• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.3
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• pp.452-460
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• 2001

Most of researches of tolerance optimization have used a simple sum of tolerance-cost functions with several constraint equations as an optimization model. However, if there is a machining sequence with more than one processes to complete a part, and machining failure, i.e., out-of-tolerance occurs at one of the intermediate processes, the tolerance-cost of this process should be added by the machining cost of all the previous processes already completed on the part. In this study, an accumulated scrap cost model(ASCM) is proposed considering the scrapped machining cost, and applied to a simple assembly example. The result of tolerance optimization using ASCM is compared with that of using a traditional optimization model to confirm its effectiveness.

• Computational Structural Engineering
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• v.11 no.1
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• pp.161-170
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• 1998

A general formulation of the long cylinder tolerance design for the joint structure is here presented. The aim of this paper is to calculate the tolerance of joint by defining tolerance as a kind of uncertainty and to obtain the robustness of the joint structure. It is formulated on the bases of the minimum sensitivity theorem. The objective function is the tolerance sensitivity for the Von-Mises stress. It also took into full account the stress, displacement and weight constraints. PLBA(Pshenichny-Lim-Belegundu-Arora) algorithm is used to solve the constrained nonlinear optimization problem. The finite element analysis is performed with CST(Constant-Strain-Triangle) axisymmetric element. Sensitivities for design variables are calculated by the direct differentiation method. The numerical result is presented for the cylindrical structure where the joint tolerance is treated as random variables.

• Proceedings of the Safety Management and Science Conference
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• 2006.04a
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• pp.115-121
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• 2006

SCM 경쟁력 재고는 기업 내의 부문별 또는 개별기업 내부의 한정된 개선 노력이 외부의 부문 또는 기업에서의 활동과 연계되어 전체의 최적화가 되지 않으면 그 성과가 극히 제한적일 수 밖에 없다. 따라서 히든 코스트(hidden cost)의 발견 및 유통물류의 최적화에 박차를 가하는 것이 현실이다. 본 연구는 순 물류로 진행한 유통 경로 상에서 만약 역 물류가 발생할 경우 순물류 비용이외 공차(empty driving)로 인한 역물류의 히든 코스트를 최소화하는 모형을 통해 물류이익을 최대화 할 수 있는 방안을 찾기 위해 노력하며 결국 순물류와 역물류상의 유통상의 비용과 이익의 쌍대성에 기초하여 Pull, Push 시스템을 이용한 최적 시스템 모델화를 수행하여 효율적인 물류비용 산정의 방법을 모색한다.

• Korean Journal of Optics and Photonics
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• v.26 no.4
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• pp.209-216
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• 2015

A new method is proposed for optimal management of the fabrication and assembly tolerance of optical systems. The practical utility of the method is shown by applying it to a wide-angle anamorphic IR optical system. In this method the wavefront error of an optical system is expressed in terms of Zernike polynomials, and the sensitivity of the expansion coefficients to the variation of design parameters is analyzed. Based on this sensitivity analysis, the optimal tolerances of the fabrication parameters are determined and the best compensators for the assembly process are selected. By using this method, one can accurately predict with good confidence the best possible performance of a completed optical system in practice.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.2
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• pp.92-99
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• 2004

The errors can cause the serious loss of the performance of a precision machine system. In this paper, we proposed the method of allocating the alignment tolerances of the parts and applied this method to get the optimal tolerances of a Confocal Scanning Microscope. In general, tight tolerances are required to maintain the performance of a system, but a high cost of manufacturing and assembling is required to preserve the tight tolerances. The purpose of allocating the optimal tolerances is minimizing the cost while keeping the high performance of the system. In the optimal problem, we maximized the tolerances while maintaining the performance requirements. The Monte Carlo Method, a statistical simulation method, is used in tolerance analysis. Alignment tolerances of optical components of the confocal scanning microscope are optimized to minimize the cost and to maintain the observation performance of the microscope. We can also apply this method to the other precision machine system.

• Korean Journal of Optics and Photonics
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• v.32 no.6
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• pp.259-265
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• 2021

Recently, lens manufacturing and assembly technology has greatly improved. However, tight requirements of manufacturing and assembly lead to an increase in cost and manufacturing time, and in some cases the performance of an optical system may deteriorate depending on the operating environment's conditions, such as temperature or vibration. In addition, the use of a compensator is an effective method to reduce sensitivity in an ultra-precision optical system, but in the case of a small lens, such as that in an endoscope, it is difficult to use a compensator due to the size limitation of the lens barrel. Therefore, minimizing lens sensitivity is the most important technology in lens design. For this reason, there have been various attempts to reduce the lens sensitivity, and there is a trend to add functions to reduce the sensitivity in the lens design S/W. In this paper, we introduce a design technology that minimizes lens sensitivity. We first design a lens with quite good performance, then analyze the sensitivity of this lens, make a multi-configuration with high-sensitivity element error, and then reoptimize it. We prove with an example that this design technique is very effective.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.4
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• pp.423-428
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• 2015

To identify locations and causes of interference among parts of an indoor air-conditioning unit, a 3D tolerance analysis was performed and optimized with respect to assembly gaps and the tolerance of each part. The maximum value of the defect rate resulting from the tolerance analysis was found to be 72.6 at the assembly portion of the body and drain. The maximum displacement caused by the thermal deformation during a heating operation was calculated to be approximately 1 mm by using finite element analysis (FEA). Therefore, it is possible that an interference among the assembled parts occurs. The tolerance of the drain was modified by the results of the sensitivity analysis. As a result, the defect rate was greatly reduced to 0.03. Through the FEA results of the indoor air-conditioning unit, it was shown that the improved tolerance of the drain decreased the interference among the assembled parts even though thermal deformation occurs during operation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.9
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• pp.903-912
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• 2009

This study is focused on simulation-based dimensional tolerance optimization process (DTOP) to minimize vehicle pulls by reduction of dimensional variation in front suspension system. In previous studies, the effect of tires and wheel alignment sensitivity have mainly been investigated to eliminate vehicle pulls in nominal design condition without allocating optimal tolerance level for selected components, among various factors regarding vehicle pulls such as vehicle design parameters, vehicle weight balance, tires, and environmental factors. Unfortunately, there are wide variations in the real vehicle, and these have impacted actual vehicle pulls, especially wheel alignment effects from suspension geometry variation has not been considered in the previous studies. In the tolerance design of suspension, tolerance variables with the uncertainty such as parts dimensional variation, assembly process, datum position and direction, and assembly tool tolerance has a great influence on the variation of the suspension dimensional performances. This study introduces total vehicle pull prediction model in considering major key factors for vehicle pull sensitivity. The Monte Carlo-based tolerance analysis model using Taguchi robust method is developed to optimize dimensional tolerance parameters, satisfying on the target variation level.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.8
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• pp.879-886
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• 2012

The ultrasonic horn used for bonding of flip chip has been designed to vibrate at a natural frequency. The ultrasonic horn must be manufactured accurately in physical terms, because the small change of mechanical properties may result in the significant change of natural frequency. Therefore, tight tolerance is inevitable to keep the natural frequency in acceptable range. However, since tightening of the tolerance increases the manufacturing cost significantly, trade-off between the cost and accuracy is necessary. In this research, an attempt was made to design the ultra sonic horn within acceptable natural frequency while the manufacturing cost was kept as low as possible. For this purpose, among the 18 tolerances of physical terms of the ultrasonic horn, the most important 4 factors were selected using Taguchi method. The equation to relate those main factors and the natural frequency was made using response surface method. Finally, optimal design scheme for minimum manufacturing cost without a loss of performance was determined using SQP method.

• Journal of the Korean Society of Radiology
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• v.3 no.4
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• pp.23-28
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• 2009

Monochromatic X-ray can make a medical image of high contrast under a low radiation dose and can be easily generated by combining an X-ray tube and a multilayer mirror. A W/C multilayer mirror was optimally designed for a characteristic X-ray generated from a X-ray tube with Mo target. The d-spacing and the thickness ratio in design parameters were determined under the maximum-reflectivity condition. Tolerances for deposition and alignment of the W/C multilayer mirror were calculated. Within a deposition tolerance of 0.2nm and a alignment tolerance of ${\pm}0.01^{\circ}$, 85% of the theoretical peak reflectivity could be achieved. A multilayer mirror can be widely used for making medical images because of generating high fluence monochromatic X-ray.