• Structural Engineering and Mechanics
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• v.31 no.6
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• pp.679-696
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• 2009

The paper aims at analyzing the stress distribution around an underground opening that is subjected to non-symmetrical surface loading with emphasis on opening shapes with sharp corners and the stress concentrations developed at these locations. The analysis is performed utilizing the BIE method coupled with the Neumann's series. In order to implement this approach, the special recurrent relations for half plane were proven and the modified Shanks transform was incorporated to accelerate the series convergence. To demonstrate the capability of the developed approach, a horseshoe shape opening with sharp corners was investigated and the location and magnitude of the maximum hoop stress was calculated. The dependence of the maximum hoop stress location on the parameters of the surface loading (degree of asymmetry, size of loaded area) and of the opening (the opening height) was studied. It was found that the absolute magnitude of the maximum hoop stress (for all possible surface loading locations) is developed at the roof points when the opening height/width ratio is relatively large or when the pressure loading area is relatively narrow (compared to the roof arch radius), and contrarily, when the opening height/width ratio is relatively small or when the surface pressure is applied to a relatively wide area, the absolute magnitude of the maximum hoop stress is developed at the bottom sharp corner points.

• Transactions of Materials Processing
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• v.29 no.2
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• pp.89-96
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• 2020

The finite element method has been widely applied in the sheet metal forming process. However, the finite element method is computationally expensive and time consuming. In order to tackle this problem, surrogate modeling methods have been proposed. An artificial neural network (ANN) is one such surrogate model and has been well studied over the past decades. However, when it comes to ANN with two or more layers, so called deep neural networks (DNN), there is distinct a lack of research. We chose to use DNNs our surrogate model to predict the behavior of sheet metal in the deep drawing process. Thickness variation is selected as an output of the DNN in order to evaluate workpiece feasibility. Input variables of the DNN are radius of die, die corner and blank holder force. Finite element analysis was conducted to obtain data for surrogate model construction and testing. Sampling points were determined by full factorial, latin hyper cube and monte carlo methods. We investigated the performance of the DNN according to its structure, number of nodes and number of layers, then it was compared with a radial basis function surrogate model using various sampling methods and numbers. The results show that our DNN could be used as an efficient surrogate model for the deep drawing process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.1
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• pp.101-106
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• 2012

The press bulging process is very useful and productive method to produce round-type mechanical components which have not been able to be manufactured because of limitation of the conventional press technology. The application of the press bulging process has expanded very quickly in the hydraulic and electronic industry and more recently it has been used to produce other mechanical parts such as the automobile and shipping parts. This expanding application also has brought some unsolved problems and leads many researchers to put their effort into the die design of the press bulging process. In this study, to obtain the optimum die shape for the press bulging process, various process parameters have been considered such as corner radius, bulging height, pressing length, and forming load, etc. The main interest of this paper is to verify the press bulging process which has more than 4.0 in height-length ratio. From this aspect, Finite Element analysis shows great ability to simulate the precise deformation process and gives us manufacturing database. Consideration of strain, stress, and strain-rate for the various cases has been also taken to keep the forming load within a particular range.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.4
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• pp.71-78
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• 2020

The rotary feed axes of a 5-axis machine tool can increase the freedom of the tool posture, while reducing feed speed and rigidity. In addition, as a ball-end mill is inevitably used during machining by rotational feed, the step-over length is reduced compared to the flat-end mill, thereby reducing the material removal rate. Therefore, this study attempts to improve the material removal rate, feed speed, and machining stability using the corner radius flat-end mill and a fixed controlled machining method for the rotary feed axes during roughing. In addition, the tapered ball-end mill and simultaneously controlled machining method for the rotary feed axes were used for finishing to improve the propeller's 5-axis machining efficiency by enhancing the surface quality. In order to create the tool path effectively and easily, we propose a specific approach for using the propeller's geometric properties and evaluate the effectiveness of the proposed method by comparing it with the method of the dedicated module.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.93-98
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• 2006

Warm forming technology was classified into hot gas forming of using compressible fluid as a nitrogen gas and warm hydroforming of using the incompressible fluid as a thermal oil by using medium fluid. In this study, the aluminum side-rail part was developed with warm hydroforming technology. For the warm hydroforming system, top and bottom die was designed to insert heating cartridge in die cavity and special indirect fluid heating system was designed to heat the thermal oil. As increase the temperature, hydroformability was increased linearly. Aluminum side-rail center part was formed 90% at the internal pressure of 100bar and perfectly formed at 300bar within a moderate temperature. The tube material used for warm hydroforming was a aluminum 6000 series alloy with the diameter of 120mm, thickness of 5mm, length of 1,300mm. Warm hydroformed side-rail center part had 20% of maximum expansion ratio and below 20% of maximum thinning ratio at corner radius. This results were provided to show warm hydroforming possibility for aluminum automotive components.

• Structural Engineering and Mechanics
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• v.60 no.5
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• pp.795-807
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• 2016

This study tries to examine the effect of different parameters on stress analysis of infinite plates with central quasi-triangular cutout using particle swarm optimization (PSO) algorithm and also an attempt has been made to introduce general optimum parameters in order to achieve the minimum amount of stress concentration around this type of cutout on isotropic and orthotropic plates. Basis of the presented method is expansion of analytical method conducted by Lekhnitskii for circular and elliptical cutouts. Design variables in this study include fiber angle, load angle, curvature radius of the corner of the cutout, rotation angle of the cutout and at last material of the plate. Also, diagrams of convergence and duration time of the desired problem are compared with Simulated Annealing algorithm. Conducted comparison is indicative of appropriateness of this method in optimization of the plates. Finite element numerical solution is employed to examine the results of present analytical solution. Overlap of the results of the two methods confirms the validity of the presented solution. Results show that by selecting the aforementioned parameters properly, less amounts of stress can be achieved around the cutout leading to an increase in load-bearing capacity of the structure.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.10
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• pp.2797-2804
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• 1994

This paper analyzes the behaviors of corrugated membrane under the cryogenic liquid pressure and thermal loading using the FEM analysis program MARC. The FEM calculations were carried out on the basis of measured data of Technigaz membrane. It is very important to know the concentration levels and distributions of stress in the corrugated membrane. A quarter of the membrane sheet in place of the whole membrane was simulated because of its geometric symmetricity. The calculated results of the concentrated stress showed that the maximum stress occurs at the knot parts and at the root corner radius of the corrugations. The FEM calculated results indicated that the ring knot membrane which was developed in this study showed uniformly distributed stress and the lowest stress levels in the cross knot area in comparison with other two membranes. These results are very important to optimize the shape and improve the safety of membrane structure.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.3
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• pp.63-70
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• 2020

Two rotational motions of the 5-axis machine tool maximize the degree of freedom of the tool axis vector, which improves tool accessibility; however, this lowers feed speed and rigidity, which impairs machining stability. In addition, cutting efficiency is lowered when compared with a flat end mill because typically, the ball-end mill is used when machining by rotational motion. This study increased cutting efficiency by using a corner radius flat end mill during impeller roughing. Furthermore, we proposed a fixed controlled machining of the rotary motion using geometric shape information to improve the feed speed and machining stability. Finally, we proposed a finishing tool path generation method using a vector net to increase the convenience and practicality of tool path generation. To verify its effectiveness, we compared the machining time, shape accuracy, and surface quality of the proposed method and an existing dedicated module.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.1
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• pp.7-12
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• 2010

In this work, optimization analysis has been accomplished to find important process factors for realization of vertical wall around holes punched by the punchless piercing process. Taguchi method was used for optimization analysis. Lemaitre damage theory, one of the ductile fracture models, was also adopted to simulate numerically formation of vertical wall. From the results of analysis the most influencing factor that affects the vertical wall has been revealed to be 'Corner Radius of Die'.

• Transactions of Materials Processing
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• v.17 no.3
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• pp.218-224
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• 2008

A recent trend in automotive parts has been an integration of sub-assemblies with unified shapes. Tube structures also have been integrated to one body structure by using a near net shape forming instead of adopting welding. A cylindrical elastomer-forming process can be utilized to form a steel tube compressed in a radial direction. This process has some advantages compared to a hydro-forming or a swaging process in the viewpoint of a lower investment and a higher productivity. In order to predict a feasible specification of products within a work capability of the elastomer-forming equipment developed previously, effects of geometrical parameters of a tube on its shape accuracy are examined. Two characteristic parameters to account for the shape accuracy are chosen. One is the curvature radius at the corner part and the other is the straight ratio of the formed region. Careful examination of two parameters has led that the shape accuracy can be easily predicted by the regression equation obtained from the response surface method.