Plastic deformation of balls in safety coupling by collision with V-Hole was investigated in the current study. Generally, when the applied torque is greater than the maximum allowable torque, balls in V-Hole get out from the holes and the coupling loses the torque transfer capability. After balls are out from the V-Holes, the balls and V-Hole rotate at a different velocity. When balls meet the next V-Hole, they collide into the wall of the V-Hole. Due to this collision, plastic deformation and wear take place. The plastic deformation and wear may reduce the torque transfer capability of the safety coupling. The reduction in torque transfer capability was observed in the experiment. In this study, plastic deformation of balls and flange was investigated through dynamic analysis of the safety coupling. Also, the effect of relative rotational velocity on the plastic deformation was investigated.

When the penetrator collides with the target, the penetrator has different penetrating characteristics and residual velocity after penetration, according to the geometry of the penetrator. In this study, we optimized the geometry of the penetrator using the artificial neural network and the genetic algorithm to derive the best penetration performance. The Latin hypercube sampling method was used to collect the sample data, Simulation for predicting the behavior of the penetrator was conducted with the finite cavity pressure method to generate the training data for the artificial neural network. Also, the optimal hyper parameter was derived by using the Latin hypercube sampling method and the artificial neural network was used as the fitness function of the genetic algorithm to optimize the geometry of the penetrator. The optimized geometry presented the deepest penetration depth.

Finite element analyses were carried out to investigate the effect of ultrasonic vibration on drawing force in large diameter tube drawing. Ultrasonic vibration was imposed to a drawing die using ultrasonic vibration horns. The horn was designed to have desired amplification ratio and natural frequency using a wave equation. The drawing forces obtained with and without ultrasonic vibration were compared. The effect of vibration amplitude and phase delay of two horns located in opposite side on drawing force was investigated. Results showed that the drawing force could be reduced about 11% by using ultrasonic vibration of 20 μm amplitude and that the phase shift of two opposite horns had a great effect on the drawing force.

A multi-step warm forging process for subminiature screws is investigated. Due to the low formability of Titanium alloys, bit forming of Titanium screws is difficult by cold forging. In order to overcome this low formability of Titanium alloys, two candidate processes, i.e., multi-step forging and warm forging are introduced. First, a multi-step (two-step) forging process is investigated. The punch shape and stroke of forging during the first step is designed via various analyses. Finally, the bit formability is investigated at different forging temperatures. Analyses are carried out for two-step forging at various temperatures and the formability under these thermal conditions is compared.

Micro-screws can be defined by their outer diameter of generally less than 1 mm. They are manufactured by head forging and thread rolling processes. In this study, the thread rolling process was numerically analyzed for a micro-screw with a diameter and pitch of 0.8 and 0.2 mm, respectively. Through finite element (FE) analysis, the effects of two design parameters (die gap and chamfer height) on the dimensional accuracy were investigated. Three combinations of chamfer heights were chosen first and the corresponding die gap candidates selected by geometric calculation. FE analyses were performed for each combination and their results indicated that the concave chamfer height should be less than 0.3 mm, while a 10 ?m difference in the die gap might cause degeneration in dimensional accuracy. These results conclude that ultra-high accuracy is required in die fabrication and assemblies to ensure dimensional accuracy in micro-screw manufacturing.

We investigated the protection capability of a plate against high speed projectiles demonstrating collision and penetration behaviors by finite element analysis. The element erosion method was used for penetration analysis, which showed that the speed of the projectile was slightly reduced by the collision with the protection plate. Protection capability was measured by the projectile’s attitude angle change because the damage of our tanks by projectiles was also dependent on the projectile-tank collision angle. When the length of the protection plate was sufficiently long, the projectile was severely deformed and incapacitated. In the case of a small plate, the projectile was deformed only in the collision region. Thus, projection capability was investigated by the change of attitude angle. The effect of collision angle, velocity, and length of the plate on the rotational and vertical velocities of the projectile was investigated.

Sheet metal-forming processes such as stamping, deep drawing, bending, shearing, hydroforming, hydromechanical deep drawing, rubber forming, and incremental forming have been widely used in the automotive, aircraft, and ship-building industries. With the expansion of the automotive industry, research on these processes has been remarkably developed in Korea since the 1980s. Here, we review the history of this research as well as recent trends in sheet metal-forming processes. This overview focuses specifically on the results of research in Korea and on the works of Professor D.Y. Yang, in honor of his retirement.

As the sizes of mobile phones and watch phones decrease, the joining bolt for the products should also be decreased to a miniature size. However, the miniature-sized bolt has to support sufficient joining and anti-releasing torque to keep the product fastened. In this study, the thread shapes are designed to improve anti-releasing performance of bolts. Especially, when bolt materials is stronger than nut materials, the design of thread shapes is needed, like bolt for wood, to improve the fastening capability. Through the joining and releasing analyses of bolts, the thread shapes for SUS302 bolt and Mg alloy nut are newly designed. It was shown that the newly designed bolt has 20 % higher anti-releasing torque and 35% lower torque loosening slope compared to the standard bolt.

In this study, the torque transmitting capability of a flexible disk coupling was investigated. Flexible disc coupling is used to transmit power between two axes, and there exist misalignments such as angle of deviation and end play between two shafts. A disk is an important part in the flexible disk coupling because the disk has to transmit power between two mis-aligned shafts. To investigate the effect of mis-alignment on load carrying capacity, finite element analyses were carried out. Analyses were carried out for two types of disk; i.e., circular and square disks. The rotational and bending stiffness of disk plates was predicted to investigate the effect of mis-alignment on stress. As a result, it was shown that the mis-alignment can cause severe decrease in load-carrying capacity. And, the square disk showed better performance than the circular disk.

In order to predict necking behaviour of aluminium sheets, a crystal plasticity model is introduced in the finite element analysis of tensile test. Due to the computational limits of time and memory, only a small part of tensile specimen is subjected to the analysis. Grains having different orientations are subjected to numerical tensile tests and each grain is discretized by many elements. In order to predict the sudden drop of load carrying capacity after necking, a wellknown Cockcroft-Latham damage model is introduced. The mismatch of grain orientation causes stress concentration at several points and damage is evolved at these points. This phenomenon is similar to void nucleation. In the same way, void growth and void coalescence behaviours are well predicted in the analysis. For the comparison of prediction capability of necking, same model is subjected to finite element analysis using uniform material properties of polycrystal with and without damage. As a result, it is shown that the crystal plasticity model can be used in prediction of necking and fracture behavior of materials accurately.

Due to environmental issues, the development of low energy consumption products has become one of the main topics in the home appliance industry. The energy consumption of a refrigerator depends on the efficiency of its compressor as well as on the refrigerator cycle design, such as the capacity modulation. In this study, a dual capacity, i.e., two-step capacity modulation (TCM), reciprocating compressor is developed. In a TCM compressor, capacity modulation is achieved by changing the dead volume in the cylinder. Instead of a concentric sleeve, an eccentric sleeve, a key, and a spring are used to change the dead volume for the clockwise and counterclockwise rotation of a motor. When the compressor changes its operating mode from full capacity to partial capacity or in opposite direction, the key may collide with the eccentric sleeve. The structural reliability and mode change reliability were confirmed by analysis and experiment.

DBD(Dielectric Barrier Discharges) plasma is often used to clean the surface of semiconductor. The cleaning performance is affected mainly by plasma density and duration time. In this study, the plasma density is predicted by coupled simulation of flow, chemistry mixing and reaction, plasma, and electric field. 13.56 ㎒ of RF source is used to generate plasma. The effect of dielectric thickness, gap distance, and flow velocity on plasma density is investigated. It is shown that the plasma density increases as the dielectric thickness decreases and the gap distance increases.