• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.7
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• pp.33-40
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• 2021

Current industrial flow is directed toward reducing the usage of raw materials by reusing parts, which is referred to as a circular economy (CE). Repair is one of the most value-added approaches in CE, which can be efficiently accomplished via additive manufacturing. The repair technology of metallic parts via the directed energy deposition process, which includes the selective removal and redeposition of damaged regions of metallic parts. Residual stress characteristics depend on the shape of the part and the shape of the redeposition region. The objective of this study is to investigate the effects of the radius and corner position of the substrate on the residual stresses for repair by using finite element analysis (FEA). The residual stress distribution of the 45° angle groove at the edge of the circular shape models on the outer and inner radii was analytically investigated. The analysis was accomplished using SYSWELD software by applying a moving heat source with defined material properties and cooling conditions integrated into the FEA model. The results showed a similar pattern of concentrated stress distribution for all models except the 40-mm and 60-mm radii, for which the maximum stress locations were different. The maximum residual stresses are high but lower than the yield strength, suggesting the absence of cracks and fractures due to residual stresses.

• Composites Research
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• v.28 no.4
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• pp.212-218
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• 2015

A large composite spar was manufactured using an automatic fiber placement (AFP) machine. To verify its structural performance, the weakest part of the structure, which is called 'corner radius', was tested under bending and examined by finite element analysis. Since the application of AFP machine to composite structure fabrication is still in early stage in Korea, this paper presents the summary of whole process for manufacturing composite spar using AFP machine from mandrel design and analysis to verification test. The deflection and stress by mandrel weight and AFP machine force, thermal deformation and natural frequency were all examined for mandrel design. The target structure was composite C-spar and cured in an autoclave. Test results were compared with nonlinear finite element analysis results to show that the structure has the strength close to the theoretical value. It was confirmed that the corner radius of the spar manufactured by AFP process showed deviation less than 20% compared with first ply failure strength. The results indicate that the AFP technology could be used for large scale composite structure production in the near future.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.381-385
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• 2006

This research introduces easy tool manufacturing method regarding tool manufacturing procedure. In the conventional method, wire cutting machining and lapping operation of corner and render region were performed after shrink-fitting to ensure the accuracy of gear profile. But lapping operation is very difficult due to corner and render is located deep inside of die. In this research, wire cutting operation was performed after $1^{st}$ ring was shrink-fitted to ease lapping operation and increase the accuracy of corner radius. Before $2^{nd}$ ring fitting, lapping was completed. Elastic deformation amount due to $2^{nd}$ ring fitting and cold forging was calculated through finite element analysis and wire cutting specification was offset in that amount. Comparison of gear dimension between analysis and forged part ensures the validity of new manufacturing methods.

• Journal of Energy Engineering
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• v.22 no.2
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• pp.105-111
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• 2013

The present study has been carried out to reduce the heat loss from a built in refrigerator by using reverse heat loss method to discern the region with larger heat loss. To perform this purpose, an infrared thermographic camera has been used to measure the surface temperature of the refrigerator and tried to improve the heat loss near the ice dispenser. The numerical heat transfer analysis also has been accomplished to clarify the heat transfer mechanism near the ice dispenser. The possible applicable method to reduce heat loss was increasing the curvature radius at the ice dispenser corner. The curvature radius has been changed from 0mm to 40mm to see the effect of the curvature at the corner. From the present research, the optimal curvature radius for the reduction of heat loss at the ice dispenser could be 30mm.

• Transactions of Materials Processing
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• v.14 no.9 s.81
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• pp.772-778
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• 2005

This paper is concerned with the analysis of material flow characteristics of combined tube extrusion using pipe. The analysis in this paper concentrated on the evaluation of the design parameters for deformation patterns of tube forming, load characteristics, extruded length, and die pressure. The design factors such as punch nose radius, die corner radius, friction factor, and punch face angle are involved in the simulation. The combined tube extrusion is analyzed by using a commercial finite element code. This simulation makes use of pipe material and punch geometry on the basis of punch geometry recommended by International Cold Forging Group. Deformation patterns and its characteristics in combined forward and backward tube extrusion process were analyzed for forming loads with primary parameters, which are various punch nose radius relative to backward tube thickness. The results from the simulation show the flow modes of pipe workpiece and the die pressure at the contact surface between pipe workpiece and punch. The specific backward tube thickness and punch nose radius have an effect on extruded length in combined extrusion. The combined one step forward and backward extrusion is compared with the two step extrusion fer forming load and die pressure.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.9
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• pp.1384-1390
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• 2004

The full containment Liquefied Natural Gas(LNG) storage tank is based on a double liquid container concept : two separate containers, one within the other, are capable of containing the LNG. The outer concrete tank provides comer protection(secondary containment) to withstand and safely contain any spill from the inner tank. The comer protection is installed on inside corner surface of outer concrete tank. Because of high and complex stresses, corner protection is designed by ASME section ⅧI Div. 2, Appendix 4 on behalf of API 620 which is main design code for LNG tank. Design guidelines to determine design factors such as liner thickness and knuckle radius are not well understood because Appendix 4 is the design method not based on equation but FEM. Recently, the volume of LNG tank shows a tendency to increase. So it is necessary to set up the design guidelines to cope with change of LNG tank capacity and height/diameter ratio. In this paper, optimum design of corner protection was performed and the design guidelines were suggested by the results of FEM for LNG tanks which have different capacities and height/diameter ratio.

• Nuclear Engineering and Technology
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• v.26 no.3
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• pp.374-380
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• 1994

A method to simulate the extent of interlinkage of grain boundary gas bubbles to the free surfaces of fuel pellet was developed. With the shape of UO$_2$gain treated as tetrakaidecahedron (TKD)), the interlinked fraction of fission gas bubbles to free surfaces at grain comers was calculated as a function of the radius of grain corner bubbles by the Monte Carlo technique. In spite of two dimensional analysis, the present method shooed reasonable agreement between predicted and measured fuel swelling at the moment that complete bubble interlinkage was achieved. However, for more realistic simulation of interlinkage, grain comer bubbles should be treated three dimensionally.

• Wind and Structures
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• v.21 no.2
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• pp.183-202
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• 2015

Experiments on two-dimensional rectangular prisms with various side ratios (B/D=2, 3, and 4, where B is the along-wind dimension, and D is the across-wind dimension) and rounded corners (R/D=0%, 5%, 10%, and 15%, where R is the corner radius) are reported in this study. The tests were conducted in low-turbulence uniform flow to measure the wind pressures on the surfaces of 12 models for Reynolds numbers ranging from $1.1{\times}10^5$ to $6.8{\times}10^5$. The aerodynamic force coefficients were obtained by integrating the wind pressure coefficients around the model surface. Experimental results of wind pressure distributions, aerodynamic force coefficients, and Strouhal numbers are presented for the 12 models. The mechanisms of the Reynolds number effects are revealed by analyzing the variations of wind pressure distributions. The sensitivity of aerodynamic behavior to the Reynolds number increases with increasing side ratio or rounded corner ratio for rectangular prisms. In addition, the variations of the mean pressure distributions and the pressure correlations on the side surfaces of rectangular prisms with the rounded corner ratio are analyzed at $Re=3.4{\times}10^5$.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.9
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• pp.186-191
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• 2001

Spinning process is a chipless metal forming method for axi-symmetric parts, which is more economical, efficient and versatile method for producing parts than the other sheet metal forming process such as stamping or deep drawing. In this study, a fundamental experiment was conducted to improve productivity with process parameters such as tool path, angle of roller holder($\alpha$), feed rate($\gamma$) and corner radius of forming roller(Rr). These factors were selected as variables in the experiment because they were most likely expected to hale an effect on spring back. The empirical results were analyzed to know how much spring back was affected by these factors. And also thickness and diameter distribution of a multistage cup obtained by spinning process were observed and compared with those of a commercial product produced by conventional deep drawing.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.349-354
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• 2002

In order to find the effect of lubricant viscosity, sheet surface roughness, tool geometry, and forming speed on the frictional characteristics in sheet metal forming, a sheet metal friction tester was designed and manufactured and friction test of various sheet were performed. Friction test results showed that as the lubricant viscosity becomes lower, the friction coefficient is higher. When surface roughness is extremely low or high, the friction coefficient is relatively high. The result also show that as the punch radius and punch speed becomes bigger, the friction coefficient is smaller. Using experimental results, the mathematical expression between friction coefficient and lubricant viscosity, surface roughness, punch comer radius, or punch speed is also described.