• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.4
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• pp.64-69
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• 2011

Magnesium alloy has been known as lightweight material in automobile and electronic industry with aluminum alloy, titanium alloy and plastic material. Friction welding is useful to join different kinds of metals and nonferrous metals they are difficult to be joined by such as gas welding, resistance welding and electronic beam welding. In this study, friction welding was performed to investigate optimization process of Mg alloy with a 20mm diameter solid bar. For that, the orthogonal array $(L_{9}(3^{4}))$ was used that contained four factors and each factor had three levels. Control factors were heating pressure, heating time, upsetting pressure and upsetting time. Also tensile tests were carried out to measure mechanical properties for welded conditions. The levels of heating pressure and upsetting pressure used were 15, 25, 35MPa, and 30, 50, 70MPa, respectively. In addition those of heating time and upsetting time were 0.5, 1, 1.5 sec and 3, 4, 5 sec., respectively, rotating speed of 2000rpm. From the experimental results, optimization condition was estimated as follows; heating pressure=35MPa, upsetting pressure=70MPa, heating time=1.5sec, upsetting time=3sec.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.1248-1253
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• 2003

Sensitivity information has been used for linearization of nonlinear functions in optimization. Basically, sensitivity is a derivative of a function with respect to a design variable. Design sensitivity is repeatedly calculated in optimization. Since sensitivity calculation is extremely expensive, there are studies to directly use the sensitivity in the design process. When a small design change is required, an engineer makes design changes by considering the sensitivity information. Generally, the current process is performed one-by-one for design variables. Methods to exploit the sensitivity information are developed. When a designer wants to change multiple variables with some relationship, the directional derivative can be utilized. In this case, the first derivative can be calculated. Only small design changes can be made from the first derivatives. Orthogonal arrays can be used for moderate changes of multiple variables. Analysis of Variance is carried out to find out the regional influence of variables. A flow is developed for efficient use of the methods. The sensitivity information is calculated by finite difference method. Various examples are solved to evaluate the proposed algorithm.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.12
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• pp.2092-2100
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• 2003

Sensitivity information has been used for linearization of nonlinear functions in optimization. Basically, sensitivity is a derivative of a function with respect to a design variable. Design sensitivity is repeatedly calculated in optimization. Since sensitivity calculation is extremely expensive, there are studies to directly use the sensitivity in the design process. When a small design change is required, an engineer makes design changes by considering the sensitivity information. Generally, the current process is performed one-by-one for design variables. Methods to exploit the sensitivity information are developed. When a designer wants to change multiple variables with some relationship, the directional derivative can be utilized. In this case, the first derivative can be calculated. Only small design changes can be made from the first derivatives. Orthogonal arrays can be used for moderate changes of multiple variables. Analysis of Variance is carried out to find out the regional influence of variables. A flow is developed for efficient use of the methods. A software system with the flow has been developed. The system can be easily interfaced with existing commercial systems through a file wrapping technique. The sensitivity information is calculated by finite difference method. Various examples are solved to evaluate the proposed algorithm and the software system.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1362-1365
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• 2003

On this study. we improved the efficiency applying algorithm that is repeatedly using orthogonal array in discrete design space and filling a defect of gradient method in continuous design space. we showed optimal ply angle that maximized buckling strength of CFRP laminated composite plate without a hole and with a hole by each aspect ratio. In the case of CFRP laminated composite plate without a hole, we confirmed the reliance and efficiency of algorithm in comparison with the result optimization achievement repeatedly using statistical orthogonal array of experimental design.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.92-97
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• 2012

Injection mold is a manufacturing process used to produce parts of complicated shape at a low cost. Many factors affect the quality of injection molded part during injection molding process. A study on the optimization of injection mold is progressed by using a simulation software like Moldflow. Filling, packing and cooling phases of injection molding processes are analyzed according to the mold design considering the shrinkage of molded part, the degree of filling rate and the wearing of a mold. Taguchi method is applied to analyze the significance of processing parameter and the dynamic characteristics according to the variation of processing parameters. From the results, the mold temperature and packing pressure influenced the shrinkage of injection molded part.

• Proceedings of the KSME Conference
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• 2001.06a
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• pp.770-775
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• 2001

Steel bar breaking system is a component of a sled test system for automobile crashworthiness. It is a recent idea for the sled test. In a sled test, a crash pulse is given as a input made from a real test. The steel bar breaking system is designed to generate a certain crash pulse. Orthogonal arrays from design of experiments (DOE) are employed. The factors of the array are panel thickness and the number of steel bars, and the levels are candidate values of them. A simulation is utilized for the crash analysis. A commercial system called LS/DYNA3D is adopted. A test system is designed based on the results.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.7
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• pp.101-108
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• 2010

Domestic three-way catalyst satisfies exhaust gas conversion efficiency or pressure drop etc. but doesn't satisfy thermal durability. Thermal stress analysis for three-way catalyst was performed based on experimental temperature distribution. Thermal safety of three-way catalyst was estimated by safety factor. Aspect ratio variable had the most significant effect on thermal stress. Thickness variable had the least significant effect on thermal stress. Optimal conditions for premature failure prevention of three-way catalyst were as follows : (1) aspect ratio of three-way catalyst : 0.6:1 (2) 2.84mm thick (3) silicon nitride. The safety of Taguchi-optimized three-way catalyst were 4.7 times higher than that of existent three-way catalyst.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.174-185
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• 2002

The automotive industry faces many competitive challenges including weight and cost reduction to meet need for higher fuel economy. Tailored blanks offer the opportunity to decrease door weight, reduce manufacturing costs, and improve door stiffness. Optimization technology is applied to the inner panel of a door which is made by tailored blanks. The design of tailored blanks door starts from an existing door. At first, the hinge reinforcement and inner reinforcement are removed to use tailored blanks technology. The number of parts and the welding lines are determined from intuitions and the structural analysis results of the existing door. Size optimization is carried out to find thickness while the stiffness constraints are satisfied. The door hinge system is optimized using design of experiment approach. A commercial optimization software MSC/NASTRAN is utilized for the structural analysis and the optimization processes.

• Transactions of the Korean Society of Automotive Engineers
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• v.7 no.5
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• pp.130-140
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• 1999

During crash of a vehicle, most of the kinetic energy of the driver is absorbed by the steering system. The deformation characteristics of the steering system has significant effects on the injury of the driver. A part of the energy is absorbed by the steering wheel and another part by the collapsable steering column. It is believed that strength distribution between the wheel and the column has an important effect on the injury of the driver. A design criterion is suggested for steering wheels for maximum protection of drivers. Tagushi method is used to analyse the effects of design parameters.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.3
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• pp.147-154
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• 2004

This paper presents a procedure for analysis and design of a fine positioning stage, which has many applications in industries for machine tools, semiconductor, LCD and so forth. The stage considered here is based on a single module with 3 axes which is composed of flexures hinges, piezoelectric actuators and their peripherals. Through a series of analysis, the structural analysis model is simplified as a rigid body(the moving part) and springs(the flexures hinges). An experimental design procedure is applied to determine the dimension of flexures hinges. A sensitivity analysis on the notch positions is also performed to obtain a guideline of fabrication accuracy for the stage. An actual fine stage is made and verified through an experiment on the dynamic characteristics.