• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.32 no.10
• /
• pp.769-775
• /
• 2008

In this study, the investigations on the dimpled type Exhaust Gas Recirculation (EGR) cooler have been focused on the high heat exchanger efficiency. To overcome low heat exchanger efficiency of general EGR cooler, the dimpled type EGR cooler was developed. It was ensured the improvement of the performance of the dimpled type EGR cooler related to the heat exchange based on a series of the experiment. These results were caused by the increase of thermal surface area in accordance with the dimple's one. The estimation model of the heat exchanger efficiency using the Effectiveness-NTU method was also developed in order to verify the validity of experimental result. Also, the program for the estimation of the heat exchanger efficiency on the EGR cooler with regard to the dimpled tube shape was developed. Resultantly, it was confirmed that the dimpled type EGR cooler could be served better performance than the conventional one in view of the heat exchanger efficiency.

• Transactions of Materials Processing
• /
• v.17 no.1
• /
• pp.35-45
• /
• 2008

Electromagnetic Forming (EMF) technology such as magnetic pulse forming, which is one of the high velocity forming methods, has been used for the joining and forming process in various industry fields. This method could be derived a series of deformation of sheet metal by using a strong magnetic field. In this study, numerical approach by finite element simulation of the electromagnetic forming process was presented. A transient electromagnetic finite element code was used to obtain the numerical model of the time-varying currents that are discharged through the coil in order to obtain the transient magnetic forces. Also, the body forces generated in electromagnetic field were used as the loading condition to analyze deformation of thin sheet metal workpiece using explicit dynamic finite element code. In this study, after finite element analysis for thin sheet metal forming process with free surface configuration was performed, analytical approach for a dimpled shape by using EMF was carried out. Furthermore, the simulated results of the dimpled shape by EMF were compared with that by a conventional solid tool in view of the deformed shape. From the results of finite element analysis, it is confirmed that the EMF process could be applied to thin sheet metal forming.

• Journal of the Korean Society for Precision Engineering
• /
• v.25 no.3
• /
• pp.115-125
• /
• 2008

Recently, Exhaust Gas Recirculation (EGR) system which re-flow a cooled exhaust gas from vehicles burning diesel as fuel to a combustion chamber of engine has been used to solve the serious air pollution. For the design and mass production of EGR system, it is essential to ensure structural integrity evaluation. The EGR system consisted of ten dimpled oval core rectangular tubes, two fix-plates, two coolant pipes, shell body and two flanges in this study. To confirm the safety of the designed system, finite element modeling about each component such as the dimpled oval core tube with the dimpled shape and others was carried out. The reliability of EGR system against exhaust gas flow with high temperature was investigated by flow and pressure analysis in the system. Also, thermal and strength analysis were verified the safety of EGR system against temperature change in the shell and tubes. Furthermore, modal analysis using ANSYS was also performed. From the results of FE analysis, there were confirmed that EGR system was safe against the flow of exhaust gas, temperature change in EGR system and vibration on operation condition, respectively.

• The KSFM Journal of Fluid Machinery
• /
• v.10 no.3 s.42
• /
• pp.39-46
• /
• 2007

This study presents a numerical procedure to optimize the shape of staggered dimple surface to enhance turbulent heat transfer in a rectangular channel. The RBNN method is used as an optimization technique with Reynolds-averaged Navier-Stokes analysis of fluid flow and heat transfer with shear stress transport (SST) turbulence model. The dimple depth-to-dimple print diameter (d/D), channel height-to-dimple print diameter ratio (H/D), and dimple print diameter-to-pitch ratio (D/S) are chosen as design variables. The objective function is defined as a linear combination of heat transfer related term and friction loss related term with a weighting factor. Latin Hypercube Sampling (LHS) is used to determine the training points as a mean of the design of experiment. The optimum shape shows remarkable performance in comparison with a reference shape.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.387-390
• /
• 2008

Electromagnetic forming (EMF) technology, which is one of the high speed forming methods, has been used for the forming process in various industry fields. Numerical approach by finite element simulation of the EMF process is presented in this study. The implicit code is used to obtain the numerical model of the time-varying currents that are discharged through the coil in order to obtain the transient magnetic forces. In addition, the body forces generated in the workpiece are used as the loading condition to analyze deformation of thin sheet metal workpiece using explicit code. Numerical approach for a dimpled shape by EMF process is carried out and the simulated results of the dimpled shape by EMF are reviewed in view of the deformed shape and formability evaluation.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.06a
• /
• pp.702-705
• /
• 2005

Metallic sandwich plates with Inner dimpled shell subjected to 3-point bending have been analyzed and then optimized for minimum weight. Inner dimpled shells can be easily fabricated by press or roll with high quality precision and bonded with same material skin sheets by resistance welding or adhesive bonding process. Optimized shape of inner dimple is a hemispherical shell to minimize weight without failure, including face yielding, face buckling and inner dimple buckling. It is demonstrated that bending stiffness of sandwich plate is 2 or 3 times than solid plates with same strength

• 한국전산유체공학회:학술대회논문집
• /
• 2007.04a
• /
• pp.159-162
• /
• 2007

This study presents a numerical procedure to optimize the shape of a staggered dimpled surface to enhance the turbulent heat transfer in a rectangular channel. A optimization technique based on neural network is used with Reynolds-averaged Navier-Stakes analysis of the fluid flow and heat transfer with Shear Stress Transport turbulence model. The dimple depth-to-dimple print diameter ratio, channel height-to-dimple print diameter ratio, and dimple print diameter-to-pitch ratio are chosen as design variables. The objective function is defined as a linear combination of terms related to heat transfer and friction loss with a weighting factor. Latin Hypercube Sampling is used to determine the training points as a mean of the Design of Experiment. Optimal values of the design variables were obtained in a range of the weighting factor.

• Proceedings of the KSME Conference
• /
• 2007.05b
• /
• pp.2552-2557
• /
• 2007

Shape optimization of an internal cooling passage with staggered dimples on single surface is performed and performances of surrogates are evaluated in this paper. Optimizations are performed so that turbulent heat transfer can be enhanced compromising with pressure loss due to friction. The three-dimensional governing differential equations have been solved to find the overall Nusselt number and friction factor which are related to the objective functions of this problem. Three design variables were selected among the dimensionless geometric variables. Basic surrogate models such as second order polynomial response surface approximation (RSA), Kriging meta-modeling technique, radial basis neural network (RBNN), and derived press based averaged (PBA) surrogate model are constructed. The optimal points are searched from the above constructed surrogates by sequential quadratic programming (SQP). It is shown that use of multiple surrogates can increase the robustness in prediction of better design with minimum computational cost.

• Journal of the Korean Society for Precision Engineering
• /
• v.23 no.8 s.185
• /
• pp.127-136
• /
• 2006

Metallic sandwich plates with inner dimpled shell subject to 3-point bending have been analyzed and then optimized for minimum weight. Inner dimpled shells can be easily fabricated by press or roll with high precision and bonded with same material skin sheets by resistance welding or adhesive bonding. Metallic sandwich plates with inner dimpled shell structure can be optimally designed for minimum weight subject to prescribed combination of bending and transverse shear loads. Fundamental findings for lightweight design are presented through constrained optimization. Failure responses of sandwich plates are predicted and formulated with an assumption of narrow sandwich beam theory. Failure is attributed to four kinds of mechanisms: face yielding, face buckling, dimple buckling and dimple collapse. Optimized shape of inner dimpled shell structure is a hemispherical shell to minimize weight without failure. It is demonstrated that bending stiffness of sandwich plate is 2 or 3 times larger than solid plates with the same strength. Failure mode boundaries and iso-strength lines dependent upon the geometry and yield strain of the material are plotted with respect to geometric parameters on the failure map. Because optimal parameters of maximum strength for given material weight can be selected from the map, analytic solutions for maximum strength are expressed as a function of only material property and proposed strength. These optimal parameters match well with numerical optimal parameters.

• Proceedings of the KSME Conference
• /
• 2008.11a
• /
• pp.554-559
• /
• 2008

Most of vehicle manufacturers have applied exhaust gas recirculation (EGR) system to the development of diesel engines in order to obtain the high thermal efficiency without $NO_X$ and Particulate Matter (PM) emitted from the engine. EGR system, which reflow a cooled exhaust gas from vehicles burning diesel as fuel to a combustion chamber of engine, has been used to solve this problem. In order to confirm the safety of the EGR system, finite element analysis was carried out. The safety of EGR system against temperature variation in the shell and tubes was evaluated through the thermal and structural analysis, and the modal analysis using ANSYS was also performed. Finally, the performance of EGR system was verified through the experiment and numerical simulation using effectiveness-NTU method. Program for the estimation of the heat exchange efficiency of the EGR system with regard to the dimpled tube shape was developed.