The most time consuming operation during the tryout of new parts is the compensation of geometric deviations induced by springback. The variation of springback due to the noise factors such as material properties and forming conditions increase the difficulties of the compensation operation. If the forming process includes a drawing operation followed by a restriking operation, a robust design for springback compensation is needed for both operations. In this study, a new 2-stage procedure for robust springback compensation using Taguchi's orthogonal array experiments combined with the Pick-the-Winner rule and the design space reduction method is proposed. The effectiveness of the proposed method is shown with an example of the sidewall curl springback compensation in U-channel forming.

Niobium is one of the most important and rarest metals, and is used in the electronic and energy industries. However, it’s extremely high melting point and oxygen affinity limits the manufacture of Nb coating materials. Here, a Nb coating material is manufactured using a kinetic spray process followed by hot isotactic pressing to improve its properties. OM (optical microscope), XRD (X-ray diffraction), SEM (scanning electron microscopy), and Vickers hardness and EPMA (electron probe micro analyzer) tests are employed to investigate the macroscopic properties of the manufactured Nb materials. The powder used to manufacture the material has angular-shaped particles with an average particle size of 23.8 μm. The porosity and hardness of the manufactured Nb material are 0.18% and 221 Hv, respectively. Additional HIP is applied to the manufactured Nb material for 4 h under an Ar atmosphere after which the porosity decreases to 0.08% and the hardness increases to 253 Hv. Phase analysis after the HIP shows the presence of only pure Nb. The study also discusses the possibility of using the manufactured Nb material as a sputtering target.

Incremental sheet metal forming is a manufacturing process to produce thin parts using sheet metals by a series of small incremental deformation. The process rarely needs dedicated dies and molds, thus, preparation time for the process is relatively short as to be compared to conventional metal forming. Spring back in sheet metal working is very common, which causes critical errors in dimensions. Incremental sheet metal forming is not fully investigated yet. Hence, incremental sheet metal forming frequently produces inaccurate parts. This paper proposes a method to minimize dimensional errors to improve shape accuracy of products manufactured by incremental forming. This study conducts experiments using an exclusive incremental forming machine and the material for these experiments are sheets of aluminum AL1015. This research defines a process parameter and selects a few factors for the experiments. The parameters employed in this paper are tool feed rate, tool diameter, step depth, material thickness, forming method, dies applied, and tool path method. In addition, their levels for each factor are determined. The plan of the experiments is designed using orthogonal array L8 (27) which requires minimum number of experiments. Based on the measurements, dimensional errors are collected both on the tool contacted surfaces and on the non-contacted surfaces. The distances between the formed surfaces and the CAD models are scanned and recorded using a commercial software product. These collected data are statistically analyzed and ANOVAs (analysis of variances) are drawn up. From the ANOVAs, this paper concludes that the process parameters of tool diameter, forming depth, and forming method are the significant factors to reduce the errors on the tool contacted surface. On the other hand, the experimental factors of forming method and dies applied are the significant factors on the non-contacted surface. However, the negative forming method always produces better accuracy than the positive forming method.

Recently as the manufacturers want competitiveness in dynamically changing environment, they are trying a lot of efforts to be efficient with their production systems, which may be achieved by diminishing unplanned operation stops. The operation stops and maintenance cost are known to be significantly decreased by adopting proper maintenance strategy. Therefore, the manufacturers were more getting interested in scheduling of exact maintenance scheduling to keep smooth operation and prevent unexpected stops. In this paper, we proposedan integrated maintenance approach in injection molding manufacturing line. It consists of predictive and preventive maintenance approach. The predictive maintenance uses the statistical process control technique with the real-time data and the preventive maintenance is based on the checking period of machine components or equipment. For the predictive maintenance approach, firstly, we identified components or equipment that are required maintenance, and then machine parameters that are related with the identified components or equipment. Second, we performed regression analysis to select the machine parameters that affect the quality of the manufactured products and are significant to the quality of the products. By this analysis, we can exclude the insignificant parameters from monitoring parameters and focus on the significant parameters. Third, we developed the statistical prediction models for the selected machine parameters. Current models include regression, exponential smoothing and so on. We used these models to decide abnormal patternand to schedule maintenance. Finally, for other components or equipment which is not covered by predictive approach, we adoptedpreventive maintenance approach. To show feasibility we developed an integrated maintenance support system in LabView Watchdog Agent and SQL Server environment and validated our proposed methodology with experimental data.

This research presents a preparation method of dental components by metal injection molding process (MIM process) using titanium scrap. About 20 μm sized spherical titanium powders for MIM process were successfully prepared by a novel dehydrogenation and spheroidization method using in-situ radio frequency thermal plasma treatment. The effects of MIM process parameters on the mechanical and biological properties of dental components were investigated and the optimum condition was obtained. After sintering at 1250oC for 1 hour in vacuum, the hardness and the tensile strength of MIMed titanium components were 289 Hv and 584 MPa, respectively. Prepared titanium dental components were not cytotoxic and they showed a good cell proliferation property.

The purpose of our study was to develop the fabrication method of porous diatomite ceramics with a porosity gradient by centrifugal molding. The processing variables of centrifugal molding were derived from Stoke's law of sedimentation, which were the radius of the particles, the acceleration due to centrifugal molding and the dynamic viscosity of the slurry. And these could be controlled by ball-milling conditions, centrifugal conditions, and the addition of methyl cellulose, respectively. The effects of processing conditions on the gradient pore structure of diatomite were investigated by particle size analysis, scanning electron microscope, and mercury porosimeter.

In this study, powder metallurgy and severe plastic deformation by high-pressure torsion (HPT) approaches were combined to achieve both full density and grain refinement at the same time. Water-atomized pure iron powders were consolidated to disc-shaped samples at room temperature using HPT of 10 GPa up to 3 turns. The resulting microstructural size decreases with increasing strain and reaches a steady-state with nanocrystalline (down to ~250 nm in average grain size) structure. The water-atomized iron powders were deformed plastically as well as fully densified, as high as 99% of relative density by high pressure, resulting in effective grain size refinements and enhanced microhardness values.

본 실험은 압출성형을 통한 저DE덱스트린 제조공정을 확립하기 위해서 수분함량 25, 35% 배럴온도 100, 120oC, 스크루 회전속도 150, 250 rpm에서 압출성형한 전분을 알파아밀라아제로 당화시켰을 때 당화특성을 연구하였다. 수분용해지수는 원료전분 수분함량이 25%로 감소할 경우 증가되었으며, 수분흡착지수도 수분의 감소와 함께 전체적으로 증가하였다. 환원당함량의 경우 수분함량이 낮고 배럴온도 높을수록 증가되었다. 120 분간 당화 후 DE 63.8로 높게 나타났다. 비기계적 에너지 투입량(SME)의 증가와 함께 수분용해도는 증가하는 경향이었다. 또한 수분함량의 감소와 함께 비기계적 에너지 투입량과 수분용해도는 증가하였다. 페이스트점도는 원료전분의 수분이 낮고, 스크루 회전 속도가 증가할수록 전분사슬의 절단에 따라 저온최고점도가 감소하는 경향을 보였다. 초기반응속도는 수분함량이 25%로 낮고 배럴온도 120oC, 스크루 회전수 250 rpm에서 2.26 × 10−3mmol/mL·min로 가장 높았다. 시중 호화전분 1.83 × 10−3mmol/mL·min에 비해서도 높은 결과를 보였다. 당화속도상수는 히구치모델을 응용하였으며, 수분함량이 낮고 배럴온도가 120oC일 때 전체적으로 높게 나타났다. 본 실험에서 초기반응속도, 당화속도상수, 당화수율 등을 고려할 때, 최적조건은 수분함량 25%, 배럴온도 120oC, 스크루 회전속도 250 rpm이었다.

Increasing needs for light weight and high safety in modern automobiles induced the wide application of high strength steels in automotive body structures. The main difficulty in the forming of sheet metal parts with high strength steel is the large amount of springback including sidewall curl and twist in channel shaped member parts. Among these shape defects, twist occurs frequently and requires numerous reworks on the dies compensate the shape deviation. But until now, it seems to be no effective method to reduce the twist in forming processes. In this study, a new forming process to reduce the twist deformation during the forming of automotive structural member was suggested. This method consists of forming and restriking of embosses on the sidewall around the stretch flanging area of the part. and was applied in the forming process design of an automotive front side inner member with high strength steel. To evaluate the effectiveness of the method, springback analysis using Pamstampa™ was done. Through the analysis results, the suggested method proven to be effective in twist reduction of channel shaped parts with stretch flanging area.

The end shape of tube for automobile power steering system has influence on the ability of performance. In this case study, we attempted to optimize the forming process of a small tube using Taguchi experimental design methodology. A preliminary experimen

경제적 잠재성이 큰 삼 종자의 식품소재로서의 활용을 모색하고자 삼 종자의 일반성분을 측정하였고 삼 종자 첨가 압출성형펠릿의 호화양상을 분석하기 위하여 페이스트 점도를 측정하였다. 또한 삼 종자 후레이크의 체적밀도, 색도, 압착강도, 수분용해지수와 수분흡착지수, 조직감 유지시간(bowl life) 등의 품질특성을 조사하였다. 압출성형 공정조건은 배럴온도 90, 100, 110oC, 수분함량 35%이었다. 삼 종자의 수분, 조단백질, 조지방, 조회분함량은 각각 5.67±0.02, 25.93±0.16, 28.21±0.56, 7.70±0.08%이었다. 압출성형 펠릿의 페이스트 점도 측정결과 삼 종자 펠릿의 제조에 적합한 압출성형 배럴온도는 100-110oC인 것으로 판단되었다. 삼 종자 후레이크의 체적밀도는 0.24-0.43 g/mL 범위로 배럴온도가 증가함에 따라 감소하는 경향을 나타내었다. 명도와 압착강도는 삼 종자 첨가량이 증가함에 따라 크게 감소하는 경향을 나타내었다. 배럴온도가 90oC에서 110oC로 증가함에 따라 수분용해지수는 감소하는 경향을 나타내었고 수분흡착지수는 증가하는 경향을 나타내었다. 조직감 유지시간은 5.8-15.5분 범위로 삼 종자 첨가량의 증가에 따라 감소하였다. 관능검사 결과 전체적인 기호도는 삼 종자 첨가량 20%일 때 가장 높은 값을 나타내었다.

Bulk nanostructured metallic materials are generally synthesized by bottom-up processing which starts from powders for assembling bulk materials. In this study, the bottom-up powder metallurgy and High Pressure Torsion (HPT) approaches were combined to achieve both full density and grain refinement at the same time. After the HPT process at 473K, the disk samples reached a steady state condition when the microstructure and properties no longer evolve, and equilibrium boundaries with high angle grain boundaries (HAGBs) were dominant. The well dispersed alumina particles played important role of obstacles to dislocation glide and to grain growth, and thus, reduced the grain size at elevated temperature. The small grain size with HAGBs resulted in high strength and good ductility.

Plasma spray forming is recently explored as a near-net-shape fabrication route for ultra-high temperature metals and ceramics. In this study, monolithic tungsten has been produced using an atmospheric plasma spray forming and subsequent high temperature sintering. The spray-formed tungsten preform from different processing parameters has been evaluated in terms of metallurgical aspects, such as density, oxygen content and hardness. A well-defined lamellae structure was formed in the as-sprayed deposit by spreading of completely molten droplets, with incorporating small amounts of unmelted/partially-melted particles. Plasma sprayed tungsten deposit had 84-87% theoretical density and 0.2-0.3 wt.% oxygen content. Subsequent sintering at 2500 promoted the formation of equiaxed grain structure and the production of dense preform up to 98% theoretical density.

가변단면 압출기술은 사용하는 금형의 조합에 의해 다양한 가공이 가능한 성형공법으로, 압출시에 금형의 움직임에 의하여 제품의 단면형상을 변화시키거나, 치수와 두께를 동시에 변화시킬 수 있다. 압출공정에서 압출속도, 압출압력, 압출온도는 압출품의 표면결함이나 내부품질에 있어 중요한 영향인자이다. 그중 일정한 압출속도는 균일한 메탈 플로를 형성하여 성형품질에 있어서 고른 상태를 유지하게 만드는 요소이다. 기존의 압출 성형에서 펌프토출양의 변화에 의한 추출속도변동 문제는 램 속도의 변화를 계측하고 토출 양을 조정함으로써 압출속도를 제어하는 방법으로 해결한다. 그러나 가변단면 압출공정에서는 제품의 단면형상의 변화에 따라 압출비가 변하므로 이에 따른 램 속도 제어가 있어야만 한다. 본 연구에서는 가변단면 압출공정에서 가공형상에 따른 제어 알고리즘을 제시하여 가변 형상에 따른 램의 이동 속도 및 위치를 제공하려 한다.

The investigation is to modify the mechanical and chemical properties of Mg alloys using a combination of rapid solidification and surface treatment. As the first approach, was gas atomized and pressure sintered by spark plasma sintering process (SPS), showing much finer microstructure and higher strength than the alloys as cast. Further modification was performed by treating the surface of PM Mg specimen using Plasma electrolytic oxidation (PEO) process. During the PEO processing, MgO layer was initiated to form on the surface of Mg powder compacts, and the thickness and the density of MgO layer were varied with the reaction time. The thickening rate became low with the reaction time due to the limited diffusion rate of Mg ions. The surface morphology, corrosion behavior and wear resistance were also discussed

In spite of relatively high prices, aluminum wheels rapidly replace traditional steel wheels because of light weight and stylish design. To cope with expanding aluminum wheel market, steel wheel makers try to produce skeleton typed steel wheels adopting high strength steel which are light, stylish and lowprice compared with conventional steel wheel. But skeleton typed steel wheel disks are difficult to form because of complex shapes and low drawability of high strength steel. This paper presents the drawing process design for 5-spoke skeleton steel wheel disk. Through the finite element simulation of various alternatives for multi stage drawing processes, desirable draw die designs were proposed.