• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.6
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• pp.961-970
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• 1997

A numerical method is presented to predict and analyze the shape of a growing billet produced from the "spray forming process" which is a fairly new near-net shape manufacturing process. It is important to understand the mechanism of billet growing because one can obtain a billet with the desired final shape without secondary operations by accurate control of the billet shape, and it can also serve as a base for heat transfer and deformation analysis. The shape of a growing billet is determined by the flow rate of the alloy melt, the mode of nozzle scanning which is due to cam profile, the initial positio of the spray nozzle, scanning angle, and the withdrawal speed of the substrate. In the present study, a theoretical model is first established to predict the shape of the billet and next the effects of the most dominent processing conditions, such as withdrawal speed of the substrate and the cam profile, on the shape of the growing billet are studied. Process conditions are obtained to produce a billet with uniform diameter and flat top surface, and an ASP30 high speed steel billet is manufactured using the same process conditions established from the simulation.imulation.

• The Transactions of The Korean Institute of Electrical Engineers
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• v.62 no.11
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• pp.1528-1534
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• 2013

This paper proposes the optimal design of stator shape for cogging torque reduction of single-phase brushless DC (BLDC) motor with asymmetric notch. This method applied size and position of asymmetric notches to tapered teeth of stator for single-phase BLDC motor. Which affects the variation of the residual flux density of the permanent magnet. The process of optimal design included the extraction of the sampling point by using Latin Hypercube Sampling(LHS), and involved the creation of an approximation model by using kriging method. Also, the optimum point of the design variables were discovered by using the Genetic Algorithm(GA). Finite element analysis was used to calculate the characteristics analysis and cogging torque. As a result of finite element analysis, cogging torque were reduced approximately 39.2% lower than initial model. Also experimental result were approximately 38.5% lower than initial model. The period and magnitude of the cogging torque were similar to the results of FEA.

• Transactions of Materials Processing
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• v.30 no.6
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• pp.291-300
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• 2021

Currently, starting with electric vehicles, the application of ultra-high-strength steel sheets and light metals has expanded to improve mileage by reducing vehicle weight. At a time when internal combustion engine vehicles are rapidly changing to electric vehicles, the application of ultra-high-strength steel is expanding to satisfy both weight reductions and the performance safety of the chassis parts. There is an urgent need to improve the quality of parts without defects. It is particularly difficult to estimate the part formability through the finite element method (FEM) in the burring operation, so product design has been based on the hole expansion ratio (HER) and experience. In this study, design of experiment (DOE), analysis of variance (ANOVA), and regression analysis were combined to optimize the formability by adjusting the process variables affecting the burring formability of ultra-high-strength steel parts. The optimal variables were derived by analyzing the influence of variables and the correlation between the variables through FE analysis. Finally, the optimized process parameters were verified by comparing experiment with simulation. As for the main influence of each process variable, the initial hole diameter of the piercing process and the shape height of the preforming process had the greatest effects on burring formability, while the effect of a lower round of punching in the burring process was the least. Moreover, as the diameter of the initial hole increased, the thickness reduction rate in the burring part decreased, and the final burring height increased as the shape height during preforming increased.

• Journal of Advanced Marine Engineering and Technology
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• v.37 no.6
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• pp.603-610
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• 2013

Finite element analysis is performed to evaluate stress and deformation of a wrinkle-type dust cover for the ball joints of tie rods of automotive steering system. Results of the analysis for assembly and operation condition show that sealing capability is good and the maximum stress on the body is smaller than the tensile strength. An optimal shape of the dust cover is obtained using the Taguchi method to reduce the maximum stress. The maximum stress of the optimal design under the operation condition is reduced by 22 per cent of that of the initial design. Results of the research show that performance evaluation and design of the dust covers can be effectively done using the proposed method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.1
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• pp.152-157
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• 2003

Process design of hot forging, asymmetric to symmetric rib-web shape steel, which is used for the turnout of railway express has been investigated. Owing to the big difference in shape between the initial billet and the final forged product, it is impossible to hot forge the rail in a single step. Therefore, multi step forging as well as die design for each step are necessary for the production. The deformation behavior during hot forging has been analyzed by the numerical simulation through commercial FEA software, $DEFORM^{TM}$-2D. Modification of the design and repeated simulation have been carried out on the basis of the simulation result. For comparison with the simulation results. flow analysis experiment using plasticine has been also carried out. The results of the flow analysis experiment showed good agreement with those of the simulation. Therefore, the developed process design could be applied to the actual production.

• Journal of the Society of Naval Architects of Korea
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• v.55 no.1
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• pp.1-8
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• 2018

A cavitator plays an important role to generate the supercavity. Most previous numerical and experimental studies have been focused on the presence of cavitators alone. However, the body behind the cavitator causes a change in the wake flow and hence it affects generation and growth of the supercavity. In this paper, we present a boundary elementary method based on a potential flow analysis, and calculate characteristics of the supercavity formation depending on the change of the body shape of two-dimensional submerged objects. Various parameters such as cone angle of the cavitator, length of the forehead and diameter of the body are considered. The results show that the longer the forepart length, the longer the cavity is created under the same conditions, and also the change in the diameter of the body is the most influential factor on the growth of the supercavity. As a result, we suggest that it is necessary to carefully consider the influence of the body shape during the initial design stage of the supercavitating underwater vehicle.

• Transactions of the Korean hydrogen and new energy society
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• v.35 no.1
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• pp.75-82
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• 2024

In this study, design parameter exploration based on finite element analysis was performed to find the optimal shape of bellows, the key component of compressor-embedded refueling tank for a newly developed hydrogen refueling station capable of high-pressure charging above 900 bar. In the design parametric study, the design variables took into account the bellows shapes such as contour radius and span spacing, and the response factors were set to the maximum stress and the gap in the contact direction. In the shape design of the compressor bellows for hydrogen refueling station considered in this study, it was found that adjusting the contour span is an appropriate design method to improve the compression performance and structural safety. From the selection of optimal design, the maximum stress was reduced to 49% compared to the initial design without exceeding the material yield stress.

• Steel and Composite Structures
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• v.30 no.5
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• pp.483-492
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• 2019

In the current study, the influence of the initial lateral (sweep) shape and the cross-sectional twist imperfection on the lateral torsional buckling (LTB) response of doubly-symmetric steel I-beams was investigated. The material imperfection (residual stress) was not considered. For this objective, standard European IPN 300 beam with different unbraced span was numerically analyzed for three imperfection cases: (i) no sweep and no twist (perfect); (ii) three different shapes of global sweep (half-sine, full-sine and full-parabola between the end supports); and (iii) the combination of three different sweeps with initial sinusoidal twist along the beam. The first comparison was done between the results of numerical analyses (FEM) and both a theoretical solution and the code lateral torsional buckling formulations (EC3 and AISC-LRFD). These results with no imperfection effects were then separately compared with three different shapes of global sweep and the presence of initial twist in these sweep shapes. Besides, the effects of the shapes of initial global sweep and the inclusion of sinusoidal twist on the critical buckling load of the beams were investigated to unveil which parameter was considerably effective on LTB response. The most compatible outcomes for the perfect beams was obtained from the AISC-LRFD formulation; however, the EC-3 formulation estimated the $P_{cr}$ load conservatively. The high difference from the EC-3 formulation was predicted to directly originate from the initial imperfection reduction factor and high safety factor in its formulation. Due to no consideration of geometric imperfection in the AISC-LFRD code solution and the theoretical formulation, the need to develop a practical imperfection reduction factor for AISC-LRFD and theoretical formulation was underlined. Initial imperfections were obtained to be more influential on the buckling load, as the unbraced length of a beam approached to the elastic limit unbraced length ($L_r$). Mode-compatible initial imperfection shapes should be taken into account in the design and analysis stages of the I-beam to properly estimate the geometric imperfection influence on the $P_{cr}$ load. Sweep and sweep-twist imperfections led to 10% and 15% decrease in the $P_{cr}$ load, respectively, thus; well-estimated sweep and twist imperfections should considered in the LTB of doubly-symmetric steel I-beams.

• Journal of Korean Society of Steel Construction
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• v.22 no.1
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• pp.33-42
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• 2010

Patterning with a geodesic line is essential for economical or efficient usage of membrane materialsin fabric tension membrane structural engineering and analysis. The numerical algorithm to determine the geodesic line for membrane structures is generally classified into two. The first algorithm finds a non-linear shape using a fictitious geodesic element with an initial pre-stress, and the other algorithm is the geodesic line cutting or searching algorithm for arbitrarily curved 3D surface shapes. These two algorithms are still being used only for the three-node plane stress membrane element, and not for the four-node element. The lack of a numerical algorithm for geodesic lines with four-node membrane elements is the main reason for the infrequent use of the four-node membrane element in membrane structural engineering and design. In this paper, a modified numerical algorithm is proposed for the generation of a geodesic line that can be applied to three- or four-node elements at the same time. The explicit non-linear static Dynamic Relaxation Method (DRM) was applied to the non-linear geodesic shape-finding analysis by introducing the fictitiously tensioned 'strings' along the desired seams with the three- or four-node membrane element. The proposed algorithm was used for the numerical example for the non-linear geodesic shape-finding and patterning analysis to demonstrate the accuracy and efficiency, and thus, the potential, of the algorithm. The proposed geodesic shape-finding algorithm may improve the applicability of the four-node membrane element for membrane structural engineering and design analysis simultaneously in terms of the shape-finding analysis, the stress analysis, and the patterning analysis.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.11
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• pp.44-51
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• 2007

Condenser tubes are mainly produced by precision extrusion with a porthole die and are used in the flow pass of refrigerant cooling systems in automobiles. The recent technical trend of condenser tube requires the tube to be of more multi cellizing, high strength and small size, and to increase the heat transfer area and heat efficiency. Hence, this paper is shown that the results of FE-simulation are in good agreement with the experimental ones. Finally, the extrusion die shape is proposed through analysis of FE-simulation and performance of trial extrusion. Chamber shape dimension and initial temperatures of die is adjusted analysis results. And the possibility of extrusion is estimated that forming load, welding pressure and stress analysis of die in this paper. The validity of simulated results was verified into extrusion experiments on the condenser tubes.