• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2000.04a
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• pp.146-150
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• 2000

In order to prevent the defects, the optimum design of the production part, strip process layout, die design, die making and try out etc. are necessary the analysis of effective factors. For example, theory and practice of metal shearing process and it's phenomena, die structure, machine tool working for die making, die materials and it's heat treatment, metal working in field, their know how etc. are included in those factors. In this study, we analyzed whole of data base, theoretical back ground of metal working process, and then performed the progressive die tryout with the screw press. Part2 of this study reveals with ultra precision progressive die design, its making and tryout.

• Proceedings of the KSME Conference
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• 2001.11a
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• pp.533-538
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• 2001

This paper describes a combinational method to compute the global and local solutions of optimization problems. The present hybrid algorithm uses both a genetic algorithm and a local concentrate search algorithm (e. g simplex method). The hybrid algorithm is not only faster than the standard genetic algorithm but also supplies a more accurate solution. In addition, this algorithm can find the global and local optimum solutions. The present algorithm can be supplied to minimize the resonance response (Q factor) and to yield the critical speeds as far from the operating speed as possible. These factors play very important roles in designing a rotor-bearing system under the dynamic behavior constraint. In the present work, the shaft diameter, the bearing length, and clearance are used as the design variables.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.1
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• pp.114-125
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• 1993

Thermoelastoplastic analysis of a typical device consisting of fixed tube and movable case having an inital clearance in between, which is subjected to pressure and thermal load, has been carried out to examine the cause of malfunction mainly at high temperature condition, and to improve the design. Stresses, deformed shape, interface state and their effects on normal function of case are discussed by using finite element method. The extraction energy can be remarkably reduced by changing the configuration of tube from the present design (Parallel type) to the improved design (Tapered type). This effect has been proved by sustained cyclic function test.

• Transactions of Materials Processing
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• v.5 no.1
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• pp.61-71
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• 1996

A computer-aided process design system for axisymmetric deep drawing products has been developed. An approach to the system is based on the knowledge based system. Knowledges for the system are formulated from the plasticity theory handbooks experimental results and empirical knowhow of the field experts. the system is composed of four main modules such as geometrical design test & rectification and user modification. The input to the system is final sheet-metal object geometry and the output from the system is process sequence with intermedi-ate objects geometries and process parameters, such as drawing load blank holding force clearance cup-drawing coefficient.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.10 no.2
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• pp.26-31
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• 2011

This article provides the systematic design methodology for a tilting pad journal bearing. First the dynamic factors for the bearing are selected with the critical speed analysis. The pad bearing is then designed to have its best mechanical efficiency by simulations with changing of the number of pad and the lubricant flow rate with meeting the design specifications such as metal temperature, clearance and so on. And the simulation results are reviewed to compare with an experimental test. Finally the stability of rotor with the designed bearing is investigated. This methodology is successfully applied to the rotor for 1.2MW turbo-blower.

• Proceedings of the KSR Conference
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• 2009.05b
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• pp.585-592
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• 2009

The performance of screw compressor depends on lots of design parameters of rotor profile, such as length of seal line, wrap angle, blow hole, suction and discharge port size, number of rotor lobe, etc. The optimum rotor profile makes it possible to increase the compression efficiency with low energy consumption, and to minimize the loss of power. In this research, a new rotor profile design and performance analysis are done by computer simulation. It is expected that the volumetric efficiency is improved because the internal leakage is reduced due to the minimization of blow hole and clearance, and the stiffness of rotors is increased due to the reduction of length to diameter ratio. Also, the specific power consumption will be secured for use ranging from low to high operation speed.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.6
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• pp.86-95
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• 2007

This paper presents the optimal design of an exhaust system of a vacuum-compatible air bearing using a genetic algorithm. To use the air bearings in vacuum conditions, the differential exhaust method is adopted to minimize the air leakage, which prevents air from leaking into a vacuum chamber by recovering air through several successive seal stages in advance. Therefore, the design of the differential exhaust system is very important because several design parameters such as the number of seals, diameter and length of an exhaust tube, pumping speed and ultimate pressure of a vacuum pump, seal length and gap(bearing clearance) influence on the air leakage, that is, chamber's degree of vacuum. In this paper, we used a genetic algorithm to optimize the design parameters of the exhaust system of a vacuum-compatible air bearing under the several constraint conditions. The results indicate that chamber's degree of vacuum after optimization improved dramatically compared to the initial design, and that the distribution of the spatial design parameters, such as exhaust tube diameter and seal length, was well achieved, and that technical limit of the pumping speed was well determined.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.10
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• pp.103-112
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• 2006

This paper describes a theoretical analysis and experimental verification on the performances of a vacuum-compatible air bearing, which is designed with a cascaded exhaust scheme to minimize the air leakage in a vacuum environment. The design of the vacuum-compatible air bearing equipped with the differential exhaust system requires great care because several design parameters, such as the number of exhaust stages, diameter of exhaust tube, pumping speed of a vacuum pump, and bearing clearance greatly influence the air leakage and thus degree of vacuum. In this study, a performance analysis method was proposed to estimate the performances of the air bearing, such as load capacity, stiffness, and air leakage. Results indicate that the load capacity and stiffness of the air bearing was improved as its boundary pressure, which was determined by the $1^{st}$ exhaust method, was lowered, and the dominant factors on the chamber's degree of vacuum were the number of exhaust stages, exhaust tube diameter and bearing clearance. A vacuum chamber and air bearing stage using porous pad were fabricated to verify the theoretical analysis. The results demonstrate that chamber pressure up to an order of $10^{-3}$ Pa was achieved with the air bearing stage operating inside the chamber, and this analysis method was valid by comparing predicted values with experimental data, for the mass flow rates from the porous pad, and pressures at each exhaust port and chamber, respectively.

• Tribology and Lubricants
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• v.34 no.3
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• pp.107-114
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• 2018

This paper presents a computational model of a gas foil journal bearing with shim foils between the top foil and bumps, and predicts its static and dynamic performance. The analysis takes the previously developed simple elastic foundation model for the top foil-bump structure and advances it by adding foil models for the "shim foil" and "outer top foil." The outer top foil is installed between the (inner) top foil and bumps, and the shim foil is installed between the inner top foil and outer top foil. Both the inner and outer top foils have an arc length of $360^{\circ}$, but the arc length of the shim foil is shorter, which causes a ramp near its leading edge in the bearing clearance profile. The Reynolds equation for isothermal and isoviscous ideal gas solves the hydrodynamic pressure that develops within the bearing clearance with preloads due to the ramp. The centerline pressure and film thickness predictions show that the shim foil mitigates the peak pressure occurring at the loading direction, and broadens the positive pressure as well as minimum film thickness zones except for the shortest shim foil arc length of $180^{\circ}$. In general, the shim foil decreases the journal eccentricity, and increases the power loss, direct stiffness, and damping coefficients. As the shim foil arc length increases, the journal eccentricity decreases while the attitude angle, minimum film thickness, and direct stiffness/damping coefficients in the horizontal direction increase.

• Design & Manufacturing
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• v.17 no.3
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• pp.15-20
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• 2023

In the fine blanking process, which is a press operation known for producing parts with narrow clearances and high precision through the application of high pressure, die roll often occurs during the shearing process when the punch penetrates the material. This die roll phenomenon can significantly reduce the functional surface of the parts, leading to decreased product performance, strength, and fatigue life. In this research, we conducted an in-depth analysis of the factors influencing die roll in the curvature area of the fine blanking process and identified its root causes. Subsequently, we designed and experimentally verified a die roll reduction process specifically tailored for the door latch manufacturing process. Our findings indicate that die roll tends to increase as the curvature radius decreases, primarily due to the heightened bending moment resulting from reduced shape width-length. Additionally, die roll is triggered by the absorption of initial punch energy by scrap material during the early shearing phase, resulting in lower speed compared to the product area. To mitigate the occurrence of die roll, we strategically selected the Shaving process and carefully determined the shaving direction and clearance area length. Our experiments demonstrated a promising trend of up to 75% reduction in die roll when applying the Shaving process in the opposite direction of pre-cutting, with the minimum die roll observed at a clearance area length of 0.2 mm. Furthermore, we successfully implemented this approach in the production of door latch products, confirming a significant reduction in die roll. This research contributes valuable insights and practical solutions for addressing die roll issues in fine blanking processes.