• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 제5회 박판성형 SYMPOSIUM
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• pp.61-67
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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 the draw-bead force. The present scheme is applied 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.

• Design & Manufacturing
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• 제16권4호
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• pp.46-51
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• 2022

The piercing process of creating holes in sheet metals for mechanical fastening generates high shear force. Real-time monitoring technology could predict tool damage and product defects due to this severe condition, but there are few applications for piercing high-strength aluminum. In this study, we analyzed the load signal to predict the punch's wear level during the process with a piezoelectric sensor installed piercing tool. Experiments were conducted on Al6061 T6 with a thickness of 3.0 mm using piercing punches whose edge angle was controlled by reflecting the wear level. The piercing load increases proportionally with the level of tool wear. For example, the maximum piercing load of the wear-shaped punch with the tip angle controlled at 6 degrees increased by 14% compared to the normal-shaped punch under the typical clearance of 6.7% of the aluminum piercing tool. In addition, the tool wear level increased compression during the down-stroke, which is caused by lateral force due to the decrease in the diameter of pierced holes. Our study showed the predictability of the wear level of punches through the recognition of changes in characteristic elements of the load signal during the piercing process.

• 한국정밀공학회지
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• 제10권3호
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• pp.198-204
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• 1993

The study is concerned with finite element analysis and design of axisymmetric deep drawing by local heating. When the bottom shape of a cup is not flat but in complex-shaped, i.e., hemispherical, the cup cannot be drawn in one or two processes in the conventional deep drawing process and the limit drawing ratio is limited as well. By introducing local heating selectively with regards to the heating position, the formability of the sheet metal can be greatly increased with the reduced number of processes. In the Process analysisthe rigid- viscoplastic finite element method is employed and the temperature effect is incorporated. Bishop's step-wise decoupled method is employed to analyze the thermomechanical interaction between deformation and heat transfer. Axisymmetric deep drawing of a hemisphere-bottomed cup has been analyzed for various combinations of heat application in the punch and the die. At the first stage of deep drawing stretch forming is practically carried out by firmly pressing the blankholder with the punch and the die heated at various levels of temperature. Then at the second stage the same cup is drawn for the saame or different combination of temperature. From the computation, it has thus been shown that the fromability of a cup is greatly increased in two-stage deep drawing with increased limet drawing ratio.

• 한국표면공학회지
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• 제42권5호
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• pp.208-215
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• 2009

We employed atmospheric plasma to reactively remove the lubricant sprayed onto such industrial electronic parts as LCD chassis during sheet-metal forming processes and investigated basically the effect of plasma parameters on cleansing the surfaces of zinc-electroplated steel plates (EGI). Specimen prepared with some controlled amount of lubricant sprayed on their surfaces beforehand were subjected to two different kinds of atmospheric plasma, one being generated by using air and the other generated by using nitrogen (99.9% purity). Locating the plasma beams at the height range between 3.5 and 13.5 mm from the surface of each specimen and radiating for 5 to 30 seconds resulted out that the cases with a position of 3.5 mm and a duration of 5 seconds or longer showed the surfaces completely cleansed without a trace of lubricant. Furthermore we found out that the plasma generated by using simple air depicted higher cleansing ability than the other one generated by using expensive nitrogen, interestingly useful very much for industrial purposes. On another aspect, we confirmed that the drilled or cut surfaces of Zn-plated steel substrate would not be oxidized even under the influence of plasma during its cleansing process. Therefore, we could probably conclude from this fore-survey that a dry process adopting atmospheric plasma for cleansing industrial parts might be determined to become successful in terms of commercialization, cautiously.

• 한국생산제조학회지
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• 제8권6호
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• pp.84-91
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• 1999

The goal of this study is to analyse the stress and the strain occurring within the work piece at the fine-blanking process and hence to assume the size direction and a distribution chart of the shearing stress as the penetration of the punch is being increased trough the application of the FEM. For this analysis we introduced the piece-wise linear method in the non linear structural analysis program for large deformation sheet metal forming and we defined it as the problem of the non linear contact. Therefore we modeled the above problems as quadratic-nodded axi-symmetrical elements for the character-istics of the work piece. From the result of this analysis it was found that the shearing stress is a great deal occurred on the surface of the work piece during the beginning process of the punch penetration and it's effect is expected to influence importantly for the formation of burnish because the deeper is the penetration of the punch in the narrow clearance zone. the greater is the degree of the strain stress.

• 한국정밀공학회지
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• 제25권7호
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• pp.55-63
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• 2008

Fine blanking is a process of press shearing which makes it possible to produce the thick sheet metal of the finished surface and the close dimensional accuracy over the whole material thickness in the single blanking operation. In this paper, a plate holder of automotive seat recliner is manufactured by FCF(Flow Control Forming) method using the conventional mechanical press instead of the fine blanking press. Main processes for manufacturing of the plate holder by FCF method are embossing, half blanking and trimming processes. Optimal clearance, stripper force and counter force to increase the dimensional accuracy of the plate holder have been investigated by FE-analysis. As a result of FE-analysis, the clearance for both embossing and half blanking processes was -2%t and the forces of stripper and counter were 25ton and 15ton, respectively. After manufacturing the plate holder by FCF method, the measured dimensional characteristics have been compared with the required specifications as the final product. Although the dimensional accuracy of the plate holder manufactured by FCF method was a little inferior to that by fine blanking process, it was satisfactory in a general sense.

• 한국산학기술학회논문지
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• 제18권6호
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• pp.692-696
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• 2017

프레스 부품의 형상은 고객 요구와 공정단축 및 비용절감으로 점점 복잡하게 변하고 있다. 또한 프레스공정은 많은 인자의 영향으로 양산 중에도 안정성이 수시로 변하고 있다. 공정의 안정성을 확보하는 데는 형상, 소재, 프레스, 금형 및 윤활에 대한 사전 연구가 충분히 되어 허용된 공차 안에서 재현성이 구현되는 공정을 수립해야 한다. 하지만 예측하지 못한 공정인자들의 변화는 양산라인 정지와 생산계획에 차질을 현장에서 야기 시키고 있다. 이에 프레스금형에 센서를 적용해 실시간 공정을 모니터링 할 수 있는 방법을 본 논문에선 소개한다. 비접촉식으로 판재의 흐름을 측정하는 센서와 그 중 양산에 적용 가능성이 높은 광학센서를 사용한 실험 사례를 제시했다. 원통드로잉금형에 광학센서를 설치해 소재, 블랭크홀더힘, 드로잉비를 변화시키며 센서의 사용 가능성을 테스트했다. 또한 각통드로잉 금형을 사용해 국부적으로 다른 판재의 흐름을 정량화 했고 측정값이 소재의 연신에 의해 드로잉 깊이보다 항상 작다는 것을 정량적으로 측정하였다. 마지막으로 프레스 금형에 센서를 접목시켜 사용할 수 있는 분야에 대해 제안을 하였다. 원가절감에 대한 Needs가 지속적으로 증가하고 이를 통해 글로벌 금형경쟁력을 확보해야하는 시점에 기여가 되었으면 한다.

• 한국산학기술학회논문지
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• 제19권5호
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• pp.184-189
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• 2018

최근에 안전기준과 환경규제 강화의 증대로 인해, 차체의 경량화에 대한 연구가 지속적으로 증가하고 있다. 고강도강의 응용은 가장 보편화 된 차체 경량화의 효과적인 방법 중에 하나이다. TWB(Tailor Welded Blank)는 다양한 두께와 용접을 사용하여 부분적인 강도와 경량화를 만족시키는 주요한 공법으로 활용되고 있다. 그러나 추가적인 용접공정으로 인해 판재간의 용접성이 중요하고 용접부에 대한 품질관리가 중요하다. 이점을 개선하기 위해, TRB(Tailor Rollded Blank)공법이 제안되었다. TRB는 롤러 압력을 조절하여 판재의 두께를 다르게 하고, 용접을 사용하는 TWB 공법보다 추가적인 용접공정이 없기 때문에 생산 비용적인 측면에서 훨씬 더 효율적이다. 본 연구에서는 Blank의 압연 영향을 조사하기 위해 스탬핑용 고강도강 TRB 판재의 성형성을 분석하였다. 성형성을 분석하기 위해, TRB 판재에서 0.8 mm, 1 mm의 두께를 갖는 부분을 채취하여 시험하였다. 시편에 새겨진 그리드마킹의 변형도를 분석하여 변형률을 조사하였고, 0.8 mm와 1.0 mm의 두께를 갖는 TRB 시편으로 Erichsen 시험을 한 후에 FE분석을 활용하여 성형성과 고유진동수를 비교하였다.

• 대한기계학회논문집A
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• 제20권11호
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• pp.3474-3490
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• 1996

A metal matrix composites(MMCs) for A16061 reinforced with silicon carbide particles is fabricated by melt-stirring method. The primary products of MMCs billets are prepared by volume fractions 5 vol% to 20 vol% and particle size $13\mu m$ to $22\mu m$.This paper will be made to examine the microstructure and mechanical properties of fabricated $SiC_p$/Al 6061 composite by melt-stirring and squeeze casting method. The MMC billets is extruded at $500^{\circ}C$ under the constant extrusion velocity $V_e$=2mm/min using curved shape die. Extrusion force, particle rearrangement, micro structure and mechanical properties of extruded composites will be investigated. The mechanical properties of primary billets manufactured by melt-stirring and squeeze casting method will be compared with extrusion specimen. The effect of volume fraction and size of the reinforcements will be studied. The increase in uniformity of particle dispersion is the major reason for an improvement in reliability due to hot extrusion with optimal shape die. Experimental Young's modulus and 0.2% offset yield strength for the extruded MMCs will be compared with theretical values calculated by the Eshelby method. A method will be proposed for the prediction of Young's modulus and yield strength in $SiC_p$ reinforced MMCs.

• 한국진공학회:학술대회논문집
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• 한국진공학회 2011년도 제40회 동계학술대회 초록집
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• pp.490-490
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• 2011

Graphene, hexagonal network of carbon atoms forming a one-atom thick planar sheet, has been emerged as a fascinating material for future nanoelectronics. Huge attention has been captured by its extraordinary electronic properties, such as bipolar conductance, half integer quantum Hall effect at room temperature, ballistic transport over ${\sim}0.4{\mu}m$ length and extremely high carrier mobility at room temperature. Several approaches have been developed to produce graphene, such as micromechanical cleavage of highly ordered pyrolytic graphite using adhesive tape, chemical reduction of exfoliated graphite oxide, epitaxial growth of graphene on SiC and single crystalline metal substrate, and chemical vapor deposition (CVD) synthesis. In particular, direct synthesis of graphene using metal catalytic substrate in CVD process provides a new way to large-scale production of graphene film for realization of graphene-based electronics. In this method, metal catalytic substrates including Ni and Cu have been used for CVD synthesis of graphene. There are two proposed mechanism of graphene synthesis: carbon diffusion and precipitation for graphene synthesized on Ni, and surface adsorption for graphene synthesized on Cu, namely, self-limiting growth mechanism, which can be divided by difference of carbon solubility of the metals. Here we present that large area, uniform, and layer controllable graphene synthesized on Cu catalytic substrate is achieved by acetylene-assisted CVD. The number of graphene layer can be simply controlled by adjusting acetylene injection time, verified by Raman spectroscopy. Structural features and full details of mechanism for the growth of layer controllable graphene on Cu were systematically explored by transmission electron microscopy, atomic force microscopy, and secondary ion mass spectroscopy.