• Transactions of Materials Processing
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• v.13 no.7
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• pp.614-622
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• 2004

A new approach for the automatic elimination of free edges in the finite element model for the analysis of sheet metal forming processes is presented. In general, the raw finite element model constructed from an automatic mesh generator is not well suited for the direct use in the downstream forming analysis due to the many free edges which requires tedious time consuming interactive graphic operations of the users. In the present study, a general method for the automatic elimination of free edges is proposed by introducing a CAD/CAE hybrid method. In the method a trimmed parametric surface is generated to fill the holes which are orginated from the free edges by using the one step elastic finite element analysis. In addition, mesh generation algorithm is suggested which can be used in the general trimmed surface. In order to verify the validity of the proposed method, various examples including actual automobile sheet metal parts are given and discussed.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.10
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• pp.121-129
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• 1995

The objective of this research is to develop an effective inspection planning strategy for sculptured surfaces by using 3-dimensional Coordinate Measuring Machine (CMM). First, the CAD/CAM database is generated by using the Bezier surface patch mathod and variable cutter step size approach for design and machining of the workpiece model. Then, optimum measuring point locations are determained based on the mean curvature analysis to obtain more effective inspection results for the given sample numbers. An optimal probe sequence generation method is proposed by implementing the Traveling Salesperson (TSP) algorithm and new guide point selection methods are suggested based on the concepts of the variable distance between the first and second guide points. Finally, simulation study and experimental work show the effectiveness of the proposed strategy.

• Journal of Korea Foundry Society
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• v.22 no.5
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• pp.265-270
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• 2002

A novel jewelry master pattern manufacturing process which reduce manufacturing steps by employing a Duraform rapid prototyping mold and a low melting alloy has been suggested. The novel process follows the steps of 'jewelry 3D CAD design ${\rightarrow}$ Durafrom RP mold ${\rightarrow}$ low melting alloy master pattern' while the previous process follows more complicated steps of 'jewelry idea sketch ${\rightarrow}$ detailed drawing ${\rightarrow}$ wax carving ${\rightarrow}$ flask ${\rightarrow}$ silver master pattern.' An upper and a lower part of molds have been manufactured of Duraform powder, of which melting point is $190^{\circ}C$. A maser pattern was manufactured by pouring a low melting alloy of Pb-Sn-Bi-Cd, so called Woods Metal, of which melting point is $70^{\circ}C$, into the mold. The master pattern is a shape of a disk of 20mm diameter that contains various design factors. The variations of dimensions, surface roughness, surface pore ratio were measured by an optical microscope, a surface roughness profilometer, and a Rockwell hardness tester. The pattern made of were maeasured by an optical microscope, a surface roughness profilometer, and a Rockwell hardness tester. The pattern made of low melting alloy has sufficient surface hardness, and surface pore ratio to be used as the jewelry master pattern.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.3 s.174
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• pp.550-559
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• 2000

One of the most important factor to be considered for the analysis of sheet metal forming processes is the tool surface description for arbitrarily- shaped sheet metal parts. In the present study , finite element approach is used to describe the arbitrarily shaped tool surface. In finite element mesh approach, tool surfaces ar, described by finite elements. The finite elements mesh description of the tool surface, which is originally described by CAD data, needs much time and time-consuming graphic operation. The method, however, has been widely used to describe a complex tool surface. In the present study, the contact searching algorithm for the finite element mesh approach is developed based on cell strategy method and sheet surface normal scheme. For the verification purpose, a clover cup drawing, Baden-Baden oilpan problem and a trunk floor drawing were investigated. The computational results based on the finite element approach were compared with the results of available parametric patch approach and experiments.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.2
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• pp.176-183
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• 2003

The paper presents a feature recognition and segmentation method for surface approximation in reverse engineering. Efficient digitizing plays an important role in constructing a computational surface model from a physical part-surface without its CAD model on hand. Depending on its measuring source (e.g., touch probe or structured light), each digitizing method has its own strengths and weaknesses in terms of speed and accuracy. The final goal of the research focuses on an integration of two different digitizing methods: measuring by the structured light and that by the touch probe. Gathering bulk of digitized points (j.e., cloud-of-points) by use of a laser scanning system, we construct a coarse surface model directly from the cloud-of-points, followed by the segmentation process where we utilize the z-map filleting & differencing to trace out feature boundary curves. The feature boundary curves and the approximate surface model could be inputs to further digitizing by a scanning touch probe. Finally, more accurate measuring points within the boundary curves can be obtained to construct a finer surface model.

• Journal of the Korean Society of Industry Convergence
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• v.16 no.3
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• pp.85-93
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• 2013

The MCT has been most extensively used in the machining. In particular, the ball endmill has been mainly adopted for finishing on the free- form surface. The advancement of CAD/CAM software has made it possible to develop various cutting pattern methods and to create diverse tool routes. Therefore, the current research made an attempt to find the optimal cutting pattern among the seven cutting patterns (i.e., Follow Periphery, Zig, Zig Zag, Concentric Zig, Concentric Zig Zag, Radial Zig, Radial Zig Zag) when aluminium 6000 series were machined by the ball endmill. The optimal pattern was found by comparing different shapes and surface roughness produced by the seven patterns. The current research found that each cutting pattern produced its own unique geometric features on the machined surface. It was found that the Radial Zig cutting pattern produced the lowest roughness on the flat surfaces. The Radial Zig Zag cutting pattern was found to produce the most accurate free-form surface. Finally, the most efficient cutting pattern in terms of machining time turned out to be the Follow Periphery.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.878-881
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• 2005

A Stereolithography technology is based on stacking of sliced layer from STL file that is converted from 3-dimensional CAD data. A microstereolithography technology is evolved from conventional stereolithography to fabricate microstructures. In this technology, we have to consider influence of resin flow to make refresh surface. To generate new resin surface, stage has to be moved downward deeply and upward to desired position. At this time, resin flow affects to refresh surface of resin. And resin viscosity is the key factor in simulation of resin flow. By setting optimal refresh time for resin surface, total fabrication time is reduced and there is no damage to fabricated layers. In this research, we simulate resin flow using CFD software and derive optimal stage moving time and dwelling time.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.7
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• pp.15-24
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• 2021

In this paper, to analyze the types of surface morphology error according to factors that cause machining error, the experiments were conducted in the ultra-precision diamond machine using a diamond tool. The factors causing machining error were classified into the pressure variation of compressed air, external shock, tool errors, machining conditions (rotational speed and feed rate), tool wear, and vibration. The pressure variation of compressed air causes a form accuracy error with waviness. An external shock causes a ring-shaped surface defect. The installed diamond tool for machining often has height error, feed-direction position error, and radius size error. The types of form accuracy error according to the tool's errors were analyzed by CAD simulation. The surface roughness is dependent on the tool radius, rotational speed, and feed rate. It was confirmed that the surface roughness was significantly affected by tool wear and vibration, and the surface roughness of Rz 0.0105 ㎛ was achieved.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.10
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• pp.17-25
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• 2000

• Korean Journal of Computational Design and Engineering
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• v.4 no.2
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• pp.79-86
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• 1999

A general approach to automatic generation of triangular meshes on three-dimensional surfaces is presented in this paper. The approach, developed with emphasis on program generality and interface with CAD/CAM systems, is based on the double mapping method and the looping method. The double mapping method is introduced and anew splitting scheme is proposed for the looping method employed for triangular mesh generation on the parametric domain. Several application examples are given.