• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.5
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• pp.57-65
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• 2016

The power flow of an 8-speed automatic transmission was analyzed using a lever analogy for the manufacturing of planetary gears. From the analysis, we found that the engine power was split between the first and second double-pinion planetary gears (DPPG1 and DPPG2), and was then passed to the DPPG3 for the fourth speed. For the fifth speed, the engine power was split between the DPPG1 and DPPG3. For the speeds 6-8, the engine power was passed only to SPPG2, while the seventh speed contained the power circulation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.4
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• pp.17-23
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• 2008

Development of die technology for holder and barrel dies is necessary according to minimization of lens assembly, image sensor, and connectors. In these cases, there are two technical problems arising from die design. One is determination of knock-out pin location in die set. Minimization of lens assembly size make it difficult to obtain ejecting space. The other is whether or not high-precision die technology is possible to reduce torque variation when holer and barrel products is assembled. In this study, multi-cavity die set was developed taking advantage of gear-driven ejecting method. In the developed technology, die manufacturing technology was guaranteed with a high-precision level.

• Proceedings of the Korean Society for Agricultural Machinery Conference
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• 2017.04a
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• pp.17-17
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• 2017

In electric agricultural machine the gearhead is needed to convert the high speed low torque rotation motion generated by DC motor to lower speed high torque motion used by the vehicle. The gearhead consist of several spur gears works as reduction gears. Spur gear have straight tooth and are parallel to the axis of the wheel. Spur gears are the most easily visualized gears that transmit motion between two parallel shafts and easy to produce. The modeling and simulation of spur gears in DC motor gearhead is important to predict the actual motion behavior. A pair of spur gear tooth in action is generally subjected to two types of cyclic stress: contact stress and bending stress including bending fatigue. The stress may not attain their maximum values at the same point of contact fatigue. These types of failure can be minimized by analysis of the problem during the design stage and creating proper tooth surface profile with proper manufacturing methods. To improve its life expectation in this study modal and stress analysis of gearhead is simulated using ansys work bench software based on finite element method (FEM). The modal analysis was done to understand gearhead deformation behaviour when vibration occurs. FEM static stress analysis is also simulated on gearhead to simulate the gear teeth bending stress and contact stress behavior. This methodology serves as an approach for gearhead design evaluation, and the study of gear stress behavior in DC motor gearhead which is needed in the small workshop scale industries.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.26 no.5
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• pp.559-566
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• 2016

This study shows a development procedure and results of noise reduction for a new developed FF 8th speed automatic transmission. Based on planetary gear operating frequency analysis using PTA(planetary transmission analysis) program developed in 2012, It is expected that gear noise of the rear planetary gear set could be recognized easily in the concept design stage. Therefore, pRMC (planetary run many cases) analysis program that is developed in 2012 was applied to minimize the planetary gear noise level and noise distributions versus torque. To minimize noises coming from oil pump and final gears of a new transmission, several changes were applied, such as changing the clearance of double angular ball bearing, the oil pump rotor tooth number from 9 to 11 and the oil pump type from parachoid to megafloid and so on. Besides, stiffness values of the transmission case and the mount bracket were measured and reinforced properly. Finally, The total noise of the new FF 8th speed automatic transmission was developed successfully. Furthermore, E.O.L. testers also have been adapted to control the noise quality of automatic transmission assembly in the manufacturing factory. This paper could provide practical solutions to the automatic transmission NVH problems.

• Korean Journal of Computational Design and Engineering
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• v.16 no.4
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• pp.260-267
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• 2011

Nowadays, automobile manufacturers are faced with increasing global competition which is required low cost as well as high quality. To reduce shipping and handling cost and delivery time, lots of automobile manufactures tried to build their new factory in the neighborhood of market. Simultaneously, many factories are under construction in developing countries to make efficient use of low-wage workers. However, because systems are installed in developing countries as the same type of domestic facilities, systems have lots of problems such as high installation cost and inefficient use of manpower. To find core problems and generate optimal solution of these problems, thinking process of TOC(Theory Of Constrains) is used. In case of transmission gear machining system, semi-auto system is proposed as the best solution to increase manpower efficiency and system utilization. Semi-auto system consists of automatic machining process and manual transporting process. The system layout is generated based on semi-auto process concept. And, 3D simulation method using QUEST is used to verify production volume of generated system.

• Journal of Korean Society for Quality Management
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• v.30 no.3
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• pp.120-138
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• 2002

In order to carry out TQM and 6 Sigma management, it is the key elements to make clear a goal and a mission. Above all, we can succeed In achieving a dramatic change and a great outcome only when we make clear the method, incentives, organization and plans under the clear objective. In order to secure the competitiveness against the external challenge, it is essential to keep the several crucial factors such as CEO's will, the systematic process to measure and manage, monitoring to satisfy customer's needs and an aggressive development of TQM activity to encourage the endeavour of the relentless enhancement, and also a positive effort Is to be made for evaluating all quality culture like training experts internally by an outstanding training program under CEO's firm leadership. This study is carried out to understand that which features and factors of success can exist in a company culture if a company accepts a theoretical basis and concept, the general of TQM and 6 Sigma which are one of a management strategy, and carries out TQM and 6 Sigma for achieving improvement of quality and customer's satisfaction.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.575-581
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• 2007

The high dimensional accuracy of the cold forged part could be acquired by the accurate dimensional modification for the die, which is, the dimensional changes from the die through forged part to final part after heat treatment were considered. The experimental and FEM analysis are performed to investigate the dimensional changes from the die to final part on cold forged part, comparing with the machined gear. The dimension of forged part is compared with the die dimension at each stage, such as, machined die, cold forged part, and heat-treated-part. The elastic characteristics and thermal influences on forging stage are analyzed numerically by the $DEFORM-3D^{TM}$. The analyzed residual stress of forged part is considered into the FE-analysis for heat treatment using the $DEFORM-HT^{TM}$. The effects of residual stress affected into the dimensional changes could be investigated by the FEA. Each residual stress of gears was measured practically by laser beam type measurement.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.35 no.4
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• pp.179-185
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• 2012

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize casting design of an automobile part (Gear Box) Computer Aided Engineering (CAE) was performed by using the simulation software (Z Cast). The simulation results were analyzed and compared with experimental results. During the mold filling, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making a better production die casting tool, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

• Journal of Powder Materials
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• v.19 no.3
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• pp.189-195
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• 2012

A novel PM (powder metallurgy) steel for automotive power-train gear components was developed to reduce manufacturing cost, while meeting application requirements. The high-density PM steel was manufactured by mixing using special Cr-Mo atomized iron powders, high-pressure compaction, and sintering. Tensile strength, charpy impact, bending fatigue, and contact fatigue tests for the PM steel were carried out and compared to conventional forged steel. Pinion gears for auto-transmission were also manufactured by helical pressing, sintering, and surface densification process. In order to evaluate the durability of the PM parts, auto-transmission durability tests were performed using dynamometer tests. Results showed that the PM steel fulfilled the requirements for pinion gears indicating suitable tensile, bending fatigue, contact fatigue strengths and improved gear tooth profile. The PM gears also showed good performance during the transmission durability tests. As a result, the PM gears showed significant potential to replace the conventional forged steel gears manufactured by tooth machining (hobbing, shaving, and grinding) processes.

• International Journal of Precision Engineering and Manufacturing
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• v.3 no.3
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• pp.28-36
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• 2002

The continuously variable transmission (CVT) mechanism considered here is the output coupled type which combines the functions of a 2K-H I type differential gear unit and a V-belt type continuously variable unit (CVU). One shaft of the CVU is connected directly to the output shaft and another shaft of it is linked to the differential gear unit. It is shown that some fundamental relations (speed ratios, power flows and efficiencies) for twelve mechanisms previously described are valid by various experimental studies, six of them produce a power circulation and the others produce a power split. Parametric analysis is carried out in relation to the efficiency, speed ratio and power ratios in order to assist in the design of an optimum configuration. Some useful properties associated with power flow modes also are discussed in the output coupled type continuously variable transmission.