• 소성∙가공
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• 제14권9호통권81호
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• pp.756-763
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• 2005

The applicability and productivity of hydroforming process can be increased by combining pre- and post-forming processes such as the bending, piercing and embedding process. For the fabrication of automotive parts, the hollow bodies with connecting nuts are widely used to connect parts together. Hollow body with connecting nuts has been conventionally fabricated by welding nuts or screwing in autobody screws. It requires multiple steps and devices fur the welding and/or screwing Therefore in this study, hydro-embedding process that combines the hydraulic embedding of connecting element(nut) with hydroforming process is investigated. Studies on the hydro-embedding technology have been performed to optimize the shape of the connecting element by analyzing the deformed mode of the embedded tube The effects of the shape of the screw tip, screw thread and shape of thread on the connection force between the tube and the connecting element have been investigated to optimize the shape of connecting element. Finite element analysis has also been performed to provide deformation behaviors of the tube surrounding a hole produced by hydro-embedding.

• 소성∙가공
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• 제15권4호
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• pp.295-303
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• 2006

Optimization is carried out to determine process parameters which reduce the amount of springback and improve shape accuracy of a deep drawn product in sheet metal forming process. The study uses the amount of stress deviation along the thickness direction in the deep drawn product as an indicator of springback instead of springback simulation. The scheme incorporates with an explicit elasto-plastic finite element method for calculation of the final shape and the stress deviation The optimization method adopts the response surface method in order to seek for the optimum condition of process parameters such as the blank holding force and the draw-bead force. The present scheme is applied to design of the variable blank holding force in an U-draw bending process and the application is further extend ε d to the design of draw-bead force in a front side member formed with advanced high strength steel (AHSS) sheets of DP60. Results show that design of process parameter is well performed to decrease the stress deviation through the thickness and to reduce the amount of springback. The present analysis provides a guideline in a design stage for controlling the springback based on the finite element simulation of the complicated parts.

• 소성∙가공
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• 제25권1호
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• pp.21-28
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• 2016

In the current study, reduction of springback is quantified and the reasons for the reduction are investigated. The testing involved a digital servo motion applied to a U-draw bending to produce a hat-type product from high strength steels such as DP780 and DP980. The change in springback is compared between the constant speed motion and three kinds of servocontrolled motions during forming experiments. In order to predict the springback for the servo-controlled tool motion, a finite element method was utilized for the springback analysis considering a kinematic hardening model for the steel. The comparison of springback between the analysis and the experiments shows that they have similar tendencies. Also, the analysis results indicate that the springback reduction is greatly influenced by a decrease in the friction coefficient, which originates from the contact and detach phenomena between the tooling and the blank during the up-and-down motion of the upper die following the servo-controlled motion.

• 소성∙가공
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• 제25권1호
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• pp.29-35
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• 2016

In the current study, finite element analysis was conducted for the press hemming of automotive panels in order to predict various hemming defects such as roll-in and turn down. The analysis used the exact punch movement based on the cam location and considered the sealer between the inner and outer panels with an artificial contact thickness. The analysis results quantify the hemming defects especially at the flange edge in the matching region of the head lamp. A design of experiments along with the parameter study was used to obtain the optimum process parameters for minimizing hemming defects. The optimization process selects the intake angle, bending angle of the hemming punch, and the flange height of the outer panel. The optimum design process determines an appropriate tool angle and flange height to reduce the roll-in and turn-down as compared to the initial design.

• 소성∙가공
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• 제23권8호
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• pp.495-500
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• 2014

Magnesium alloys are currently expected to be widely used for weight reduction of cars and as high efficient materials in the automotive and electronics industries. Although the specific strength of magnesium is excellent, it cannot be easily formed at room temperature due to its HCP structure. However in order to improve the formability of magnesium, it is necessary to investigate its formability in the warm temperature range. In the current study, the aim was to add to the magnesium property database so that the mass production of a magnesium car body can be accomplished. Warm tensile tests were conducted and the forming limit diagram was determined to confirm formability characteristics of magnesium AZ31B alloy sheet. In addition the bending formability and the magnesium damping capacity were evaluated for AZ31B and compared to SPRC440E which is a sheet steel used for car bodies.

• 한국기계가공학회지
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• 제16권3호
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• pp.138-145
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• 2017

With the increasing use of smart electronic devices, the size of the related I/O interface market is increasing rapidly. Demand is also growing for the continuous increase of data and video signals-such as faster data processing speed and data storage capacity-in the smart electronic device input/output interface market. Currently, the POF hybrid cable used in the smart electronic device input / output interface market cannot transmit over a long distance because the optical loss is too large, and the GOF hybrid cable is both vulnerable to bending and other sudden outside changes, and expensive. Therefore, in this study, the design and fabrication of a GOF hybrid cable and fiber guide were carried out in order to develop a cable which can easily withstand external impact, has low optical losses, and meets the demand for continuous data and video signal increase in the smart electronic device input / output interface market.

• 한국레이저가공학회지
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• 제6권2호
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• pp.1-7
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• 2003

Defocused CO$_2$ laser beam irradiation strengthening of 60kgf/$\textrm{mm}^2$ grade steel sheet was investigated to obtain the tensile strength similar to that of fully penetrated one by the focused beam. The melted line width by the defocused beam was 3∼4 times larger compared to that of the focused beam. However, the increase of tensile strength with 1 line irradiation by the defocused beam was similar to that of 2~3 lines by the focused beam. The increase(37.6%) of bending strength with 1 line by the defocused beam was higher than the increase(12.9%) of tensile strength. Also, the effect of cooling gas to strengthening was observed.

• 한국가구학회지
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• 제24권4호
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• pp.345-349
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• 2013

Yellow poplar is well known commercial hardwood species in the world because of its availability, rapid growth, large size, excellent form, early natural pruning, and the good working quality of the wood. Therefore, yellow poplar (Liriodendron tulipifera L.) has been adopted in South Korea for decades ago, and its cultivating the saplings and silvicultural system have been studied. However, yellow poplar is still embroiled in controversy for utilization of use and worth. This species has not only advantages such as lower weight, light color, and higher machinability and bending processing, but also has disadvantages which are bad smell and different colors on heartwood and sapwood. In this study, the objective was that use of yellow poplar board as furniture materials by drying and painting process. Thirty years old yellow poplar was cut and dried for 7 days by high-frequency dryness. Adjustment of color tone to walnut color was conducted with multiple colorants and various number of spread times. Uniform color of yellow poplar on heartwood and sapwood was accomplished by applying 1 time stain (green), 2 times transparent primer, 1 time middle-painting (walnut), and 2 times top-painting (walnut) in sequentially. The painted yellow poplar board was used to manufacture table and dressing table. During the furniture manufacture process, no critical issues were occurred on part of jointing and painting. This painting method may be useful data for future use of yellow poplar as furniture materials.

• 소성∙가공
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• 제12권8호
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• pp.710-717
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• 2003

The implicit, finite element analysis program for analyzing the springback in the warm forming process of aluminum alloy sheets was developed. For the description of planar anisotropy in warm forming temperatures, Barlat's yield function is employed, and the power law type constitutive equation is used in terms of working temperatures for the depiction of work hardening in high temperatures. Also, Jetture's 4-node shell elements are introduced for reflecting the mechanical behavior of aluminum alloy sheet and the non-steady heat balance equations are solved for considering heat gain and loss during the forming process. For the springback evaluation, Newton-Raphson iteration method is introduced for overcoming the geometric nonlinearlity problem. In order to verify the validity of the FEM program developed, the stretching bending and springback processes are simulated. Though springback analysis results are slightly bigger than experimental ones, they have the same trend of the decreasing springback as the forming temperature increases.

• 소성∙가공
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• 제15권8호
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• pp.609-614
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• 2006

Micro-alloyed steels(MA steels) for cold forging was developed to replace the usual quenched and tempered steel. MA steels have several advantages over the conventional quenched and tempered carbon steels. First of all, energy consumption could be lowered due to the elimination of spherodizing annealing and quenching/tempering heat treatment. Also, bending during quenching could be avoided when MA steels are applied for manufacturing of long fastener parts. However, larger amount of load is exerted on the dies compared than in the case of conventional mild steels, which might lead to the earlier fracture of dies, when MA forging steels are applied in forging practice. Therefore, die lift could be a critical factor to determine whether HA forging steels could be widely applied in cold forging practice. In the present study, authors have investigated the forging characteristics of non-heat treated micro-alloyed steel by using a series of experimental and numerical analyses. Firstly, microstructural features and its effect on the deformation behavior have been studied. Numerical analysis has been done on the forging of guide rod pin to investigate for the optimization of forging process and die stress prediction.