg/m^3$, respectively. They were lower than a threshold limit value level($5mg/m^3$) of welding fumes. Conclusions: These findings indicate that an occupational exposure to welding fumes can exist among the operators. Consequently, we need to be keeping the operators under a constant assessment in the operator process of overhead traveling crane.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.4
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• pp.321-327
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• 2017

In this study, to investigate the shape of the back bead as a weld quality parameter and to select the optimal condition of the root-pass TIG welding of a horizontal butt-joint, an experimental design and the response surface method (RSM) have been employed. Three parameters are used as input variables, which include the base current, peak current, and welding speed. The back bead width is selected as an output variable representing the weld quality, the target value of the width is 5.4 mm. Conducting the experiments according to the Box-Behnken experimental design, a $2^{nd}$ regression model for the back bead width was made, and the validation of the model was confirmed by using the F-test. The desirability function was designed through the nominal-the-best formula for the appropriate back bead width. Finally, the following optimal condition for welding was selected using the RSM: base current of 0.9204, peak current of 0.8676, and welding speed of 0.3776 in coded values. For verification, a test welding process under the optimal condition was executed and the result showed the back bead width of 5.38 mm that matched the target value well.

• International Journal of High-Rise Buildings
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• v.3 no.3
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• pp.205-214
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• 2014

The super high rise building construction is characterized by a large quantity of engineering works and structural components, high demanding of construction technology and complex cross operations. As the height of super high rise building increases, the construction difficulties increase, it is challenging the steel structural building construction technology. In this paper, the key technologies in the construction of Chinese modern super high rise steel structure building have been studied. The innovative tower crane supporting frame suspension disassembly technology has been developed to allow the crane supporting frame to turnover in the air without occupying materials stockyard. A new self-elevating platform technique which is capable of striding over structural barriers has been developed. This new technology allows the platform to be self-elevated along variable cross section column with a maximum 600 mm size change. A new automatic submerged arc welding technology has also been developed to ensure the process continuity and quality stability of welding job on the construction site.