• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.215-218
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• 2005

For the production of cold forged parts with near-net-shape attributes, the quality of the tool system is responsible for an essential portion of costs fer the finished components. Therefore, a tool lift is one of the important issues on cold forging industry. There are many complicated variables related with tool life, such as material, heat-treatment, coating, lubricant, process design. In this study, heat-treatment of tool material and lubricant are investigated to improve the tool life. Deep cryogenic treatment of tool steel is very efficient to improve the wear resistance due to the fine carbide. And, friction factor of lubricants for cold forging are measured by the ring compression test. Zinc-Phosphate and $MoS_2$ lubricant is effective to sustain the friction factor under 0.1.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.3
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• pp.83-90
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• 2004

This paper proposes a tool path generation method for machining impellers with 5-axis machining center. The shape of impeller is complex, being composed of pressure surface, suction surface and leading edge, and so on. The compound surface which is made of ruled surface such as pressure surface and suction surface and leading edge such as fillet surface, makes the tool path generation much complicated. To achieve efficient roughing, cutting area is divided into two region and then tool radius of maximum size that do not cause tool intereference is selected for shortening machining time. In finishing, accuracy is improved using side cutting for blade surface and point milling for leading edge.

• Proceedings of the KSME Conference
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• 2007.05b
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• pp.3116-3121
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• 2007

In this paper, the inverse shape design is introduced using the permeable wall boundary condition. Inverse shape design defines the blade shape for the prescribed Mach numbers or pressure distribution on its surface. It calculates the normal mass flux from the difference between the calculated and prescribed pressure at the surface. A new geometry can be achieved after applying the quasi one-dimensional continuity equation from the leading edge to the trailing edge. For validation of this method, two test cases are studied. The first test case of inverse shape design illustrates the cosine bump with a strong shock. After seven geometry modifications, the shock-free bump geometry can be obtained. The second example concerns the redesign of a transonic turbine cascade. The initial isentropic Mach distribution has a peak on the upper surface. The target isentropic Mach number distribution was imposed smoothly. The peak of Mach distribution has disappeared at the final geometry. This proposed inverse design method has proven to be an efficient and robust tool in turbomachinery design fields.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.531-536
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• 2001

The structural shape optimization is a useful tool for engineers to determine the shape of a structure. During the optimization process, relocations of nodes happen successively. However, excessive movement of nodes often results in the mesh distortion and eventually deteriorates the accuracy of the optimum solution. To overcome this problem, an efficient method for the shape optimization has been developed. The method starts from the design domain which is large enough to hold the possible shape of the structure. The design domain has pre-defined uniform fine meshes. At every cycle, the method judges whether all the elements are inside of the structure or not. Elements inside of the structure are assigned with real material properties, however elements outside of the structure are assigned with nearly zero values. The performance of the method is evaluated through various examples.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.3
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• pp.96-102
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• 2007

An Optimal shape design of the boom system in high ladder vehicles is performed using 3-D finite element method (FEM). Results of structural analyses providing displacements, stresses are implemented for the optimum shape design. Lanzcos algorithm is used for the modal analysis in order to find natural frequencies. The optimal shape including cross sectional thickness and length of the boom system is controlled by the subproblem method besed on displacement and Von Mises stress. It is found that a plenty of materials can be saved by using shape design optimization in high ladder vehicles. It is also found that the natural frequency is increased until 6th mode and maintained similarly or decreased after 6th mode.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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• pp.40-45
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• 2001

The relationship between structural geometry and number of life cycles to failure is investigated to improve the fatigue life of structural components. The linear elastic fracture mechanics(LEFM) approach is integrated with shape optimal design methodology. The primary objective of this study is to decide an optimal shape for enhancing the life of the structure. The results from LEFM analyses are used in the fatigue model to predict the life of the structure before failure is occurred. The shape of the structure is optimized by using the growth strain method. Relevant issues such as problem formulation, finite element modeling are explained. Three design examples are solved, and the results show that, with proper shape changes, the life of structural systems subjected to fatigue loads can be enhanced significantly.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.53-57
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• 1996

The side burrs and shape distortion resulting from the micromachining of an array of V-shape microgrooves in optical components were experimentally invesigated and a simplified model for their formation is proposed. Burr/shpae distortion should be kept to a minimum level since they degrade the characteristics and performance of these parts. The focus of this study is on the influence of depth of cut and workpiece material. The workpiece materials use were brass, bronze and copper. From the obsevation of the chip shape and burr/shape distortion, the proposed model, that the compressive force at the cutting edge causess the ductile uncut chip material to flow plastically outward toward the free surface to result in a burr, was verified.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.1
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• pp.65-70
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• 2008

The shape and the material of a reflective sheet affect the amount and the range of retroreflection on incident angle of light, significantly. In this study, the method to determine the shape and the material of the reflective sheet is introduced for the maximum retroreflection. Since the microprism shape with an equilateral triangle base has been used widely, the shape optimization of the microprism shape is carried out. The path of the light within the prism is geometrically calculated to find the relationship between incoming and outgoing light to and from a microprism. The optimal shape of a microprism found by the simulation has almost same figure with the one being used in industry for the maximum retroreflection. It is also found that the refraction index of the reflective sheet is another parameter to control for maximum retroreflection and the range of retroreflection.

• Journal of Ocean Engineering and Technology
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• v.11 no.1
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• pp.36-43
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• 1997

Weld bead shape is an important measure for evaluation of weld quality. Many welding parameters have influence on the weld bead shape. The quantitative relationship between welding parameters and bead shape, however, is not determined yet because of their high complexity and many unknown factors. Fuzzy expert system is an advanced expert system which uses fuzzy rules and approximate reasoning. It is a vert useful tool for welding technology because is can process rationally the uncertain and inexact information such as the welding information. In this paper, the empirical and the qualitative relationship between welding parameters and bead shape are analyzed and represented by fuzzy rules. They are converted to the quantitative relationship by use of approximate reasoning of fuzzy expert system. Weld bead shape is estimated from the welding parameters using fuzzy expert system. The result of comparison between measured values of weld bead by welding experiments and the estimates values by fuzzy expert system shows a good consistancy.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.4
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• pp.112-118
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• 2008

In order to meet the optical performance in the process of the micro lens manufacturing with plastics, it is important to embody accuracy in shape and surface roughness to the intended design. Since it is difficult to machine exactly the mold core of lens fit to the designed shape, in this paper, a simple program using MATLAB is developed for shape correction of the mold core after first machining it. This program evaluates correction parameters(aspheric coefficients and curvature) and generates aspheric NC data for compensating the core surface in prior machining process. The program provides the way to manufacture plastic injection molding lens with aspheric shape of high precision, and is expected to be effective for correction and to shorten the processing time.