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다단냉간단조 비가공 타입에서 볼하우징 인서트 다이의 금형설계 검증
황원석(Won-Seok Hwang),최종원(Jong-Won Choi),정의은(Eu-Enn Jung),강명창(Myungchang Kang) 한국기계가공학회 2021 한국기계가공학회지 Vol.20 No.12
Cold forging is a method in which molding is performed at room temperature. It has a high material recovery rate and dimensional precision and produces excellent surface quality, and it is mainly used for the production of bolted or housing products. The lifespan of cold forging molds is generally determined by the wear of the mold, plastic deformation of the mold, and fatigue strength. Cold forging molds are frequently damaged due to fatigue destruction rather than wear and plastic deformation in a high-temperature environment as it is molded at room temperature without preheating the raw material and mold. Based on the results analyzed through FEM, an effective mold structure design method was proposed by analyzing the changes in tensile and compressive stresses on molds according to the number of molds and reinforcement rings and comparing the product geometry and mold stress using three existing mold models.
전자식 파킹 브레이크용 세레이션 기어의 냉간다단단조 공정 설계 및 후방 압출특성에 관한 평가
서주한(Ju-Han Seo),최종원(Jong-Won Choi),정의은(Eu-Enn Jung),강명창(Myungchang Kang) 한국기계가공학회 2022 한국기계가공학회지 Vol.21 No.2
Reducing production costs through net-shaped cold forging is an important aspect in the automobile industry. In this study, we intend to produce a net-shaped electronic parking brake (EPB) serration gear for automobiles, using multi-stage cold forging. These serrations are then assembled to the reduction gear of an EPB actuator. The forging process of the serrations and the cold forging design were verified through finite element analysis (FEA) in order to evaluate metal flow. The forging machine was selected by checking the load using FEA. Based on the FEA results, molds were designed, and parts were made using multi-stage cold forging to produce a net-shaped serration gear.
차량용 컨트롤 암 강도 최적화를 통한 서스펜션 경량화 효과
이진태(Jintae Lee),박정훈(Jeonghun Park),장병옥(Byeongok Jang),강명창(Myungchang Kang) 한국기계가공학회 2023 한국기계가공학회지 Vol.22 No.2
Recently, the lightweight paradigm has emerged in the automobile industry. Moreover, there are three main methods for reducing the weight of the control arm during design. The first method involves using lighter materials in place of heavy ones. The second method is via optimization analysis technique using CAE. The third is via correlation, which checks the correlation between CAE results and actual testing. Because the CAE includes a safety rate, checking the difference between the actual tests and reducing the weight based on the difference are possible. The forged control arm can be thickened using mold open tolerances, the strength range of the mold open tolerance can be determined, and the optimal strength can be derived. The optimal strength control arm derived from the correlation reduces the ratio compared with the existing design, which can lead to weight reduction.
35㎛ 점탄성수지가 적용된 1.035㎜ 제진강판의 이종소재간 저항점용접 특성분석
배기만(Ki-Man Bae),백종진(Jong-Jin Baek),신창열(Chang-Yeul Shin),김승경(Seung-Kyung Kim),강명창(Myungchang Kang) 한국기계가공학회 2021 한국기계가공학회지 Vol.20 No.12
Recently, owing to the high demand for eco-friendly cars in the automotive industry, noise and vibrations have become major challenges. The use of laminated damping steel is increasing in response to these demands. Laminated damping steel is primarily used in sound insulation plates. The vibration energy is converted into thermal energy due to the viscoelastic resin being located between two steel sheets and being able to damp the vibrations when an external force, such as, noise or vibration is applied to the steel plate. Laminated damping steel is chiefly applied to dash panels in automotive body parts, and because of its structure, junction technology for bonding with other components is necessary. However, there has not been sufficient research conducted on junctions. In this study, regardless of the electrode shape, in the range of 4.0 ~ 8.0 kA welding current, the same welding force and welding time were applied which were 2.8 kN and 200 ㎧ (12 cycles) and the tensile shear load and nugget size were analyzed after the resistance spot welding between different materials of laminated damping steel with a thickness of 1.035 mm. The results show that in the range of 5 ~ 8 kA welding current, 1.035 mm laminated damping steel meets the MS181-15 standard, which is the technical standard of Hyundai-Kia Motors.
미니 하이드로 사이클론 분리기의 이중배열을 통한 성능특성 평가
권제영(Je-Young Kwon),김승경(Seung-Kyung Kim),홍준규(Jun-Gyu Hong),이형욱(Hyung-Wook Yi),강명창(Myungchang Kang) 한국기계가공학회 2021 한국기계가공학회지 Vol.20 No.11
A cyclone is a dust-separating mechanism that works on the principle of centrifugal force. The performance of a cyclone is evaluated using pressure loss and collection efficiency. A multi-cyclone arrangement is used to improve the collection efficiency within a limited area. In this study, experiments and numerical analyses were conducted on a dual arrangement of mini-hydrocyclone separators, which was fabricated using 3D printing. The experiment was performed at an inlet flow rate of 0.7 m/s, and alumina powder with a particle size of 0.5, 15, and 50 μm. ANSYS FLUENT, was used for the numerical analysis. The reliability of the numerical analysis was verified through a comparison with the experimental results. The errors in the experiment and numerical analysis were confirmed to be 2% at the outlet flow rate.
엔지니어링 플라스틱 소재별 보강뿔대 형상에 따른 산업용 안전모의 구조 최적화
박만호(Man-Ho Park),이여울(Yeo-Wool Lee),이용문(Yong-Moon Lee),박재하(Jae-Ha Park),강명창(Myungchang Kang) 한국기계가공학회 2019 한국기계가공학회지 Vol.18 No.3
The industrial safety helmets are personal protective equipment (PPE), used to protect the head against falls from a height. This study indicated the necessity of wearing a safety helmet while working at heights below 4 m, through analysis of fall accidents occurring in the industrial field. The stress, displacement, and strain of the safety helmet shell structure have been analyzed using the finite element method with various thicknesses, engineering plastics, and designs. It was preferred that the safety helmet shell structure had a reinforcement frame of uniform thickness in terms of increased impact strength and strain energy absorption rate. The thickness can be reduced to lighten the total weight for workers wearing safety helmets.
간접냉각시스템을 이용한 인코넬 718소재의 가공성 평가
김진형(Jin-Hyeong Kim),이여울(Yeo-Wool Lee),박성환(Seong-Hwan Park),이동진(Dong-Jin Lee),강명창(Myungchang Kang) 한국기계가공학회 2019 한국기계가공학회지 Vol.18 No.2
This paper presents a machinability evaluation of Inconel 718 material when using a new uniform-temperature indirect cooling method that incorporates constant-pressure liquid nitrogen (LN2). The flank wear of a TiAlN coated tool used with this indirect cooling system was much lower than that of the tool used with dry machining under all machining conditions. Also, the surface roughness resulting from machining with this indirect method was far less than that of a dry machined surface after the same cutting time. Reduced heat generation and uniform temperature in turning operations play important roles in tool life and surface quality.