Seokmoo Hong

Finite-Element Analysis of Warm Square Cup Deep Drawing Process of Magnesium Alloy AZ31 Sheet

Magnesium alloys are expected to be widely used fur the parts of structural and electronic appliances due to their lightweight and EMI shielding characteristics. While the die casting has been mainly used to manufacture the parts from the magnesium alloys, the press forming is considered as an alternative to the die casting for saving the manufacturing cost and improving the structural strength of the magnesium alloy parts. However, the magnesium alloy has low formability at room temperature and therefore, in many cases, forming at elevated temperatures is necessary to obtain the required material flow without failure. In the present study, square cup deep drawing tests using the magnesium alloy AZ31 sheet were experimentally conducted at various elevated temperatures as well as room temperature, and the corresponding finite-element simulations, which calculated the damage evolution based on the Oyane`s criterion, were conducted using the stress-strain relations from the tensile tests at various temperatures. The formability predictability by the finite-element analysis was investigated by comparing the predicted damage distributions over the deformed AZ31 sheet at elevated temperatures with the corresponding experimental deformations with failures.

A Progressive Fine Blanking Process Design for Forming of Carrier Plate

Blanking process is widely used fur producing various structural parts. However, fine blanking technology is frequently used as a single step blanking operation with clean cut surface of a sheared surface because the fractured surface of parts causes serious problems in the final product and therefore it must be removed by the post-processing in case of the conventional blanking. In the present investigation, a fine blanking process was designed within the framework of progressive die to produce a carrier plate assembled within the auto transmission. Finite element analysis of the shearing behavior at the respective stage of the progressive fine blanking was conducted to validate the designed die parameters. Finally the designed progressive fine blanking process was experimentally evaluated by using the machined die.

A study on the mechanical properties and deformation behavior of injection molded PMMA-TSP laminated composite

To evaluate the deformed features of a polymer and touch screen panel laminated material and to secure a reliability of the design method, it is crucial to predict a thermo-mechanical behavior of the polymers. The reliability problems of polymer-TSP laminated module subjected to temperature and humidity changes mainly occur due to features with time-dependent material properties as well as differences in the coefficients of thermal expansion between the polymer and TSP. Therefore, it is necessary to consider the viscous behavior which causes changes in material properties which include temperature-dependent properties along with the time-dependent properties. In this study, a tensile test is conducted to obtain fundamental material properties and a creep test is used to characterize viscous properties of the polymer. Material properties from the tensile and the creep test are verified by the tensile and creep simulations. Also, the finite element analysis is used to simulate the time-dependent behaviors during a high temperature conditions while predicting thermal deformations. Numerical results are compared with experimental results. The result shows that the shape deformations of the polymer-TSP laminated module calculated by the finite element analysis with visco-elastic-plastic material model are in a good agreement with the experiment. Based on analytical results, we predict the thermal deformation of the PMMA-TSP composite plate in consideration of the effect of viscous features and set up the organized numerical analysis procedure using FE analysis.

Numerical Analysis on the High Speed Precision Press for Ultra-thin Sheet Metal Forming

Ultra-thin sheet metal forming techniques are required in precision forming of miniaturized and integrated products. In order to manufacture a good quality and low cost ultra-thin sheet metal products, a highly precise high-speed press is needed. The precision of a press is related with its vibration characteristics during pressing operation. This study evaluated the vibration characteristics of a proposed press design using computer simulation. The analysis compares the static deformation characteristics of the slide and the slide motion for the metal forming of an ultra-thin sheet of thickness less than 0.1mm. Further, in order to minimize the vibrations during high speed pressing operation, revolution balances of the eccentric shaft and the balance weight device is also considered. Finally, modal analysis is used to characterize the natural frequency of vibration of the press.

Induction Heating Apparatus for Rapid Heating of Flat-Type Metallic Mold in Hot Embossing

Hot embossing, one of Nanoimprint Lithography(NIL) techniques, has been getting attention as an alternative candidate of next generation patterning technologies by the advantages of simplicity and low cost compared to conventional photolithographies. A typical hot embossing usually, however, takes more than ten minutes for one cycle of the process because of a long thermal cycling. Over the last few years a number of studies have been made to reduce the cycle time for hot embossing or similar patterning processes. The target of this research is to develop an induction heating apparatus for heating a metallic micro patterning mold at very high speed with the large-area uniformity of temperature distribution. It was found that a 0.5 mm-thick nickel mold can be heated from within 1.5 seconds with the temperature variation of in 4-inch diameter area, using the induction heating apparatus.

Creep Behavior of ABS Polymer in Temperature–Humidity Conditions

Acrylonitrile-Butadiene-Styrene (ABS), also known as a thermoplastic polymer, is extensively utilized for manufacturing home appliances products as it possess impressive mechanical properties, such as, resistance and toughness. However, the aforementioned properties are affected by operating temperature and atmosphere humidity due to the viscoelasticity property of an ABS polymer material. Moreover, the prediction of optimum working conditions are the little challenging task as it influences the final properties of product. This present study aims to develop the finite element (FE) models for predicting the creep behavior of an ABS polymeric material. In addition, the material constants, which represent the creep properties of an ABS polymer material, were predicted with the help of an interpolation function. Furthermore, a comparative study has been made with experiment and simulation results to verify the accuracy of developed FE model. The results showed that the predicted value from FE model could agree well with experimental data as well it can replicate the actual creep behavior flawlessly.

Finite Element Analysis of Dynamic Deformation of Refrigerator's Lower Hinge during Drop Test

In this paper dynamic deformation of lower hinge of refrigerator is simulated using dynamic finite element analysis while refrigerator is being dropped. The flow stress curves considering velocity dependency of hinge and lower packing material are determined through bending test and compression test at several dropping speeds. The determined material properties and flow stress from reverse engineering were used as input data for refrigerators drop test using a dynamic finite element analysis software LS-DYNA. Additionally the result between CAE and 3D deformation measurement from real refrigerator drop test are compared and the result shows that the proposed analysis model is very useful to design lower hinge and lower packing endurable to the impulsive drop impact.

Study of Tube Expansion to Produce Hair-Pin Type Heat Exchanger Tubes using the Finite Element Method

To predict the deformation and fracture during tube expansion using the finite element (FE) method, a material model is considered that incorporates the damage evolution due to the deformation. In the current study, a Rice-Tracey model was used as the damage model with inclusion of the hydrostatic stress term. Since OFHC Cu is not significantly affected by strain rate, a Hollomon flow stress model was used. The material parameters in each model were obtained by using an optimization method. The objective function was defined as the difference between the experimental measurements and FE simulation results. The parameters were determined by minimizing the objective function. To verify the validity of the FE modeling, cross-verification was conducted through a tube expansion test. The simulation results show reasonable agreement with the experiments. The design for a minimum diameter of expansion tube using the FE modeling was verified by a simplified tube expansion test and simulation results.

Study for Mechanical Strength according to Thickness of Specimen in the Ceramic Injection Molding Process

The importance of shape design for strength is highly regarded when applied to thin plate products in Ceramic Injection Molding (CIM), such as cases for electronic goods. This study analyzed the characteristics of the mechanical strength of CIM product by measuring the flexural strength and elastic modulus through a 3-point bending test according to the thickness of a thin plate test piece prepared by CIM. The specimen with a thickness of 0.48mm required a 82.9~94.5N fracture load, whereas a 1.0mm thick test piece required 233.6~345.8N. The increase in thickness by 0.5mm resulted in a 3-fold increase in the fracture load, whereas the elastic modulus decreased by 20%. The thicker the specimen, the lower relative density and surface hardness of the specimen. This is because the thicker the specimen, the lower the powder fraction of the ceramic mixture, and the material properties partially change after sintering.

Analysis of the Effect on the Process Parameters for the Thin Ceramic Plate in the Ceramic Injection Molding

Ceramic Injection Molding (CIM) is one of wide used processes in industry field and the applications are gradually being expanded to parts of medical and electric devices. In this study, the CIM process were analyzed with FEM and process parameters were studied and analyzed the effect on product quality. The shape of simple flat plate was compared to the shapes with the hole, with the round corner portion or with the side wall portion. If there are holes then the hole around the uneven density distribution and the defects such as weld lines could be occurred. The Large radius of the corners of the product give good formability and fluidity. Not only the shape parameters of product but also the process parameters during CIM are studied. The simulation results showed that the process parameters of temperature, initial fractions and velocity are important design parameters to improve the quality of products.