• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.1
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• pp.92-99
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• 2014

An aspherical lens, which resolves several problems with a spherical lens,typically serves asa key part of an optical system. Generally, an aspherical lens is fabricated using a diamond turning machine or by mean of injection molding. However, residual stress and/or tool marks can arise when using a commercial fabricating method such as DTM or injection molding. A polishing process, thus, is commonly used to obtain a high-precision aspherical lens. In this study, a polishing method using MR fluid was applied to minimize several problems, in this case residual stress and the creation of tool marks, during the cutting process. The MR polishing system was developed to polish aspherical lenses. A series of experiments were performed to obtain a very fine surface roughness. PMMA (the lens material for molding) was used as a workpiece, and the gap size, magnetic field intensity, wheel speed and feed rate were selected as the parameters in this study. Finally, a very fine surface roughness of Ra=2.12nm was obtained after MR polishing.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.25 no.1
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• pp.95-103
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• 2015

Objectives: This study was conducted in order to better understand the conceptual model and Stoffenmanager nano module and apply it to the synthesis and packing processes of nanomaterials. Methods: Site visits were conducted to five nanomaterial production processes. Product and exposure variables were investigated in these workplaces. Hazard banding and exposure classification of the synthesis and packing processes of nanomaterials were conducted using documents and the website of Stoffenmanager Nano. Results: The five sites featured different products, packing tasks, ventilation and local exhaust, and others. The hazards for nano-nickel and copper were classified as E. The hazards for both fumed silica and indium tin oxide were classified as D. The hazard for spherical silica was classified as C. The exposure classes in the synthesis process of nanomaterials ranged from 2 through 4. The exposure classes in the packing process of nanomaterials ranged from 1 through 4. Conclusions: Application of Stoffenmanager nano to the synthesis and packing processes of nanomaterials helped to better understand the control level of the work environment and to suggest appropriate actions. The comparison of each process showed the effect of the production process and handling of solids and ventilation on exposure class.

• Carbon letters
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• v.19
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• pp.23-31
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• 2016

Carbon rich fly ash was recently reported to have compositions that are ideal for use as a precursor and catalyst for carbon nanotube growth. This fly ash powder is mostly composed of pure carbon, predominantly present as sp². In this work, the effect of sonication time on the morphology and structural properties of carbon rich fly ash particles is reported. The obtained results show that ultrasound treatment is an effective tool for producing ultrafine particles/fragments with higher porosity, which might be suitable for the adsorption of gasses. Moreover, carbon nanoparticles (CNPs) of this fly ash were produced in parallel using the ball milling technique, and were evaluated as reinforcements for epoxy based composites. These CNPs have almost spherical shapes with particle sizes of around 30 nm. They were found to have strong C=O carbonyl group bonds, which might be generated during the ball milling process. The tensile testing results of a fly ash CNP reinforced epoxy composite showed significant improvements in the mechanical properties, mainly in the stiffness of the polymer. The stiffness value was increased by around 23% of that of neat epoxy. These CNPs with chemically active groups might also be useful for other applications.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.10a
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• pp.214-219
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• 2001

One of the major limitations of productivity and quality in metal cutting is the machining accuracy of machine tools. The machining accuracy is affected by geometric errors, thermally-induced errors, and the deterioration of the machine tools. Geometric and thermal errors of machine tools should be measured and compensated to manufacture high quality products. In metal cutting, the machining accuracy is more affected by thermal errors than by geometric errors. In this study, the compensation device and temperature-based algorithm have been presented in order to compensate thermal error of machine tools under the real-time. The thermal error is modeled by means of angularity errors of a column and thermal drift error of the spindle unit which are measured by the touch probe unit with a star type styluses, a designed spherical ball artifact, and five gap sensors. In order to compensate thermal characteristics under several operating conditions, experiments performed with five gap sensors and manufactured compensation device on the horizontal machining center.

• Journal of Mechanical Science and Technology
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• v.16 no.6
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• pp.799-809
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• 2002

In order to utilize a parallel mechanism as a machine tool component, it is important to estimate the errors of its end-effector due to the uncertainties in parts. This study proposes an error analysis for a new parallel device, a cubic parallel mechanism. For the parallel device, we consider two kinds of errors. One is a static error due to link stiffness and the other is a dynamic error due to clearances in the parts. In this study, we propose a stiffness model for the cubic parallel mechanism under the assumption that the link stiffness is a linear function of the link length. Also, from the fact that the errors of u-joints and spherical joints are changed with the direction of force acting on the link, they are regarded as a part of link errors, and then the error model is derived using forward kinematics. Lastly, both the error models are integrated into the total error, which is analyzed with a test example that the platform moves along a circular path. This analysis can be used in predicting the accuracy of other parallel devices.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.124-127
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• 2000

The finite element analyses of the wrinkling initiation and growth in the sheet metal forming process provide the detailed information about the wrinkling behavior of sheet metal. The direct analyses of the wrinkling initiation and growth, however, bring about a little difficulty in complex industrial problems because it needs large memory size and long computation time. For the description of wrinkling growth, the mesh elements should be sufficiently small and the size of finite element matrix becomes large. In the static implicit finite element method therefore, the direct analysis of wrinkling growth in a complex sheet metal forming process is rather difficult. From the industrial viewpoint of tooling design, the readily available information of possibility and location of wrinkling is sometimes more preferable to the detailed time-consuming information. In the present study, therefore, the wrinkling factor that shows locations and relative possibility of wrinkling initiation is proposed as a convenient tool of relative wrinkling estimation based on the energy criterion. The location and relative possibility of wrinkling initiation are predicted by calculating the wrinkling factor in various sheet metal forming processes such as cylindrical cup deep drawing, spherical cup deep drawing, and elliptical cup deep drawing. The wrinkling factor is also implemented in the analysis of the door inner stamping process to predict wrinkling.

• Korean Journal of Computational Design and Engineering
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• v.11 no.2
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• pp.97-106
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• 2006

Voronoi diagrams have been known for numerous important applications in science and engineering including CAD/CAM. Especially, the Voronoi diagram for 3D spheres has been known as very useful tool to analyze spatial structural properties of molecules or materials modeled by a set of spherical atoms. In this paper, we present two algorithms, the edge-tracing algorithm and the region-expansion algorithm, for constructing the Voronoi diagram of 3D spheres and applications to protein structure analysis. The basic scheme of the edge-tracing algorithm is to follow Voronoi edges until the construction is completed in O(mn) time in the worst-case, where m and n are the numbers of edges and spheres, respectively. On the other hand, the region-expansion algorithm constructs the desired Voronoi diagram by expanding Voronoi regions for one sphere after another via a series of topology operations, starting from the ordinary Voronoi diagram for the centers of spheres. It turns out that the region-expansion algorithm also has the worst-case time complexity of O(mn). The Voronoi diagram for 3D spheres can play key roles in various analyses of protein structures such as the pocket recognition, molecular surface construction, and protein-protein interaction interface construction.

• Nuclear Engineering and Technology
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• v.32 no.4
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• pp.410-423
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• 2000

A two-dimensional numerical model is developed and applied to the LAVA-EXV tests performed at the Korea Atomic Energy Research Institute (KAERI) to investigate the external cooling effect on the thermal margin to failure of a reactor pressure vessel (RPV) during a severe accident. The computational program was written to predict the temperature profile of a two-dimensional spherical vessel segment accounting for the conjugate heat transfer mechanisms of conduction through the debris and the vessel, natural convection within the molten debris pool, and the possible ablation of the vessel wall in contact with the high temperature melt. Results of the sensitivity analysis and comparison with the LAVA-EXV test data indicated that the developed computational tool carries a high potential for simulating the thermal behavior of the RPV during a core melt relocation accident. It is concluded that the main factors affecting the RPV failure are the natural convection within the debris pool and the ablation of the metal vessel, The simplistic natural convection model adopted in the computational program partly made up for the absence of the mechanistic momentum consideration in this study. Uncertainties in the prediction will be reduced when the natural convection and ablation phenomena are more rigorously dealt with in the code, and if more accurate initial and time-dependent conditions are supplied from the test in terms of material composition and its associated thermophysical properties.

• Transactions of Materials Processing
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• v.17 no.8
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• pp.570-578
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• 2008

A flexible forming apparatus is composed a number of punches which have spherical pin tip shape instead of conventional solid die. The flexible forming tool consisted of punch array in a matrix form was proposed as an alternative forming method to substitute the conventional line heating method which use heat source to induce residual stress along specified heating lines. In this study, application of the flexible forming process to the small scale curved plate forming was conducted. Numerical simulations for both solid and flexible die forming process were carried out to compare the shape of the products between flexible and conventional die forming process. In addition, spring-back analysis was conducted to figure out the feasibility of the flexible forming process comparing with the die forming process in view of final configuration of the specimens. Moreover, experiment was also carried out to confirm the formability of the process. Consequently, it was confirmed that the flexible die forming method has capability and feasibility to manufacture the curved plates for shipbuilding.

• Journal of the Korean Ceramic Society
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• v.41 no.1
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• pp.19-23
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• 2004

The Hertzian indentation contact damage behavior of porous alumina with controlled pore shape was investigated by experiments. Porous alumina ceramics containing well-defined pore shape, size and distribution were prepared by incorporation of fugitive spherical starch. Porous alumina with isolated pore structure was prepared with porosity range up to 30%. The indentation stress-strain curves of porous alumina were constructed. Elastic modulus and yield stress can be obtained from the stress-strain relationship. Impulse excitation method for the measurement of elastic modulus was also conducted as well as Hertzian indentation and was confirmed as a useful tool to evaluate the elasticity of highly porous ceramics. Elastic modulus of the inter-connected pore structure is more sensitive to porosity than that of the isolated pore structure. When the specimen had isolated pore structure, higher yield point was obtained than it had inter-connected pore structure. This study proposed that the elastic modiulus of porous ceramics is strongly related to not only porosity, but also the structure of pore.