• Steel and Composite Structures
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• 제34권5호
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• Geomechanics and Engineering
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• 제8권4호
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• pp.495-510
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• 2015

The applications of water jet cutting (WJC) in coal mine have progressed slowly. In this paper, we analyzed the possibility and reasonableness of WJC application to pressure relief in hard coal seam, simulated the distributive characteristics of stress and energy fields suffered by hard coal roadway wallrock and the internal relationships of the fields to the instability due to WJC (including horizontal radial slot and vertical annular slot) on roadway wallrock. The results showed that: (1) WJC can unload hard coal seam effectively by inducing stress release and energy dissipation in coal mass near its slots; its annular slots also can block or weaken stress and energy transfer in coal mass; (2) the two slots may cause "the beam structure" and "the small pillar skeleton", and "the layered energy reservoir structure", respectively, which lead to the increase in stress concentration and energy accumulation in coal element mass near the slots; (3) the reasonable design and optimization of slots' positions and their combination not only can significantly reduce the scope of stress concentration and energy accumulation, but also destroy coal mass structure on a larger scale to force stress to transfer deeper coal mass.

• 한국정밀공학회지
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• 제30권5호
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• pp.474-479
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• 2013

Mass reduction of the machine tool movable parts is a tool for achieving lower energy demands of the machine tool operation. The realization of lightweight design in machine tool can be achieved by structural lightweight design and material lightweight design. In this study, topology optimization strategy was applied to design optimized structures of movable parts of 5 axis machining center. The weight of ram which has most significant influence on the stiffness of whole machine tool was reduced without stiffness deterioration. The redesigned optimized ram has 24.2% less weight while maintaining the same displacement caused by cutting force.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.1257-1260
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• 2005

Grinding process has unique characteristics compared with other machining processes. The cutting edges of the grinding wheel don't have uniformity and act differently on the workpiece at each grinding. The response surface analysis is one of various methods for optimizing and evaluating the process parameters to achieve the desired output. In this study, the effect of the grinding parameters on outcomes of the surface grinding was analyzed experimently. To predict the grinding outcomes and to select the grinding conditions before grinding, the second-order response surface models for the grinding force and the surface roughness were developed.

• 한국생산제조학회지
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• 제7권2호
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• pp.9-14
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• 1998

One of the areas in the continuous casting process that up to this point, has not been definitively instrumented is a method of reliably locating the part of a continuously cast strand that remains liquid for a period after the outer portion has solidified. To solve the problem. Electromagnetic Trandsducers(EMAT) which operate across an air gap without the need for a coupling medium has been developed. The system was designed to employ a through transmission technique which enhanced the signal-to-noise ratio. The Al 75$\times$75mm and 75$\times$100mm simulators with 2, 4, 8, 16, 32 mm hole respectively has been produced in order to verify the developed EMAT system and to measure to liquid core in continuous casting strand. The system developed can be employed for the optimization of torch cutting speed and for the final cut length of the bloom as well as calculation of average bloom temperature.

• 항공우주시스템공학회지
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• 제12권4호
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• pp.18-25
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• 2018

가공의 정밀도와 난삭재 가공이 요구되는 항공기부품용 공작기계의 헤드프레임 구조는 정밀 고속가공을 위해 경량화 및 절삭력에 의한 변형최소화가 필요하다. 본 논문에서는 고강성 경량화 구조 최적설계를 위해 유한요소해석을 수행하여 초기형상을 설계하였고, 컴플라이언스를 최소화하여 경량, 고강성 및 저진동 구조의 위상 최적화 설계를 수행하였다. 최적화 설계결과 프레임 중량은 17.3% 감소되었고, 최대 처짐량은 0.007 mm 이하, 고유진동수는 30.6% 증가되었다. 구조 정강성은 각 축 방향으로 증가되었고, 동강성은 축에 따라 상반된 결과를 나타내었다. 위상 최적화 설계 구조에서 저진동의 고강성을 갖는 최적화된 구조를 확인하였다.

• 한국생산제조학회지
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• 제22권2호
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• pp.179-184
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• 2013

In this article, we introduce the study case of technology that can automatically compensate the errors of these factors of a machine during processing on the machine tool's CNC(Computerized Numerical Controller) in real time. The biggest factors that lower the machining accuracy are thermal deformation and chatter vibration. This study is related to the detection and compensation of thermal deformation and chatter vibration that can compensate for faster and produce processed goods with more precision by autonomous compensation. In addition, this study is related to the active control of vibration during machining, monitoring of cutting force and auto recognition of machining axes origin. Thus, we attempt to introduce the related contents of the development we have made in this article.

• 한국식품영양과학회지
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• 제44권9호
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• pp.1364-1373
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• 2015

본 연구에서는 고추장 소스를 주 절임원으로 하여 단감 침지액의 염 농도(0, 2, 4, 6, 8%)와 침지시간(4, 8, 12, 16, 20분)을 달리하여 단감 고추장 장아찌를 제조하였다. $20^{\circ}C$에서 0~60일간 저장하면서 경시적으로 시료를 채취하여 단감과 소스를 분리한 후 단감 고추장 장아찌의 염도, 당도, pH, 색도, 물성 및 관능검사를 측정하였고, 반응표면분석법을 이용하여 단감 고추장 장아찌 최적 제조 조건을 설정하였다. 단감 침지액의 염 농도, 침지시간, 단감 고추장 장아찌의 저장기간을 달리하여 제조한 단감 고추장 장아찌에 대한 분석 결과 염도, 당도, pH, 색도의 L, a, b 값, 관능검사의 색, 향미, 맛, 물성 및 전체적 선호도는 독립변수 간의 교호 작용하는 quadratic model이 선택되었고, 절단력은 linear model 이 선택되었다. 독립변수인 단감 침지액의 염 농도, 침지시간, 단감 고추장 장아찌의 저장기간의 범위 내에서 반응표면 분석에 의해 유의적으로 평가된 각 항목별 최적조건으로 canonical 모형의 수치 최적화를 통하여 설정된 최적조건은 침지액의 농도 6.91%, 침지시간 11.36분, 저장기간 25.18일이 가장 적합한 장아찌 품질 조건으로 나타났다.

• 실천공학교육논문지
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• 제13권2호
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• pp.327-332
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• 2021

교육용으로 사용되는 피삭재(소재)는 SM20C, Al6061, 아크릴 등의 소재를 사용한다. SM20C 소재는 탄소강으로서 자격증 시험 및 기능경기대회에서 많이 사용되지만 산업현장에서도 많이 사용된다. Al6061 소재는 탄소강에 비하여 경도가 낮아지고 전성(연성)이 강한 소재이기에 공구의 구성인선이 많이 발생하는 소재 라고 한다. 아크릴 소재를 이용하여 학생들에게 실습지도 하면 어느 부분에서 과다 절삭으로 인하여 진동이 발생하고 공구의 파손이 발생하는 소재이다. 이러한 과정에서 5축장비인 2NC헤드에게 가해지는 충격이 정밀도 제어에는 어느정도 영향을 줄 수 있는지 알아본다. 5축장비의 가장 취약한 부분은 AC축을 제어하는 헤드가 가장 약한 부분이라 할 수 있다. 이 부분의 정밀도 및 누적 공차가 발생할 경우 모든 제품의 정밀도가 떨어지는 현상이 발생한다. 따라서 2NC헤드의 핵심적인 부분, 스핀들 하우징은 Al7075 T6(미국 알코아사) 소재를 사용하고 전체 바디는 FCD450 (구상흑연주철) 사용하여 진행하였다. 이 두가지 소재에서 작용되는 진동 및 절삭 과정에서 힘을 극한조건에서 유한요소 해석으로 적용되는 값을 밝혀 내고자 해석을 진행하였다. 이러한 해석 데이터를 활용하여 학생들이 5축절삭 보다 5축 가공기의 구조를 보고 이해하는데 도움이 되기를 기대한다.