• 한국재료학회:학술대회논문집
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• 한국재료학회 2012년도 춘계학술발표대회
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• pp.81.2-81.2
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• 2012

To fabricate a metal mold for injection molding, hot-embossing and imprinting process, mechanical machining, electro discharge machining (EDM), electrochemical machining (ECM), laser process and wet etching ($FeCl_3$ process) have been widely used. However it is hard to get precise structure with these processes. Electrochemical etching has been also employed to fabricate a micro structure in metal mold. A through mask electrochemical micro machining (TMEMM) is one of the electrochemical etching processes which can obtain finely precise structure. In this process, many parameters such as current density, process time, temperature of electrolyte and distance between electrodes should be controlled. Therefore, it is difficult to predict the result because it has low reliability and reproducibility. To improve it, we investigated this process numerically and experimentally. To search the relation between processing parameters and the results, we used finite element simulation and the commercial finite element method (FEM) software ANSYS was used to analyze the electric field. In this study, it was supposed that the anodic dissolution process is predicted depending on the current density which is one of major parameters with finite element method. In experiment, we used stainless steel (SS304) substrate with various sized square and circular array patterns as an anode and copper (Cu) plate as a cathode. A mixture of $H_2SO_4$, $H_3PO_4$ and DIW was used as an electrolyte. After electrochemical etching process, we compared the results of experiment and simulation. As a result, we got the current distribution in the electrolyte and line profile of current density of the patterns from simulation. And etching profile and surface morphologies were characterized by 3D-profiler(${\mu}$-surf, Nanofocus, Germany) and FE-SEM(S-4800, Hitachi, Japan) measurement. From comparison of these data, it was confirmed that current distribution and line profile of the patterns from simulation are similar to surface morphology and etching profile of the sample from the process, respectively. Then we concluded that current density is more concentrated at the edge of pattern and the depth of etched area is proportional to current density.

• 소성∙가공
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• 제21권7호
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• pp.412-419
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• 2012

The ingot-breakdown scheme of a tower flange material (low-alloy steel) for offshore wind turbine was investigated using finite element (FE) simulations and experimental analyses. Based on compression test results of the low-alloy steel, a deformation processing map was generated using the superposition approach between the dynamic materials model (DMM) and Ziegler's instability criterion. The deformation processing map allowed determination of the optimum process conditions for the tower flange material. Within the FE simulations of the ingot breakdown process, the Cockcroft-Latham criterion, which considers ductile fracture, was used to predict the possibility of forming defects during the hot working process. In general, the critical value for the ductile fracture of steel is 0.74. During the ingot-breakdown under optimum process conditions, the actual tower flange forgings exhibited a relatively uniform shape without any forming defects.

• Smart Structures and Systems
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• 제12권5호
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• pp.483-499
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• 2013

A new piezoceramic $d_{15}$ shear-induced torsion actuation mechanism representative benchmark is proposed and its experimentations and corresponding 3D finite element (FE) simulations are conducted. For this purpose, a long and thin smart sandwich cantilever beam is dimensioned and built so that it can be used later for either validating analytical Saint Venant-type solutions or for analyzing arm or blade-based smart structures and systems applications. The sandwich beam core is formed by two adjacent rows of 8 oppositely axially polarized d15 shear piezoceramic patches, and its faces are dimensionally identical and made of the same glass fiber reinforced polymer composite material. Quasi-static and static experimentations were made using a point laser sensor and a scanning laser vibrometer, while the 3D FE simulations were conducted using the commercial software $ABAQUS^{(R)}$. The measured transverse deflection by both sensors showed strong nonlinear and hysteretic (static only) variation with the actuation voltage, which cannot be caught by the linear 3D FE simulations.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.322-325
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• 2005

TTX(Tilting Train eXpress) is being designed for improving the speed of conventional railway. The purpose of this study is to evaluate energy absorbing capacity and driver's survivability for a design candidate of the front end structure of TTX. A FE model with honeycomb block, under frame, and body frame is generated for crash simulation. Based on a level-crossing accident scenario, numerical simulation is performed using LS-DYNA. The results of crash analysis show that strength improvement of the current front end structure design candidate is needed to ensure driver safety.

• 소성∙가공
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• 제15권2호
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• pp.143-147
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• 2006

Effect of processing condition on the hot extrusion of Al-Zn-Mg-Sc alloy was investigated. For this purpose, hot compression test and FE-simulation were conducted via Thermecmaster-Z and DEFORM-3D, respectively. The microstructure evolution during hot extrusion and post heat-treatment was investigated and deformation mechanisms were analyzed by constructing processing map. FE-simulation results show that the temperature difference between container and billet has considerable influence on the final shape of extruded T-shape bar. The relation between applied load and processing time was predicted by the FE-analysis as well as punch speed vs. stroke chart.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.202-205
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• 2005

Effect of processing condition on the hot extrusion of Al-Zn-Mg-Sc alloy was investigated. For this purpose, hot compression test and FE-simulation were conducted via Thermecmasteer-Z and DEFORM-3D, respectively. The microstructure evolution during hot extrusion and post heat-treatment was investigated and deformation mechanisms were analyzed by constructing processing map. FE-simulation results show that the temperature difference between container and billet has considerable influence on the final shape of extruded T-shape bar. The relation between applied load and processing time was predicted by the FE-analysis as well as punch speed vs. stroke chart.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2004년도 춘계학술대회
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• pp.905-910
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• 2004

Vibration characteristics of the FIV test loop for the Flow-Induced Vibration(FIV) study of a PWR partial(5x5) fuel assembly are investigated by the Finite Element(FE) analysis and the modal test. For the FE analysis, 3-D beam element is used for the pipes and the test section and mass element used for the valves and flanges. The 'U' restrainer stiffness determined by numerical simulation is used for the FE model. The result of the FE analysis is compared with that of the modal test. The higher mode similarity between the test and analysis is observed in a few low modes. After that, the mode similarity reduce as the mode goes high. It is concluded that the first to the third vibration modes are observed at the lower parts of the 6 inches restoring line, followed by a local mode at the test section, and the natural frequencies of the modes are 22.4 Hz, 26.0 Hz, 27.5 Hz and 31.4 Hz.

• 한국전산구조공학회논문집
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• 제33권3호
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• pp.145-152
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• 2020

본 논문에서는 유한요소해석을 이용하여 흉요추 후방 고정술의 고정분절 변화에 따른 척추 안정성을 평가하였다. 이를 위해 추간판, 인대, 추간관절(Facet joint) 등을 포함한 정상 흉요추(T10-L4)의 유한요소모델을 구축하였으며, 문헌으로 보고된 재료물성치를 부여하였다. 한편, L1을 병변 부위로 가정하였으며, L1-L2, T12-L2, T12-L1-L2 총 3가지 종류의 후방 고정술을 흉요추 유한요소모델에 구현하고 전방 굽힘, 후방 굽힘, 측면 굽힘, 축 회전의 하중 조건을 부여하였다. 시리즈 유한요소해석을 통해 고정분절에 따른 척추경 나사못, 척추골, 추간판의 변형량, 등가 응력, 운동 범위, 모멘트를 계산하였으며, 그 결과를 바탕으로 척추 안정성을 평가하였다.

• Structural Engineering and Mechanics
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• 제67권6호
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• pp.643-658
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• 2018

In this paper, we introduce a new framework for running the finite element (FE) packages inside an online Loop together with MATLAB. Contrary to the Hardware-in-the-Loop techniques (HiL), in the proposed Software-in-the-Loop framework (SiL), the FE package represents a simulation platform replicating the real system which can be out of access due to several strategic reasons, e.g., costs and accessibility. Practically, SiL for sophisticated structural design and multi-physical simulations provides a platform for preliminary tests before prototyping and mass production. This feature may reduce the new product's costs significantly and may add several flexibilities in implementing different instruments with the goal of shortlisting the most cost-effective ones before moving to real-time experiments for the civil and mechanical systems. The proposed SiL interconnection is not limited to ABAQUS as long as the host FE package is capable of executing user-defined commands in FORTRAN language. The focal point of this research is on using the compiled FORTRAN subroutine as a messenger between ABAQUS/CAE kernel and MATLAB Engine. In order to show the generality of the proposed scheme, the limitations of the available SiL schemes in the literature are addressed in this paper. Additionally, all technical details for establishing the connection between FEM and MATLAB are provided for the interested reader. Finally, two numerical sub-problems are defined for offline and online post-processing, i.e., offline optimization and closed-loop system performance analysis in control theory.

• 한국재료학회지
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• 제22권9호
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• pp.482-488
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• 2012

To fabricate a precise micro metal mold, the electrochemical etching process has been researched. We investigated the electrochemical etching process numerically and experimentally to determine the etching tendency of the process, focusing on the current density, which is a major parameter of the process. The finite element method, a kind of numerical analysis, was used to determine the current density distribution on the workpiece. Stainless steel(SS304) substrate with various sized square and circular array patterns as an anode and copper(Cu) plate as a cathode were used for the electrochemical experiments. A mixture of $H_2SO_4$, $H_3PO_4$, and DIW was used as an electrolyte. In this paper, comparison of the results from the experiment and the numerical simulation is presented, including the current density distribution and line profile from the simulation, and the etching profile and surface morphology from the experiment. Etching profile and surface morphology were characterized using a 3D-profiler and FE-SEM measurement. From a comparison of the data, it was confirmed that the current density distribution and the line profile of the simulation were similar to the surface morphology and the etching profile of the experiment, respectively. The current density is more concentrated at the vertex of the square pattern and circumference of the circular pattern. And, the depth of the etched area is proportional to the current density.