• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.5
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• pp.10-22
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• 2008

In an automotive body structure, a design configuration that fulfills structural requirements such as deflection, stiffness and strength is necessary for structural design and is composed of various components. The integrated design is used to obtain a minimum weight structure with optimal or feasible performance based on conflicting constraints and boundaries. The mechanical design must begin with the definition of one or more concepts for structure and specification requirements in a given application environment. Structural optimization is then introduced as an integral part of the product design and used to yield a superior design to the conventional linear one. Although finite element analysis has been firmly established and extensively used in the past, geometric and material nonlinear analyses have also received considerable attention over the past decades. Also, nonlinear analysis may be useful in the area of structural designs where instability phenomena can include critical design criteria such as plastic strain and residual deformation. This proposed approach can be used for complicated structural analysis for an integrated design process with the nonlinear feasible local flexibilities between system and subsystems.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.13 no.8
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• pp.3319-3325
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• 2012

This paper describes the development of the TrackSim, which is a discrete event simulation tool for photolithography equipment of semiconductor industry. The TrackSim is focused on the accurate simulation model of the photolithography equipment and easy-to-use user interfaces. TrackSim provides 3D simulation environment for evaluating, validating, and scheduling the photolithography process. One of the major characteristics of TrackSim is in that it is developed based on Applied Materials' AutoMod, a discrete event simulation software broadly used in semiconductor industry. Accordingly, the photolithography model of TrackSim can be used to perform simulation connected with other simulation models built with AutoMod.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.132-141
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• 2013

Robotic Drilling Systems(RDSs) set the standard for the factory automation systems in aerospace manufacturing. With the benefits of cost effective drilling and predictive maintenance, RDSs can provide greater flexibility in the manufacturing process. The system can be easily adopted to manage very complex and time-consuming processes, such as automated fastening hole drilling processes of large aircraft sections, where it would be difficult accomplished by workers following teaching or conventional guided methods. However, in order to build an RDS based on a CAD model, the precise calibration of the Tool Center Point(TCP) must be performed in order to define the relationships between the fastening-hole target and the End Effector(EEF). Based on the kinematics principle, the robot manipulator requires a new method to correct the 3D errors between the CAD model of the reference coordinate system and the actual measurements. The system can be called as a successful system if following conditions can be met; a. seamless integration of the industrial robot controller and the IO Level communication, b. performing pre-defined drilling procedures automatically. This study focuses on implementing a new technology called iGPS into the fastening-hole-drilling process, which is a critical process in aircraft manufacturing. The proposed system exhibits better than 100-micron 3D accuracy under the predefined working space. Based on the proposed EEF fastening-hole machining process, the corresponding processes and programs are developed, and its feasibility is studied.

• Journal of the korean Society of Automotive Engineers
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• v.14 no.6
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• pp.113-126
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• 1992

Recently the multi-kind, small-amount manufacturing system has been replacing the mass manufacturing system, and domestic machining inustry also is eager to absorb the new technology because of its high productivity and cost reduction. The optimization of the cutting condition has been a vital problem in the machining industry, which would help increase the productivity and raise the international competitiveness. It is intended in this study to investigate the machining costs per unit time which is essential to the analysis of the optimal cutting condition, to computer the cutting speed that lead to the minimum machining costs and the maximum production to suggest the cutting speed range that enables efficient speed cutting, and to review the machining economy in relation to cutting depth and feed. Also considered are the optimal cutting speed and prodution rated in rrelation with feed. It is found that the minimum-cost cutting speed increases and the efficient cutting speed range is reduced as machining cost per unit time increases since the cutting speed for maximum production remains almost constant. The machining cost is also lowered and the production rate increases as the feed increases, and the feed should be selected to satisfy the required surface roughness. The machining cost and production rate are hardly affected by the cutting depth if the cutting speed stays below 100m/min, however, they are subject to change at larger cutting depth and the high-efficient speed range also is restricted. It can be established an adaptive optimal cutting conditions can be established in workshop by the auto-selection progam for optimal operation. It is expected that this method for choosing the optimal cutting conditions might contribute to the improvement of the productivity and reduced the cost. It is highly recommended to prepare the optimal cutting conditionthus obtained for future use in the programing of G-function of CNC machines. If proper programs that automatically select the optimal cutting conditions should be developed, it would be helpful to the works being done in the machine shops and would result in noticeable production raise and cost reduction.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.23 no.1
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• pp.27-31
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• 2014

This paper describes a tomographic imaging technique for evaluating the thickness reduction of a plate-like structure using a noncontact sensor network based on an electromagnetic acoustic transducer that generates shear horizontal plate waves. Because this technique is based on the effect of mode cutoff and time of flight of guided waves caused by a change in thickness, the tomographic image provides information on the presence of defects in the structure. To verify the performance of the method, artificial defects with various thickness reduction ratios were machined in an aluminum plate, and the tomographic imaging results are reported. The results show that the generated tomographic image displays the thickness reductions and can identify their locations. Therefore, the proposed technique has good potential as a tool for health monitoring of the integrity of plate-like structures.

• Transactions of Materials Processing
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• v.20 no.3
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• pp.214-221
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• 2011

In recent years, automotive seat components have been manufactured by the fine blanking process, allowing an improvement of dimensional accuracy at sheared surface in series production. However, the rollover has increased and die failures have occurred more frequently when manufacturing gears by fine blanking. Consequently, important goals for manufacturing seat recliner parts with gears have been to decrease the rollover as well as to improve the tool life. In this study, the half blanking and shaving processes were introduced to improve aforementioned problems for the lower tooth, the main component of a seat recliner. For this purpose, the half blanking process was optimized using the finite element (FE) analysis and design of experiment (DOE). The optimized conditions resulting from this study were an offset of 0.2 mm, a clearance of 0.1 mm and a penetration depth of 4.5 mm. Fine blanking experiment conducted under the optimal condition resulted in a rollover depth decrease from 1.9 to 1.3 mm, and no die failure occurrence.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.2
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• pp.117-123
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• 2014

In order to provide a mobile robot with omnidirectionality, various types of omnidirectional wheels have been developed. This paper deals with an improved design and structural analysis of a Mecanum wheel, which is the type of omnidirectional wheels most commonly used in industrial fields. A geometric formulation for manufacturingthe Mecanum wheel is presented and two types of Mecanum wheels are designed and fabricated in this research. While conventional assembled-type Mecanum wheels have a complicated structure and the high possibility of mutual interference between sub-components, a unified type of Mecanum wheel reduces the number of sub-components and increases the degree of structural rigidity. The stress and strain properties of the two designs are compared to confirm the quantitative improvement of the new design by a commercial structural analysis tool. The analysis results show that the unified type of Mecanum wheel has properties superior to the assembled type of Mecanum wheel in terms of its ability to reduce interference.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.173-176
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). In this study, process design for closed-die forging of a Lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of Lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.6
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• pp.106-112
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• 2019

Rotary swaging is a method of forging automotive drive shafts. In this paper, we propose a new two-hammer forging technique by applying the problem-solving approach TRIZ to improve the efficiency and productivity of the rotary swaging automation process. We will simplify the materials and hammers via the 3D modeling tool SolidWorks for high accuracy of a comparative analysis of existing and proposed methods under the same boundary conditions. In addition, we will compare the stress trends of the proposed model using ANSYS Workbench and verify the feasibility through a comparison of the simulation results using DEFORM. Relative to the existing method, the proposed method can decrease production costs and improve efficiency of the automation process by reducing the power source.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.1
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• pp.16-23
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• 2019

Cooking oil in kitchen-fog is the most harmful factor to the health of a cook. The proposed filter is a tool that protects the cooked state, to prevent users from inhaling oil mist in the kitchen. Due to efficiency issues, existing filters are of the mesh type or baffle type. In this paper, CFD analysis is carried out to select a filter with low pressure loss and low efficiency, and to attach the sub-filter to improve efficiency. The results of the analysis on the collection efficiency and pressure loss of three sub-filters, i.e., circle type, droplet type, and cone type, showed that the collection efficiency was 64.09% and the pressure loss was 1.26 mmAq when the circle type sub-filter was applied. The position of the sub-filter showed the best efficiency and pressure loss when it was located at the bottom of the center of the gap of the main filter.