• Journal of the Korean Institute of Gas
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• v.13 no.6
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• pp.29-33
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• 2009

In this study, the strength safety of a composite fuel tank which is fabricated by an aluminum liner of Al6061-T6 materials and composite layers of carbon/epoxy-glass/epoxy composites has been analyzed by using a finite element analysis technique. In order to enhance the durability of the composite fuel tank, an autofrettage process was used and compressed natural gas was supplied to the prestressed fuel tank. The FEM computed results on the stress safety of autofrettaged gas tanks were compared with a criterion of design safety of US DOT-CFFC and Korean Standard. The FEM computed results indicated that the stress safety of autofrettaged fuels tanks shows instability at the dome zone and uniform stability at the parallel body, which provide an evaluation data for a strength safety of autofrettaged composite fuel tanks. The computed results show that the stress safety of 9.2 liter composite fuel tanks satisfied the safety criteria of four evaluation items, which are provided by US DOT-CFFC and KS and indicated a safe design.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.4
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• pp.483-490
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• 2013

In aluminum sheet metal forming, the conventional forming methods of T4 or T6 heat-treated sheets result in low formability and dimensional accuracy. This study suggests a new forming method for aluminum sheets called as hot forming quenching (HFQ) that solves the problems faced in the conventional method. HFQ combines the heat treatment and forming processes through the forming die during the quenching of a solid solution. To evaluate the application of HFQ to the sheet forming of aluminum, an Erichsen and V-bending test are performed in this study to measure the dimensional accuracy and formability, which are then compared with those of the conventional forming method. Furthermore, the strength and hardness of the products formed by HFQ are measured to confirm the degradation in mechanical properties compared with the conventional forming method, which shows the validity of the application of HFQ to aluminum sheet metal forming.

• Journal of Practical Engineering Education
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• v.14 no.1
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• pp.119-125
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• 2022

Materials used for education are materials such as SM20C, Al6061, and acrylic. SM20C materials are carbon steel and are often used in certification tests and functional competitions, but are also widely used in industrial sites. The Al6061 material is said to be a material that has lower hardness and stronger flexibility than carbon steel, so it is a material that generates a lot of compositional selection of tools. If students are taught practical training using acrylic materials, vibration occurs due to excessive cutting in some parts and damage to the tool occurs. In this process, we examine to what extent the impact on the 2NC head, which is a five-axis equipment, can affect precision control. The weakest part of the five-axis equipment can be said to be the weakest part of the head that controls the AC axis. When the accuracy and cumulative tolerance of this part occur, the accuracy of all products decreases. Therefore, the core part of the 2NC head, the spindle housing, was carried out using an Al7075 T6 (Alcoa, USA) material. In the process of vibration and cutting applied to this material, the analysis was conducted to find out the value applied to the finite element analysis under extreme conditions. It is hoped that this analysis data will help students see and understand the structure of 5-axis machining rather than 5-axis cutting.

• Journal of the Korean Institute of Gas
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• v.15 no.1
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• pp.30-34
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• 2011

This paper presents a strength safety evaluation of composite pressure container for hydrogen fuel tanks with a storage capacity of 104 liter and 70MPa pressure. The carbon fiber composite container is manufactured by an aluminum liner of Al6061-T6 and composite multi-layers of hoop winding layer in circumferential direction, $12^{\circ}C$ inclined winding layer and $70^{\circ}C$winding layer in helical direction respectively. The FEM results on the strength safety of composite fuel tanks were evaluated with a criterion of design safety of US DOT-CFFC and KS B ISO 11119-2 codes. The FEM computed results indicate that the proposed design model of 104 liter composite container is safe based on two strength safety codes. But, the computed results of carbon fiber fuel tanks based on US DOT-CFFC code is safer compared with that of KS B ISO 11119-2. Thus the hydrogen gas pressure container of 70MPa may be evaluated and designed by US DOT-CFFC code for more strength safety.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.3
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• pp.614-618
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• 2018

The changes in the mechanical properties according to the width of the tool shoulder, rotation speed and moving speed in friction stir welding (FSW) are evaluated using Al 6061-T6. The results indicated that the tensile strength value increases with increasing rotation speed. The higher the moving speed of the tool shoulder, the lower the tensile strength, regardless of the tool type. A higher tensile strength value was generally obtained with a tool shoulder diameter of 12mm (TSD12) than with 8mm. When the moving and rotation speeds exceed a limiting value, a stabilization stage is reached, in which (the tool shoulder diameter?) no longer affects the material properties. At a tool shoulder diameter of 8mm (TSD8), the material properties are decreased and the mixture of material in the welding area is incomplete in comparison with the tool type of TSD12. The tensile strength value is decreased at a rotation speed of 1500 rpm. As a result, a rotation speed higher than the threshold value is needed in order for and the transition temperature to be reached, which allows the complete mixing of the material in the welding area.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.145-148
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• 2006

Cold gas dynamic spray is a relatively new coating process by which coatings can be produced without significant heating during the process. Cold gas dynamic spray is conducted by powder sprayed by supersonic gas jet, and generally called the kinetic spray or cold-spray. Cold-spray was developed in Russia in the early 1980s to overcome the defect of thermal spray method. Its low process temperature can minimize thermal stress and also reduce the deformation of the substrate. Most researches on cold-spray have focused on micro scale coating, but our research team tried to apply this method to macro scale deposition. The macro scale deposition causes deformation of a thin substrate which is usually convex to the deposited side. In this research, the main cause of the deformation was investigated using 6061-T6 aluminum alloy and properties of deposited aluminum layer such as coefficient of thermal expansion, Elastic modulus, hardness, electric conductivity were measured. From the result of the analysis, it was concluded that compressive residual stress was the main reason of substrate deformation while CTE had little effect.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.99-100
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• 2006

Cold gas dynamic spray or cold-spray is a deposition process, which causes deformation of a thin substrate. The deformation is usually convex to the deposited side. In this research, the main cause of the deformation was investigated using 6061-T6 aluminum alloy. The effects or anisotropic coefficient or thermal expansion (CTE) or the deposited layer by cold-spray and residual stress were studied by experiments and finite element analysis. The Hole Drilling method was applied to measure residual stress in the cold-spray layer and substrate. The data obtained by the experiments were used for the analysis of substrate deformation. From the result of the analysis, it was concluded that compressive residual stress was the main reason of substrate deformation while CTE had little effect.

• Design & Manufacturing
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• v.14 no.4
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• pp.46-51
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• 2020

The purpose of this study was to analyze the change in tensile strength characteristics of the weld when the welding speed and rotational speed of the tool, which are representative variables of the friction stir welding process. The equipment used in the experiment was Machining Center No. 5. The material used in the experiment is an AA6061-T6 alloy, and a rolled plate with a thickness of 2mm was used. Two experimental variables were selected, the welding speed of the tool and the rotational speed of the tool. The experimental conditions were selected in the range in which a healthy weld could be obtained through a preliminary experiment. The welding speed of the tool was increased to 100mm/min, 200mm/min, and 300mm/min, and the rotational speed of the tool was increased to 1000rpm, 2000rpm, and 3000rpm. As a result of the experiment, the tensile strength increased as the rotational speed of the tool changed at each tool welding speed. In addition, as the welding speed of the tool increased, the tensile strength of the weld was increased. The condition with the highest tensile strength of the weld was found to be a tool feed speed of 300 mm/min and a tool rotation speed of 3000rpm.

• Journal of the Korean Society of Safety
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• v.13 no.4
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• pp.19-24
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• 1998

Elastic-plastic fracture toughness($J_{IC}$) by ultrasonic method is evaluated in terms of width and thickness. Widths of specimen in 6061-T6 aluminum alloy are 50mm and 100mm, thicknesses of those are 20mm and 25mm, respectively. Elastic-plastic fracture toughness by ultrasonic method is independent of specimen thickness and side groove. Angle beam probe which are placed on the end of the compact specimen detect the maximum crack extension effectively. Comparing with elastic-plastic fracture toughness by ultrasonic method and that of unloading compliance method, $J_{IC}$ of ultrasonic method are underestimated to that of unloading compliance method. Elastic-plastic fracture toughness of width 100mm specimen are underestimated to that of width 50mm specimen about 20%.

• Transactions of Materials Processing
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• v.3 no.2
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• pp.215-228
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• 1994

The purpose of this paper is to pursue a general method to determine both the flow stress of a material and the friction factor by ring compression test. The materials are assumed to obey the expanded n-power hardening rule including the strain-rate effect. Ring compression is simulated by the rigid-plastic finite element method to obtain the database used in determining the flow stress and friction factor. The Simulation is conducted for various strain hardening exponent, strain-rate sensitivity, friction factor, and compressing speed, as variables. It is assumed that the friction factor is constant during the compression process. To evaluate the compatibility of the database, experiments are carried out at room and evaluated temperature using specimens of aluminum 6061-T6 under dry and grease lubrication condition. It is shown that the proposed test method is useful and easy to use in determining the flow stress and the friction factor.