• 동력기계공학회지
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• 제18권2호
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• pp.50-56
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• 2014

Friction welding is a very useful joining process to weld metals which have axially symmetric cross section. In this paper, for the friction welding with tube-to-tube shape, the feasibility of industry application was determined using analyzing mechanical properties of weld and optimized welding variables was suggested. In order to accomplish this object, rotating speed, friction heating pressure, and friction heating time were selected as the major process variables and the experiment was performed in three levels of each parameter. Weld characteristic was investigated in terms of weld shape and metal loss, and 7mm of metal loss was regarded as the optimal metal loss. By tensile test, tensile strength and yielding strength was measured and fracture was occurred at base metal. In order to optimize the welding condition, fitness function was defined with respect to metal loss and yielding strength and the fitness values for each welding condition could be calculated in experimental range. Consequently, we set the optimal welding condition as the point which had maximum value of fitness function. As the result of this paper the optimal welding variables could be suggested as rotating speed was 1300 rpm, friction heating pressure was 15 MPa, and friction heating time was 10 sec.

• 소성∙가공
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• 제19권2호
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• pp.79-87
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• 2010

The Pipe bending process using high frequency local induction heating is an advanced technique to bend pipes with a small bending radius and a large diameter. Even though the pipe bending process is a quite widespread engineering practice, it depends heavily upon trial and error method by field engineers with several years of experience. So it is necessary to develop an integrated methodology for optimum design of the pipe bending process. During hot pipe bending using induction heating, outward wall thickness of a pipe is thinned due to tensile stress and the reduction of wall thickness is not allowed to exceed 12.5%. Taguchi method and dynamic reverse moment is proposed to maintain a reduction ratio of thickness within 12.5%, when D/t ratio is high. An application of the proposed approach was compared with those of the finite element analysis and has good in agreements.

• 소성∙가공
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• 제11권1호
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• pp.45-53
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• 2002

The forming process of metal matrix composites by die casting and squeeze casting process are limited in size and dimension In term of final parts. The melt strirring method have the problems that the homogeneous distribution of the reinforcements is difficult due to the low weldability and the density difference between the molten metal and the reinforcement. The thixoforming process for metal matrix composites has numerous advantages compacted to die casting, squeeze casting and compocasting. However, for the thixofoming process, the billet with the desired volume fraction must be heated to obtain a uniform temperature distribution over the entire cross-sectional areas. To obtain the reheating conditions of composites, the particulate reinforced metal matrix composites for thixoforming were fabricated by combined stirring process which is simultaneously performed with electro-magnetic stirring and mechanical stirring process. The matrix alloy and reinforcement are used to aluminum alloy(A357) and SiCp with diameter 14, $25{\mu}m$, respectively. The microstructure characteristics were investigated by changing the volume fraction and reinforcement size. The heating conditions to obtain the uniform temperature distribution in cross section area of fabricated metal matrix composites billet are proposed with heating time, the heating temperature and the holding time.

• 임산에너지
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• 제22권1호
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• pp.37-43
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• 2003

천연셀룰로오스의 탄화과정에서 탄화수율에 영향을 미치는 인자는 탄화온도, 승온속도 및 탄화로 내의 분위기를 들 수 있다. 일반적으로 탄화수율을 높이기 위해서는 탄화목표온도를 낮추고, 승온속도를 느리게 하면 탄화로의 분위기를 불활성가스의 조건에서 탄화수율이 높아진다고 보고되어 있다. 본 연구에서는 탄화조건 중에서 가장 유동성을 가지고 있는 승온속도를 조절하고, 탈수촉매제로서 황산을 첨가함으로서 탄화수율의 향상과 탄화과정에서 천연셀룰로오스를 재료로 하여 탄화특성에 대하여 조사하였다. 그 결과 황산무처리시료에 대하여는 승온속도가 증가함에 따라 수율이 상당히 감소하였지만 황산처리 시료는 승온속도가 증가하여도 수율 감소 폭이 크지 않았다. 본 연구의 결과에서 탄화과정에 있어서 승온속도의 조절과 적당한 탈수제의 첨가는 탄화재료의 수율 향상과 탄화시간 단축에 유용한 기초자료가 될 것으로 생각된다.

• 대한조선학회논문집
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• 제35권2호
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• pp.104-113
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• 1998

선박 생산 현장에서는 선체의 곡가공을 위해 선상가열법이 널리 사용되고 있다. 최근 선박 생산성 향상을 위하여 선상가열법에 의한 강판 곡가공 자동화 시스템에 대한 연구가 활발히 진행되고 있으나, 그 연구들은 주로 각각의 가정된 역학 모델을 도입하여 가열에 의한 판의 변형 거동을 해석하는 데에 집중되고 있고, 실제 곡면 가공에 이용될만한 실용성있는 가열선 결정 방법을 제시하는 것은 드물다. 본 논문에서는 선상가열 공정을 시뮬레이션하기 위해 새로운 가열선 결정 알고리즘을 제안한다. 이 알고리즘의 특징은 가공곡면과 목적곡면의 차이를 나타내는 변위차이곡면의 곡률을 계산하는 것이다. 몇 가지의 전형적인 곡면 형상에 대해 점검한 결과, 실용성과 적용 가능성을 확인하였다.

• 한국정밀공학회지
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• 제19권6호
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• pp.136-144
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• 2002

Melting method has long been considered difficult to realize because of problems such as the low foamability of molten metal, the varying size of cellular structures and solidification shrinkage. The parameters to solve the problem in electric furnace were stirring temperature, stirring velocity, heating velocity and foaming temperature It is important to consider the effects of induction heating, because it brings about the inner flow by the temperature gradient. Aspect ratio also depends on the induction heating. Mechanical properties are dependent on cell sizes and aspect rations. Therefore, this paper presents the effects of these parameters on the cell sizes. For the sake of this, combined stirring process was used to fabricate aluminum foam materials by the above mentioned parameters. Image analysis was performed to calculate the cell sizes, distributions, and aspect ratioes at the cross section of feared aluminum in the direction of height.

• Tribology and Lubricants
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• 제33권6호
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• pp.296-302
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• 2017

Ball milling of elemental powders in advance and using an induction heating system for intermetallic coatings are known to enhance the reactivity of combustion synthesis. In this work, the effects of simultaneously applying these two incentive methods on the properties of intermetallic coatings are studied. Ni-Al powder compacts ball-milled with three different ball-to-powder weight ratio mixtures are synthesized and coated on mild steel by combustion synthesis in an induction heating system. Consequently, similar to an electrical heating system, the positive effects of ball milling on the combustion synthesis are confirmed in the induction heating system. The enhancement in synthetic reactivity achieved by applying the two incentive methods at the same time is greater than that by applying each incentive method separately. In particular, the enhancement is remarkable at low reaction temperature. However, there are limitations to improving the reactivity by simultaneously applying the two incentive methods to the combustion synthesis, unlike the reaction temperature. The microstructure and hardness of the coating layer are both influenced by the ball-charging ratio employed in the ball-milling process.

• Journal of Welding and Joining
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• 제28권1호
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• pp.92-99
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• 2010

For the last couple of decades many studies have been carried out to find out solutions to improve the effectiveness and productivity of the plate forming process. The practical way for the automation of the plate forming process has not been, however, developed yet. Since the characteristics of heating machines may be different form each other, it is necessary to investigate the thermal deformation characteristics of the heating machine to be used in the automation system. And their characteristics may be updated as new information about thermal deformation by heating is accumulated. In this paper, data base system has been constructed based on the results of experiments and numerical analyses, which will be used in deriving the deformation estimation formula. The computer code which can automatically derive the deformation estimation formula has been also developed. This paper also illustrates how the formula is updated as experimental data are added. From the present findings, it can be said that the automatic deriving procedure may be important in the automated plate forming system since the heating line information to be generated must be directly influenced by the deformation estimation formula.

• 열처리공학회지
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• 제25권3호
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• pp.126-133
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• 2012

Semi-solid forming of the high melting point alloys such as steel is a promising near-net shape forming process for decreasing manufacturing costs and increasing the quality of the final products. This paper presents the microstructure characteristics of SKH51 (high speed tool steel) during heating and holding in the mushy zone between $1233^{\circ}C$ and $1453^{\circ}C$, which has been measured by differential scanning calorimetry (DSC). The results of heating/holding experiments showed that the grain size and the liquid fraction increased gradually with temperature up to $1350^{\circ}C$. The drastic grain growth occurred at heating above $1380^{\circ}C$. The strain-induced melt-activated (SIMA) process has been applied to obtain globular grains in the billet materials. Working by mechanical upsetting and successive heating of SKH51 into the temperatures in the mushy zone resulted in globular grains due to recrystallization and partial melting.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1997년도 춘계학술대회논문집
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• pp.125-129
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• 1997

Induction is a method of heating electrically conductive materials such as metals. It is commonly used in process heating prior to metalworking and in heating, welding, and melting. The number of industrial and consumer items which undergo induction heating during some stage of their production is very large and rapidly expanding. So a program to analyze the induction heating system was developed through the research. This thesis contains the procedure for developing the program. Both eddy current and temperature distribution are obtained through the analysis of the induction heating system. The program was developed to calculate 2-dimensional axisymmetric problem. The validity of the program is scrutinized through the comparison between the analytic solution and the numerical solution.