• Journal of the Korean Society for Precision Engineering
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• v.5 no.1
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• pp.84-93
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• 1988

The on-line detection of the chip flow is one of the most important technologies in com- pletly automatic operation of machine tool, such as FMS and Unmanned Factories. This problem has been studied by many researchers, however, it is not solved as yet. For the recognition of chip flow in this study, the dynamic cutting force components due to the chip breaking were measured by dynamometer of piezo-electric type, and the frequency components of cutting force were also analyzed. From the measured results, the effect of cutting conditions and tool geometry on the dynamic cutting force component and chip formation were investigated in addition to the relationships between frequency of chip breaking (fB) and side serrated crack (fC) of chip. As a result, the following conclusions were obtaianed. 1) The chip formations have a large effect on the dynamic cutting force components. When chip breaking takes place, the dynamic cutting force component greatly increases, and the peridoic components appear, which correspond to maximum peak- frequency. 2) The crater wear of tool has a good effect on the chip control causing the chiup to be formed as upward-curl shape. In this case, the dymamic cutting force component greatly increases also 3) fB and fC of chip are closely corelated, and fC of chips has a large effect on the change of the situation of chip flow and dynamic cutting force component. 4) Under wide cutting conditions, the limit value (1.0 kgf) of dynamic cutting force component exists between the broken and continuous chips. Accordingly, this value is suitable for recognition of chip flow in on-line control of the cutting process.

• Journal of computational fluids engineering
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• v.19 no.3
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• pp.77-84
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• 2014

The lattice Boltzmann (LB) method has been used to simulate rarefied gas flows in a micro-system as an alternative tool. However, previous results were mainly focused on a simple geometry with flat walls because the LB method is modeled on uniform Cartesian lattices. When previous boundary conditions for the microflows are applied to curved walls, the use of them requires approximation of the curved boundary by a series of stair steps, and introduces additional errors. For macroflows, no-slip curved wall boundary treatments have been developed remarkably in order to overcome these limits. However, the investigations for the slip curved wall boundary have rarely been performed for microflows. In this work, a curved boundary treatment of the LB method for a slip flow has been introduced. The results of the LB method for 2D microchannel and 3D microtube flows are in excellent agreement with the analytical solutions.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.96-102
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• 2008

In order to design establish automation or optimization of the machining process, predictions of the forces in machining are often needed. In this paper, a theoretical model in face milling is presented based on Oxley's predictive machining theory, where the cutting forces are predicted from input data of fundamental work material properties, tool geometry and cutting conditions without any preliminary cutting experiment. A simulation system for the cutting forces in face milling is developed using the model. Milling experimental tests are conducted to verify the model and the predictive results are compared and discussed with the experimental results.

• Journal of the Korean Institute of Telematics and Electronics A
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• v.32A no.11
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• pp.17-28
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• 1995

In this paper, we developed a two-dimensional numerical simulator which could analyze the stripe geometry semiconductor laser diodes by modifying the commercial semiconductor device simulator, MEDICI. In order to study the characteristics of semiconductor laser diodes, it is necessary to solve the Helmholtz wave equation and photon rate equation in addition to the basic semiconductor equations. Also the recombination rates due to the spontaneous and the stimulated emissions should be included, which are very important recombination mechanisms in semiconductor laser diodes. Therefore, we included the solution routines which analyzed the Helmholtz wave equation and the photon rate equation and two important recombination rates to simulate the semiconductor laser diodes. Then we simulated the gain-guiding and index-guiding DH(Double Heterostructure) semiconductor laser diodes to verify the validity of the implemented functions. The results obtained from simulation are well consistent with the previously published ones. This allows us to know the operating characteristics of DH laser diodes and is expected to use as a tool for optimum design.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.6
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• pp.701-708
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• 2004

This paper discusses applicability of the enhanced reference stress method to estimate J-integral along the semi-elliptical surface crack front. It is found that angular variations of normalized J­integral are strongly dependent on the geometry, loading mode and loading magnitude. As application of the reference stress approach to semi-elliptical surface cracks implies proportional increases in the normalized J-integral, the present results pose a question in applicability of the reference stress approach. However, investigation of the error in the estimated J-integral in the present work suggests that the enhanced reference stress approach, recently proposed by authors, provides an effective engineering tool fur estimating crack driving force along the semi-elliptical surface crack front.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.22 no.1
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• pp.34-49
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• 1998

In this study, turbulent flows in a grooved channel are numerically investigated by Large Eddy Simulation (LES). Especially, a parametric study is carried out to study effects of length and depth of a groove on large-scale flow structures. For one test case, comparison of LES results with those of DNS reveals a good agreement even though the number of grid points of LES is only 6.5% of that of DNS. This confirms that LES is a suitable tool for a parametric study of turbulent flows. The subsequent parametric study using LES shows that the large-scale turbulent structures are significantly affected by the geometry of the groove. Especially, when the length of the groove is short such that the recirculation region occupies the entire groove, the turbulent flow in the groove becomes very weak in both mean and fluctuation quantities.

• Transactions of Materials Processing
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• v.19 no.1
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• pp.32-37
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• 2010

Hydroforming has attracted a great deal of attention in the manufacturing industries for vehicles and transportation systems. Hydroforming technology contributes to weight reduction, increased strength, improved quality and reduced tooling cost. Hydroformed automotive parts used as structure components in vehichle body frame often have to be structurally joined at some point. Therefore it is useful if the hydroformed automotive parts can be given a localized attachment flange. For a given flange shape, a parting plane for the dies is established relative to which the various surfaces of the flange shape, in cross section, have no significant reverse curvature. In this study, hydroforming process for flange forming was proposed. FE analysis to form flanged circular shape and flanged rectangular shape was preformed with Dynaform 5.5. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as tool geometry and hydraulic pressure has been performed and optimized. The results show that flanged automotive parts can be successfully produced with tube hydroforming.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.1
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• pp.42-49
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• 2010

In general, the direct experimental approach to study machining processes is expensive and time consuming, especially when a wide range of parameters are included: tool, geometry, materials, cutting conditions, etc. The aim of this study is to verify the effectiveness of finite element method for orthogonal cutting process by comparing the simulated cutting forces with measured results. Two commercialized finite element codes $AdvantEdge^{TM}$ and Deform-$2D^{TM}$ have been used to simulate the cutting forces in orthogonal cutting process. In this paper, estimated cutting and feed force components are compared with experimental results for different two materials. As a result, it has been found that FEM simulation is effective for understanding and predicting the orthogonal cutting process although some improvements on friction model and remeshing process are needed.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.592-597
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• 2001

An automobile lower arm has been fabricated in a prototype form by hydroforming with the aids of numerical analysis and experiments. For the numerical process design, a program called HydroFORM-3D developed here on the basis of a rigid-plastic model, has been applied to the lower arm hydroforming. The friction calculation between die and workpiece has been dealt carefully by introducing a new scheme in three-dimensional surface integration. To accomplish successful hydroforming process design, thorough investigation on proper combination of process parameters such as internal hydraulic pressure, axial feeding, and tool geometry has been performed. Results obtained from numerical simulation for a lower arm in hydroforming process are compared with a series of experiments. The comparison shows that the numerical analysis successfully provides the manufacturing information on the lower arm hydroforming, and it predicts the geometrical deformation and the thinning.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.585-590
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• 2002

Abrasive water-jet(AWJ) machining is a new cutting technology. The AWJ can cut various materials touch as metal, glass and stone. However, the AWJ machining makes troubles including kerf, rounding and side taper. In this study, we investigated the correlation between parameters of abrasive water-jet machining arid cutting characteristics. The machining parameter were the material thickness and the traverse speed. The experiment was conducted to cut the stainless steel(STS41) and the mild steel(SS41) specimens. The results of the experiment weirs presented as the relation between cutting conditions and trouble of a dimension error, a conner error, an uncut width and a kerf.