• 대한조선학회논문집
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• 제52권6호
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• pp.501-508
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• 2015

Lately, much research on hull plate forming has been successful in improving productivity of the forming process. Those researches include forming methods, forming information, and automation. After forming each plate, the fabricated surface is compared with the corresponding designed surface. Two sets of data from the designed and fabricated surfaces are matched in order to complete the forming process. However, only a few papers deals with comparison of two surfaces. This paper presents a new matching method based on the bounding volume hierarchy (BVH). By comparing the conventional method, this new approach using BVH shows not only good agreement but also better advantages.

• 대한조선학회논문집
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• 제39권2호
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• pp.28-33
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• 2002

조선소에서 사용되는 선각 외판 부재는 선박 한 척을 건조하는데 사용되는 부재의 수가 매우 많고, 각 가공 외판 부재는 상대적으로 크기가 크고 각각 상이한 부재 형상을 가지고 있다는 특징이 있다. 또한 이 중에서, 선체의 외판 곡 부재를 가공할 때는 각 부재의 초기 형상과 가공 목적형상에 대한 정보를 가지고 냉간, 열간 가공을 통하여 설계된 형상으로 가공을 수행하여야 한다. 이때, 최초 가공 시 및 추가 가공 중에 부재의 형상을 확인하여 주어진 정도에 부합할 때까지 가공을 수행 하여야 하며, 이와 같은 특징 때문에 선체 외판 부재의 가공 시에는 수시로 가공중인 부재의 형상 및 가공정도를 확인하여야 하는 과정, 즉 시간을 최소화하면서 효율적으로 가공형상을 확인하는 대형곡면 계측 기술과, 곡면 비교 기술이 필요하게 된다. 본 논문에서는, 이러한 가공환경 하에서 적용 가능성이 있는 효율적인 계측, 비교를 위한 S/W, H/W 통합 시스템 구축을 수행하였다.

• 대한조선학회 특별논문집
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• 대한조선학회 2011년도 특별논문집
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• pp.32-35
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• 2011

Template has been widely used for hull forming process in most of shipyards. It is used to estimate the curvature of deformed shape in comparison with design shape. SHI (Samsung Heavy Industry) had used AutoKon system for ship manufacturing design in the past. The AutoKon used the global coordinate system of ship (frame, water line and so on) to create template data. It brought the mismatched angles between templates and a curved shell plate. The mismatched angle is measured by forming worker to place template on shell forming stage. However, the mismatched angle is difficult to place template with exactly required angle because the shell plates have various curvature and size. It causes incorrect shape of formed shell plates. The attached angle of template should be 90 degree to place template easily on forming shell plates. Currently, SHI has been applied GSCAD for ship manufacturing design process which is 3D solid modeling system. The GSCAD is the rule-based system which can automate 3D modeling and control the manufacturing data by rule. The rule can easily provide methods to create and automate template object with regular attached angle in comparison with AutoKon system. Therefore, SHI developed new template rule which it can automatically create template object with regular attached angle in GSCAD.

• 한국항해학회지
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• 제23권1호
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• pp.29-43
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• 1999

The production process of the compound-curved hull plates includes hull design, definition, fairing, modeling, lofting, cutting, and forming in sequence. Traditional fabrication methods and shop environment caused low level to productivity in medium and small sized shipyards. The most effective solution to solve those problems is to rationalize the layout of facilities. For the well-balanced development of domestic shipbuilding industry, it is urgently required to reduce the gap between modernized large sized shipyards and traditional small and medium sized shipyards in production technologies and efficiencies. For the efficient and accurate hull piece forming, all information from design to forming should be clarified and organized in a systematic manner. Thus, management of the information plays an important role in the computerized and automated of hull piece forming. The object of this paper is to survey the status of the field, to find out the feasibility and to introduce a draft of hull piece fabrication line for small and medium sized shipyards. The development of required system follows the object oriented technology to extend to simulation based system for carrying out physical product flow and facilities layout analysis. It is feasible to operate such a modernized facility for a group of small and medium shipyards who are unable to have each of their own facility because of its large amount of initial investment and insufficient work load.

• 대한조선학회논문집
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• 제48권6호
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• pp.528-538
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• 2011

As a forming method for curved hull plates more efficient than the flame bending, mechanical bending using multi point press forming and die-less forming is discussed in this paper. the mechanical forming is a flexible manufacturing system for automatically forming of hull parts. It is especially suited to varied curved parts. This paper discusses a multiple point pressing machine composed of a pair of reconfigurable punches in order to achieve the rapid forming of curved hull plates using division forming and presents how forming information is obtained from the given design surface. Although the mechanical forming can be efficient in the metal forming, spring back after pressing is a phenomenon which must be carefully considered when quantifying the process variables. If the spring back is not accurately controlled, the fabricated shell plate cannot meet assembly tolerance. This paper describes the principles to calculate the proper stroke of each punch at the divided areas. the strokes are determined by an iterative process of sequential pressing and spring back compensation from an unfolded flat shape to its given design surface. FEA(finite element analysis) is used to simulate the spring back of the plate and the IDA(iterative displacement adjustment) method adjusts the offset of pressing punches from the deformation results and the design surface. The shape deviations of two surfaces due to spring back are compensated by integrated system using FEA and IDA method. For the practical application, It is aimed to develop an integrated system that can automatically perform the compensation process and calculate strokes of punches of the double sides' reconfigurable multiple-press machine and some experimental results obtained with mechanical bending are presented.

• 해양환경안전학회지
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• 제17권3호
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• pp.275-281
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• 2011

선박의 건조 공정 중 병목공정에 해당하며 전적으로 숙련자의 수작업으로만 이루어지는 공정이 곡가공 공정이다. 이러한 곡가공 공정을 자동화 하고자 산업계와 학계의 많은 노력이 경주되었다. 기존의 곡가공 자동화 시스템 개발은 산업계와 학계에서 오랜 동안 연구되어 왔음에도 불구하고 실제로 생산현장에 투입되어 성공적으로 운영되는 사례는 없었다. 본 연구는 이러한 기존 곡가공 자동화 시스템 개발의 문제점을 파악하고 이를 해결할 수 있는 대안으로 요구사항 정의, 시스템 설계, 하부시스템 및 구성요소의 구현, 시스템 통합 및 검증의 4단계 시스템 엔지니어링 기반의 시스템 개발방법론을 제안하였다. 제안된 개발방법론을 기반으로 선체 곡가공 자동화 시스템 프로토타입 개발에 적용하고 결과를 고찰하여 기존 곡가공 자동화 시스템 개발에서의 문제점을 해결할 수 있는 대안이 될 수 있음을 확인하였다.

• 한국CDE학회논문집
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• 제17권3호
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• pp.188-197
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• 2012

Recently, aluminum ships are constructed more than ever because of the environmental pollution generated by FRP (Fiber Reinforced Plastic) ships. In particular, FRP ships have been replaced by the Aluminum ships. The forming process of the curved aluminum plate has been performed only by labor works without systematic technique. Therefore, it is difficult to construct the aluminum ship that the design satisfies both required propulsion performance and hull design. Present study introduces a MPSF (Multi Point Stretching Forming) that is a flexible manufacturing technique to form large sheet panels of doubly curvature. The hull pieces are stretch-formed over the MPSD (multi-point stretching die) generated by the punch element matrix. In this study, MPSF is applied to deform the doubly curved surfaces of aluminum ship. The forming system including FEA (finite element analysis) of the processes for stretching the plate were carried out by static implicit analysis is suggested. Residual deformation of the surface is modeled by an elasto-plastic contact phenomena while the forming process is simulated by FEA. Finally, the proposed system is also validated, comparing the deformed shape by MPSF with that of object surfaces.

• Journal of Ship and Ocean Technology
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• 제12권3호
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• pp.1-13
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• 2008

In shipbuilding, diverse manufacturing techniques for automation have been developed and used in practice. Among them, however, the hull forming automation is the one that has not been of major concern compared with others such as welding and cutting. The basis of the development of this process is to find out how to extract thermal forming information. There exist various methods to obtain such information and the 3D design shape that needs to be formed should be extracted first for getting the necessary thermal forming information. Except well-established shipyards which operate 3D design systems, most of the shipyards only rely on 2.5D design systems and do not have an easy way to obtain 3D surface design data. So in this study, various shipbuilding design systems used by shipyards are investigated and a 3D design surface data extraction method is proposed from those design systems. Then an example is presented to show the extraction of real 3D surface data using the proposed method and computation of thermal forming information using the data.

• 소성∙가공
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• 제18권7호
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• pp.556-564
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• 2009

Flexible forming process for sheet material using reconfigurable die is introduced based on numerical simulation. In general, this flexible forming process using the reconfigurable die has been utilized for manufacturing of curved thick plates used for hull structures, architectural structures and so on. In this study, numerical simulation of sheet metal forming process is carried out by using flexible dies model instead of conventional matched die set. The numerical simulation and experimental verification for sheet metal forming process using a flexible forming machine that is more suitable for thick plate forming process are carried out to confirm the appropriateness of the simulation process. As an elastic cushion, urethane pads are utilized using hyperelastic material model in the simulation for smoothing the forming surface which is discrete due to characteristics of the flexile die. In the flexible forming process for sheet metal, effect of a blank holder is also investigated according to blank holding methods. Formability in view of occurrence of dimples is compared with regard to the various punch sizes. Consequently, it is confirmed that the flexible forming for sheet material using urethane pad has enough capability and feasibility for manufacturing of smoothly curved surface instead of conventional die forming method.

• 한국산학기술학회논문지
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• 제16권7호
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• pp.4381-4387
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• 2015

선체의 외판은 복잡한 곡면 형상이며 대부분의 조선소에서는 이의 제작을 위해 가스 토치를 이용한 선상 가열 방법을 사용하고 있다. 가스 토치를 이용한 전통적인 선상 가열 방법은 입열량의 제어가 어려울 뿐만 아니라 고압의 가스 분출에 따른 소음과 대기 오염 등 열악한 작업 환경의 문제점을 안고 있다. 최근에는 입열량의 제어가 비교적 용이하고 친환경적인 고주파 유도 가열에 주목하여 이를 가열 열원으로 하는 강판의 성형 자동화 연구들이 진행되고 있다. 본 연구에서는 강판의 곡면 성형을 위한 유도 가열 시뮬레이션 방법을 개발하였으며 유도 가열 실험 결과와 비교하여 그 유효성을 검증하였다. 개발된 유도 가열 시뮬레이션 방법은 효율적인 유도 가열 코일 설계와 최적 성형 조건 산출 등 유도 가열을 이용한 선체 외판의 곡가공 자동화 시스템 개발에 유용한 해석적 툴로 활용될 수 있을 것으로 기대된다.