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Development of Spot Welding and Arc Welding Dual Purpose Robot Automation System
이용중,김태원,이형우,Lee, Yong-Joong,Kim, Tae-Won,Lee, Hyung-Woo The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.4
A dual purpose robot automation system is developed for both arc welding and spot welding by one robot within a cell. The need for automation of both arc welding and spot welding processes is urgent while the production volume is not so big as to accommodate separate station for the two processes. Also, space is too narrow for separate station to be settled down in the factory. A spot welding robot is chosen and the function for arc welding are implemented in-house at cost of advanced functions. For the spot welding, a single pole type gun is used and the robot has to push down the plate to be welded, which causes the robot positioning error. Therefore, position error compensation algorithm is developed. The basic functions for the arc welding processes are implemented using the digital I/O board of robot controller, PLC, and A/D conversion PCB. The weaving pattern is taught in meticulously by manual teach. A fixture unit is also developed for dual purpose. The main aspects of the system is presented in this paper especially in the design and implementation procedure. The signal diagrams and sequence logic diagrams are also included. The outcome of the dual purpose welding cell is the increased productivity and good production stability which is indispensable for production volume prediction. Also, it leads to reduction of manufacturing lead time.
A Study on the Progressive Die Development of Sheet Metal Forming Part
심성보,이성택,Sim, Sung-Bo,Lee, Sung-Taeg The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.4
The production parts have required multiple processes such as drawing, piercing, blanking and notching etc. are performed with a high production rates in progressive die. In order to prevent the defects of process result, the optimization of strip process layout design, die design, die making, and tryout etc. are needed. According to these factors of die development process, it has been required that the theory and practice of metal working process and its phenomena, die structure, machining conditions for die making, die materials, heat treatment of die components, processing know-how and so on. In this study, we designed and analyzed die components through the carrying out of upper relevant matters also simulated the strip process layout of multiple stage drawing by DEFORM. Especially the result of tryout and its analysis became to the feature of this study with a system of PDDC(Progressive Die design by computer).
A Study on the Temperature Dependence of Electro-Rheological Fluids with Electric Field Control
장성철,박창수,이찬규,Jang, Sung-Cheol,Park, Chang-Soo,Lee, Chan-Kyu The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.2
Electro-Rheological(ER) fluids consist of suspensions of fine polarizable particles In a dielectric oil, which upon application of an external electric field control take on the characteristics of the Bingham solid. In this study, the temperature dependence of the viscosity was Investigated for an ER fluid consisting of 35 weight % of zeolite particles in hydraulic oil 46cSt. Thermal activation analysis was performed by changing the ER fluid's temperature from $-10^{\circ}C$ to $50^{\circ}C$. According to the analysis, the activation energy for flow of the ER fluid was 79.6 kJ/mole without applying electric field. On the other hand, with the electric field of 2kV/mm, the linearity between viscosity and temperature was not existed By changing the temperatures the viscosity (or shear stress) versus shear rates were measured. In this experiment shear rates were increased from 0 to $200s^{-1}$ in 2 minutes. Generally, the hydraulic oil 46cSt will be operated at the temperature of about $40^{\circ}C$, thus, the ER fluid's electric field dependence of viscosity was examined at this temperature. Also, an influence of adding the dispersant(Carbopl 940) on ER effect was discussed.
Development of SFM System for Nano In-Process Profile Measurement
권현규,최성대,홍성욱,Kweon, Hyun-Kyu,Choi, Seong-Dae,Hong, Sung-Wook The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.2
In this paper, we propose a new multi-purpose Scanning Force Microscope (SFM) system. The system can be used for nano/micro-scratching, in-process profile measurement, and observation of potential surface defects which occur during the scratching in air or liquid. Experimental results of nano/micro-scratching show that the smallest scratching depth can be controlled to be 10nm, which corresponds to the stability of the SFM system. Profile measurements of nano/micro-scratching surfaces have also been performed by the method of on-machine measurement and in-process measurement. Two measurement results were in good agreement with each other. The maximum difference was approximately 10 nm, which was mainly caused by the sampling repeatability error that influences the measurement accuracy Also, micro-defects on the micro-scratching surface were successfully detected by the SFM system. It was confirmed that the number of micro-defects increases when the surface is subjected to a cyclic bending load. The maximum depth was less than 100nm.
A Study on the Friction and Wear of Bronze Sintered Friction Materials
이종형,박무수,양성현,Lee, Jong-Hyung,Park, Moo-Soo,Yang, Seong-Hyeon The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.3
The effect of bronze sintered friction materials on frictional and mechanical properties is studied with the content(8~18 wt,%) and shapes (flake and irregular) of graphite that is used as solid lubricants to meet diverse characteristics such as low coefficient of friction, low wear rate and high bending strength. The content and shapes of graphite are optimized by statistical experiments. Friction test was carried out measure friction coefficient, temperature dependence and wear rate. As a result of experiments, the density, hardness and bending strength with a shape of flake graphite are lower and decrease rapidly than that of Irregular, as the content of graphite increases up to 18 wt% Aftei friction test, coefficient of friction is 0.3~0 4 and wear rate is $0.32{\sim}2.98{\times}10^{-7}cm^3/kg{\cdot}m$. When the content of graphite increases, coefficient of friction increases In a shape of flake graphite and decreases in a shape of irregular graphite.
박동환,윤재정,홍진태,권혁홍,Park, Dong-Hwan,Yun, Jae-Jung,Hong, Jin-Tae,Kwon, Hyuk-Hong The Korean Society of Manufacturing Process Engine 2017 한국기계가공학회지 Vol.16 No.4
In the sand casting process, the flow of liquid metal affects the quality of casting products and their die life. To determine the optimal bush part design process, this study performed various analyses using commercial finite element analysis S/W. The simulation focused on the molten metal behaviors during the mold filling and solidification stages of sand casting. This study aims to develop methods to reduce the cost and increase the tool life of the continuous hot zinc plating roll.
Flash Temperature Analysis on the Contact Surfaces between Cam and Roller-Follower Mechanism
구영필,김민남,김남식,Koo, Young-Pil,Kim, Min-Nam,Kim, Nam-Shik The Korean Society of Manufacturing Process Engine 2004 한국기계가공학회지 Vol.3 No.2
The flash temperature distribution on the contact surfaces between cam and roller-follower mechanism was analysed numerically. The elasto-hydrodynamic lubrication pressure and film thickness were used to get the accurate analysis results. The temperature distribution was obtained by numerical integration by making use of Carslaw and Jaeger's formulation to the whole contact surfaces. The maximum flash temperature was increased with both the increasing slip ratio of the contact surface and increasing external load Profile of the temperature distribution was affected by the sliding velocity of the surface.
Prediction of Laser Process Parameters using Bead Image Data
전예랑,최해운,Jeon, Ye-Rang,Choi, Hae-Woon The Korean Society of Manufacturing Process Engine 2022 한국기계가공학회지 Vol.21 No.6
In this study reports experiments were conducted to determine the quality of weld beads of different materials, Al and Cu. Among the lasers used to make battery cells for electric vehicles, non-destructive testing was performed using deep learning to determine the quality of beads welded with the ARM laser. Deep learning was performed using AlexNet algorithm with a convolutional neural network structure. The results of quality identification were divided into good and bad, and the result value was derived that all the results were in agreement with 94% or more. Overall, the best welding quality was obtained in the experiment for the fixed ring beam output/variable center beam output, in the case of the fixed beam (ring beam) 500W and variable beam (center beam) 1,050W; weld bead failure was seldom observed. The tensile force test to confirm the reliability of welding reported an average tensile force of 2.5kgf/mm or more in all sections.
Development of an Automatic Marking System for Fabric Inspection Machine
김재연,이재용,Kim, Jae-Yeon,Lee, Jae-Yong The Korean Society of Manufacturing Process Engine 2022 한국기계가공학회지 Vol.21 No.6
In this study, an automatic marking system for fabric inspection machines was developed. The main objectives of the study were to promote intelligence and automation for the inspection process, as well as to increase textile industrial productivity. Generally, when a worker manually inspects and marks a fabric, human error and reduced efficiency are unavoidable. To overcome these problems, we developed an automatic marking system that uses robots. This system incorporates a vision camera to automatically recognize defects, and an optical fiber sensor to detect the side of the fabric. To verify the performance, the control system sends a command directly to the robot to mark the fabric. Finally, the actual production confirmed that the proposed system could perform the desired motion.
조동현,이종선,Cho, Dong-Hyun,Lee, Jong-Sun The Korean Society of Manufacturing Process Engine 2017 한국기계가공학회지 Vol.16 No.4
In the present study, we used a loop thermosyphon heat exchanger consisting of condensers with internal fins and external plate fins which are 480 mm wide, 68 mm long, and 1,000 mm high. The heat transfer pipes in the heat exchanger were 15 mm in diameter and 1,000 mm in length, and 98 heat transfer pipes were installed in the heat exchanger. According to the experimental results, as the spaces between the internal discontinuous pins decreased, the frequency of pressure drops increased and changes in temperature at the outlet of the condenser were shown to be a little smaller. Therefore, we can see that as the spaces between internal discontinuous pins decreased, the heat transfer performance increased. For the loop heat pipe heat exchanger consisting of a condenser with internal and plate fins, as the temperature of the air flowing into the condenser increased, the condensation heat transfer rate also increased, and as the condenser refrigerant inflow temperature increased, the condensation heat transfer rate increased as well.