• 열처리공학회지
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• 제20권4호
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• pp.175-180
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• 2007

The hardness of cold-forged products is in close relationship with its effective strain. This study presented the estimating method of hardness for cold-forged SKH9 products without hardness tests in view of resistance to plastic deformation using finite element code, DEFORM$^{TM}$. The flow stress equation obtained from the compression test was only used as a basic data to estimate the relationship between effective strain and hardness. In addition, this new estimating method was applied to the cold-forged product which was widely used in industrial field to show the feasibility. As a result, the predicted hardness numbers through FE simulation showed good agreement with the measured hardness numbers. It is possible to estimate the hardness not by hardness tests, but by only computer simulations for the deformed products. Also, effective strain values were possibly estimated by measuring hardness numbers, and vice versa.

• 한국정밀공학회지
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• 제27권8호
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• pp.35-41
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• 2010

White Etching Layer(WEL) is a phenomenon that occurs on the surface of rail due to wheel/rail interactions such as excessive braking and acceleration. Rolling Contact Fatigue(RCF) cracks on the surface of rail have been found to be associated with WEL. In this study, we have investigated RCF damages of white etching layer using twin disc testing and fatigue analysis. These tests consist of wheel flat tests and rolling contact fatigue tests. WEL has been simulated by wheel flat test. It has been founded that the WEL with a bright featureless contrast is formed on the surface of specimen by etching. Rolling contact fatigue test was conducted by using flat specimens with the WEL generated by the wheel flat test. It has been observed that two types of cracks occur within the specimen. The contact fatigue test was simulated in 2D elastic-plastic FE simulations. Based on loading cycles obtained from the finite element analysis, the fatigue life analysis according to the thickness variation of WEL was carried out. The longest fatigue life was observed from the thickness of 20um.

• 한국정밀공학회지
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• 제30권8호
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• pp.815-823
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• 2013

The hot curvature forming of large aluminum plates is a process used to produce spherical liquefied natural gas (LNG) tanks. In this study, we describe a method to determine the optimum shape of blanks to minimize the root gap in the forming process. The method proposed in this study was applied to a small-scale model for thick plates with a curvature of 1500 mm and thickness of 6 mm. First, the shape of the curved shells was determined as the target shape, and then a coordinate transform was used to determine the optimum blank shape, which was then iteratively modified using the results of finite element method (FEM) simulations, including heat transfer, until the shape error was minimized. Experiments in forming using Al5083 thick plate were carried out, showing that the method can determine the optimum blank shape within an allowable root gap of 0.1 mm.

• Steel and Composite Structures
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• 제26권3호
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• pp.255-263
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• 2018

A steel-concrete composite (SC) panel typically consists of two steel faceplates and a plain concrete core. This paper investigated the impact response of SC panels through drop hammer tests and numerical simulations. The influence of the drop height, faceplate thickness, and axial compressive preload was studied. Experimental results showed that the deformation of SC panels under impact consists of local indentation and overall bending. The resistance of the panel significantly decreased after the local failure occurred. A three-dimensional finite element model was established to simulate the response of SC panels under low-velocity impact, in which the axial preload could be considered reasonably. The predicted displacements and impact force were in good agreement with the experimental results. Based on the validated model, a parametric study was conducted to further discuss the effect of the axial compressive preload.

• Structural Engineering and Mechanics
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• 제67권3호
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• pp.301-310
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• 2018

In this paper, a multi-objective multiparameter optimization procedure is developed by combining rigorously developed metamodels with an evolutionary search algorithm-Genetic Algorithm (GA). Response surface methodology (RSM) is used for developing the metamodels to replace the tedious finite element analyses. A nine-node isoparametric plate bending element is used for conducting the finite element simulations. Highly accurate numerical data from an author compiled FORTRAN finite element program is first used by the RSM to develop second-order mathematical relations. Four material parameters-${\frac{E_1}{E_2}}$, ${\frac{G_{12}}{E_2}}$, ${\frac{G_{23}}{E_2}}$ and ${\upsilon}_{12}$ are considered as the independent variables while simultaneously maximizing fundamental frequency, ${\lambda}_1$ and frequency separation between the $1^{st}$ two natural modes, ${\lambda}_{21}$. The optimal material combination for maximizing ${\lambda}_1$ and ${\lambda}_{21}$ is predicted by using a multi-objective GA. A general sensitivity analysis is conducted to understand the effect of each parameter on the desired response parameters.

• 대한기계학회논문집A
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• 제31권3호
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• pp.304-312
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• 2007

The objective of this study is to develop a local failure criterion for a wall thinning defect of piping components. For this purpose, a series of tensile tests was performed using several types of simulated specimens with different stress states, including smooth round bar, notched round bar (five different notch radii), and grooved plate (three different groove radii). In addition, finite element (FE) simulations were performed on the simulated specimen tests and the results were compared with the test results. From the comparisons, the equivalent stress and strain corresponding to maximum load and final failure of notched specimens were proposed as failure criteria under tensile load. The criteria were verified by employing them to the estimation of failure of grooved plate specimens that simulate the wall thinning defect. It showed that the proposed criteria accurately estimate the maximum load and final failure of grooved plate specimen tests.

• 소성∙가공
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• 제20권4호
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• pp.273-278
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• 2011

Employing the TRIZ problem solving technique, a hybrid-type center plate for the molten carbonate fuel cell(MCFC) was developed for the purpose of improving gas sealing and maintenance. The manufacturing method of the hybrid-type center plate was divided into a trimming operation and a two-step bending process. In the latter, a modified punch shape was used to reduce springback. Using finite element(FE) simulations, bending stresses in the thickness and the in-plane directions were computed and the bending conditions were optimized. The optimized results of the two-step bending process were used as a basis for the design of the trimming process of the hybrid-type center plate. Finally, the external manifold-type center plate and the hybrid-type center plate were fabricated using a die set that accounts for the optimized conditions. It was found that the numerical simulation results were in good agreement with the experiments.

• 소성∙가공
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• 제23권7호
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• pp.419-424
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• 2014

In order to improve efficiency, an outdoor unit using a refrigerant cooling method is designed into many air conditioner systems. The heat exchanger is composed of a Cu tube and an plate. The optimal design for the cold plate is very important because the efficiency of the heat transfer depends on the contact area between the Cu tube and the cold plate. The current study focused on the design of the cold plate to obtain a uniform contact between the Cu tube and the cold plate. Both FE(finite element) analysis and optimization were used in the design. The contact area between the tube and plate was predicted and improved by 16% through the press forming simulations. The springback after press forming was also reduced when the optimized design parameters were used. To verify the validity of the optimal cold plate design, a verification test was conducted. As a result, the performance of the heat exchanger improved by 34% when compared to benchmarked products.

• 한국분무공학회지
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• 제17권3호
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• pp.128-133
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• 2012

The present study aims to examine the influence of flame spray distance on the thermal behavior of micro-metal particles and the morphological characteristics of $Ni_{20}Cr$ layers coated on the preheated SCM415 substrates by using the conventional flame spray system. Commercially available nickel-based $Ni_{20}Cr$ particles with a mean diameter of $45{\mu}m$ were used. In addition, CFD simulations using a commercial code (FLUENT ver. 6.3.26) were conducted to estimate temperature and velocity distributions of the continuous and discrete phases before impact on the substrate. From FE-SEM images of coated layers on the substrates, it was observed that as the spray distance decreased, the metal particle morphology showed splash-like patterns and such a short stretch shape, resulting from higher particle momentums and the impact of partially melted particles. Moreover, it was found that the spray distance should be considered as one of important parameters in controlling the porosity and the adhesion strength.

• Structural Engineering and Mechanics
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• 제41권1호
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• pp.25-41
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• 2012

Kriging surrogate model provides explicit functions to represent the relationships between the inputs and outputs of a linear or nonlinear system, which is a desirable advantage for response estimation and parameter identification in structural design and model updating problem. However, little research has been carried out in applying Kriging model to crack identification. In this work, a scheme for crack identification based on a Kriging surrogate model is proposed. A modified rectangular grid (MRG) is introduced to move some sample points lying on the boundary into the internal design region, which will provide more useful information for the construction of Kriging model. The initial Kriging model is then constructed by samples of varying crack parameters (locations and sizes) and their corresponding modal frequencies. For identifying crack parameters, a robust stochastic particle swarm optimization (SPSO) algorithm is used to find the global optimal solution beyond the constructed Kriging model. To improve the accuracy of surrogate model, the finite element (FE) analysis soft ANSYS is employed to deal with the re-meshing problem during surrogate model updating. Specially, a simple method for crack number identification is proposed by finding the maximum probability factor. Finally, numerical simulations and experimental research are performed to assess the effectiveness and noise immunity of this proposed scheme.