• 소성∙가공
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• 제9권6호
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• pp.653-662
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• 2000

Wrinkling is one of the major defects in sheet metal products together with tearing, springback and other geometric and surface defects. The initiation and growth of wrinkles are influenced by many factors such as stress ratios, mechanical properties of the sheet material, geometry of the workpiece, contact condition, etc. It is difficult to analyze the wrinkling initiation and growth considering all the factors because the effects of the factors are very complex and the wrinkling behavior may show a wide scatter of data even for small deviations of factors. The finite element analyses of the wrinkling initiation and growth in the sheet metal forming process provide the detailed information about the wrinkling behavior of sheet metal. The direct analyses of the wrinkling initiation and growth, however, bring about a little difficulty in complex industrial problems because it needs large memory size and long computation time. In the present study, therefore, a global-local analysis technique is introduced for the computational efficiency. Through the analysis of wrinkling in the door inner stamping process, the efficiency of the global-local analysis technique is investigated.

• 소성∙가공
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• 제23권7호
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• pp.431-438
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• 2014

For electromagnetic forming(EMF) the most important feature is a forming coil which creates the electromagnetic force(Lorentz force), using current density and a magnetic field. Most previous papers have concentrated on the final configuration of the blank or the efficiency of EMF process. Studies focused on the design parameters affected by the forming coil performance have not been conducted. In order to design a suitable forming coil for an object, the current study uses LS-DYNA EM-Module to not only optimize the coil but also to examine the effect of coil performance. By this method a suitable forming coil was made and tested to determine whether or not good formability was achieved in a free bulge test Numerical analysis was also used. The workpiece was Al 1100-O with a thickness of 1.27mm and the coil was made from copper CW004A, which has good electrical conductivity and is suitable for electrical components.

• 소성∙가공
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• 제27권1호
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• pp.28-36
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• 2018

Electromagnetic forming is a type of high-speed forming process to deform a workpiece through a Lorentz force. As the high strain rate in an electromagnetic-forming simulation causes infeasibility in determining constitutive parameters, we employed inverse parameter estimation in the previous study. However, the inverse parameter estimation process required us to spend considerable time, which leads to an increase in computational cost. To overcome the computational obstacle, in this research, we applied two types of surrogate modeling methods and compared them to each other to evaluate which model is best for the electromagnetic-forming simulation. We exploited an artificial neural network and we reduced-order modeling methods. During the construction of a reduced-order model, we extracted orthogonal bases with proper orthogonal decomposition and predicted basis coefficients by utilizing an artificial neural network. After the construction of the surrogate models, we verified the artificial neural network and reduced-order models through training and testing samples. As a result, we determined the artificial neural network model is slightly more accurate than the reduced-order model. However, the construction of the artificial neural network model requires a considerably larger amount of time than that of the reduced-order model. Thus, a reduced order modeling method is more efficient than an artificial neural network for estimating the electromagnetic forming and for the rapid approximation of structural simulations which needs repetitive runs.

• 한국기계가공학회지
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• 제13권6호
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• pp.119-126
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• 2014

Micro-holes of conductive ceramic are required in micro structures. Micro-electrical discharge machining (Micro-EDM) is an effective machining method since EDM is as process for shaping hard metals and complex-shaped holes by spark erosion in all kinds of electro-conductive materials. However, as the depth of micro hole increases, the machining condition becomes more unstable due to inefficient removal of debris between the electrode and the workpiece. In this paper, micro-EDM was performed to evaluate machining characteristic such as electrode wear, machining time, taper angle, radial clearance with varying voltage and ultrasonic vibration on 10 vol.% Carbon-nanotube reinforced conductive $Al_2O_3$ composite fabricated by spark plasma sintering in previous research.

• 한국공작기계학회논문집
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• 제17권4호
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• pp.95-103
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• 2008

Diamond core drills are applied to drill difficult-to-cut materials. This paper proposes basic understanding of ceramic drilling mechanics and characteristics of main factors affecting tool life, tool wear, cutting force, and chipping thickness. In contrast to conventional drilling, the core drilling process make deep grooves on the workpiece. One difficulty of it is the evacuation of chips from the drilled groove. As the drilling depth increases, an increased amount of chips tend to cluster together and clog the groove. Eventually severe wear develops and diamond grits are separated from the drill body. To relieve the clogging problem and to evacuate chips from the groove easily, the helical drilling process is applied for the core drilling process. To analyze drilling characteristics and derive optimal drilling conditions, tool life, tool wear, cutting force, and chipping thickness are quantified through the monitoring system and the Taguchi method. Mathematical models for the tool life and chipping thickness are derived from the response surface method. Optimal drilling database has been constructed through the experimental models.

• 한국생산제조학회지
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• 제19권3호
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• pp.419-425
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• 2010

To machine the micro hole, laser machining system is widely used, however, the system cannot fabricate the micro hole with high aspect ratio and good surface finish. To break the obstacles, the high frequency vibration mechanism with PZT (Piezoelectric Transducers) is proposed in this paper. The mechanism will vibrate the laser beam in vertical direction so that the aspect ratio and surface finish may be higher than the conventional. The mechanism vibrates the eyepiece of laser optics. In addition to the benefits, the mechanism enables us to have high precision and flexibility. It decreases burr and debris during machining. And it is able to machine various materials of workpiece. This research include high frequency and large travel range of the proposed mechanism. The PZT motion of mechanism and analysis on the sensitivity of design parameters are extracted from a finite element method (FEM) simulation. In the analysis, the target vibration mode without parasitic motion is designated to have the target frequency and high amplitude.

• 소성∙가공
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• 제13권6호
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• pp.503-508
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• 2004

Preform design techniques have been investigated to reduce die wear and forming load and to improve material flow, filling ratio, etc. In hot forging processes, a thin deformed part of a workpiece, known as a flash, is formed in the narrow gap between the upper and lower tools. Although designers make tools that generate a flash intentionally in order to improve flow properties, excessive flash increases die wear and forming load. Therefore, it is necessary to make a preform shape that can reduce the excessive flash without changing flow properties. In this paper, a new preform design technique is proposed to reduce the excessive flash in a metal forging process. After a finite element simulation of the process is carried out with an initial billet, the flow of material in the flash region is traced from the final shape to the initial billet. The region belonging to the flash is then easily found in the initial billet. The finite element simulation is then carried out again with the modified billet from which the selected region has been removed. In several iterations of this technique, the optimal preform shape that minimizes the amount of flash without changing the forgeability can be obtained.

• 소성∙가공
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• 제12권5호
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• pp.440-448
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• 2003

Sheet or plate bending is one of the most important industrial metal forming processes. Considerable attention has been focused on gaining a better understanding of bending characteristics. One of defaults in bending process is the springback. In this study, the springback characteristics of tailor-welded strips in U-bending process was investigated. Furthermore, effect of the process variables such as the geometry of the tools, thickness combination of workpiece, and welding prcoessing on springback were experimentally clarified. First, tailor-welded strips are joined by the laser welding process and consisted of two types of thickness combinations of the SCPl sheet, $0.8t{\times}1.2t$ and $0.8t{\times}1.6t$ to investigate the effect of different thickness combination on the springback. Secondly, two different directionly welded strips, one was welded along the centerline of the strip-width and the other was along the centerline of strip-length, were adopted to compare the effects of the location of weld line on the springback. Some cases of the experimental results were compared to the results simulated by using a commercial FEM code, PAM-STAMP and the theoretical results using the springback formula as well.

• 한국기계가공학회지
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• 제18권10호
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• pp.60-67
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• 2019

Recently, lightweight materials such as Ti alloys have been used increasingly in the aerospace and high-tech industries for weight loss and fuel efficiency. Because of built-up edges and workpiece deflection due to low stiffness, the Ti alloys have poor machinability. In our study, systematic experiments were conducted to investigate the milling characteristics of the Ti alloy (Ti-6A1-4V) with endmills. The independent variables in the experiment were spindle speed, feed per tooth, and axial depth. Cutting force, acceleration RMS, and surface roughness were measured. Using the response surface method, the optimal cutting conditions were analyzed to improve machining quality and productivity.

• Design & Manufacturing
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• 제17권2호
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• pp.15-21
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• 2023

In this study, a diamond turning machine and a laser-assisted machining module were utilized for the complex combined cutting of aspheric shapes and fine patterns on the surface of high-hardness brittle material, silicon. The analysis of material's form accuracy and corrective machining was conducted based on key factors such as laser output, rotational speed, feed rate, and cutting depth to achieve form accuracy below 1 ㎛ and surface roughness below 0.1 ㎛. The cutting condition and corrective machining methods were investigated to achieve the desired form accuracy and surface roughness. The rotational speed of the spindle and the linear feed rate of the diamond turning machine were varied in five stages for the cutting condition test. Surface roughness and form accuracy were measured using both a contact surface profilometer and a non-contact surface profilometer. The experimental results revealed a tendency of improved surface roughness with increased rotational speed of the workpiece, and the best surface roughness and form accuracy were observed at a feed rate of 5 mm/min. Furthermore, based on the cutting condition experiments, corrective machining was performed. The experimental results demonstrated an improvement in form accuracy from 0.94 ㎛ to 0.31 ㎛ and a significant reduction in the average value of the surface roughness curve from 0.234 ㎛ to 0.061 ㎛. This research serves as a foundation for future studies focusing on the machinability in relation to laser output parameters.