• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.419-422
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• 2005

Many process parameters have an effect on the auto-body panel forming process. A well-designed blank shape causes the material to flow smoothly, reduces the punch and yields a product with uniform thickness distribution. Therefore, the determination of an initial blank shape plays the important role of saving time and cost in the auto-body panel forming process. For these reasons, some approaches to estimate the initial blank shape have been implemented in this paper, the one-step approach by using a finite element inverse method will be introduced to predict the initial blank shape the developed program is applied to auto-body panel forming.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2006.04a
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• pp.299-306
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• 2006

Using a level set method and topological derivatives, a topological shape optimization method that is independent of an initial design is developed for linearly elastic structures. In the level set method, the initial domain is kept fixed and its boundary is represented by an implicit moving boundary embedded in the level set function, which facilitates to handle complicated topological shape changes. The 'Hamilton-Jacobi (H-J)' equation and computationally robust numerical technique of 'up-wind scheme' lead the initial implicit boundary to an optimal one according to the normal velocity field while minimizing the objective function of compliance and satisfying the constraint of allowable volume. Based on the asymptotic regularization concept, the topological derivative is considered as the limit of shape derivative as the radius of hole approaches to zero. The required velocity field to update the H -J equation is determined from the descent direction of Lagrangian derived from optimality conditions. It turns out that the initial holes is not required to get the optimal result since the developed method can create holes whenever and wherever necessary using indicators obtained from the topological derivatives. It is demonstrated that the proper choice of control parameters for nucleation is crucial for efficient optimization process.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.208-213
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• 2003

The methodology to design initial blanks considering the reduction of both springback and flange trimming amounts is studied. Three dimensional forming analysis of a trial blank Is first carried out using FEM and the tentative Initial blank shape is then determined by cutting the outer edge of the trial blank whose shape is nearly matched with the trimming line. During the shaping the blank edge, tile movement of blank outer line is described with random variables to reduce the sensitivity of initial blank geometry. After performing 2-D FEM forming and springback simulations for selected sections and optimizing the trimming and springback amounts in terms of section length of the blank, the initial blank is finally determined. In order to see tile springback reduction in the initial blank determined by the proposed method, a stepped s-rail is stamped and the sppingback is measured. The springback of newly designed initial blank of stopped s-tail is tremendously reduced.

• Transactions of Materials Processing
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• v.7 no.3
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• pp.260-273
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• 1998

A new blank design method is proposed to predict the optimum initial blank shape in the sheet metal forming process. The rollback method for blank shape design takes the difference between final deformed shaped and target contour shape into account. Based on the method a computer program composed of blank design module FE-analysis program and mesh generation module is developed. The rollback method is applied to square cup drawing process with the flange of unifiorm size around its periphery to confirm its validity. The optimum initial blank shape is obtained from an arbitrary square blank after three modification. Good agreements are recognized between the numerical results and the published results for initial blank shape and thickness strain distribution. The optimum blank shape for two parts of automobile sub-frame is designed, The thickness distribution and the level of punch load is improved. Also the method is applied to design the weld line in the tailor-welded blank. It is concluded that the rollback method is an effective and convenient method for an optimum blank shape design.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 1998.04a
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• pp.175-182
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• 1998

The object of this study is shape finding and cutting pattern generation of membrane structures under the following assumptions : (1) material is linearly elastic (2) stress state is plane stress. Cable and membrane structures should introduce the nonlinear analysis considering geometric nonlinearity because these structures deform largely under the external loads. The analysis procedure is consisted of three steps considering geometric nonlinearity unlike any other structures. First step is the shape finding analysis to determine the initial equilibrium shape. Second step is the stress-deformation analysis to investigate the behaviors of structures under various external loads. Once a satisfactory shape has been found, a cutting pattern based on the shape finding analysis may be generated from the view point of construction. In this paper, (1) shape finding analysis formulation and an example, (2) cutting pattern determination procedure using weighted least-square minimization flattening method and some results are presented.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.2
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• pp.86-93
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• 2010

The tilting index table has attached to CNC machining center with 3axes, it can be improvement of its performance and its machining efficiency. The tilting index table is a key unit in order to manufacture some non-rotational and 3-dimensional parts, using the conventional machining center. In this study, structural analysis is carried out by FEM simulation using the commercial software ANSYS Workbench 11 to develop tilting index table using direct drive motor. The shape of the tilting index table obtained from the optimization was analyzed and compared with the initial model. Also, the initial model was modified based on the optimization model and the result was verified to have the acceptable improvement.

• Journal of Korean Society on Water Environment
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• v.24 no.6
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• pp.793-800
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• 2008

Recently domestic drinking water industry has recognized membrane-based technology as a promising alternative for water treatment. To ensure successful application of membrane processes, the integrity of membrane systems should be maintained. According to US EPA guidance, the pressure decay test based on the bubble point theory is recommended to detect any membrane defection of which size is close to the smallest diameter of Cryptosporidium oocysts, $3{\mu}m$. Proper implementation of the pressure decay test is greatly affected by initial test pressure, and the interpretation of the test results is associated with upper control limit. This study is conducted to investigate various factors affecting determination of initial test prtessure and upper control limit, including membrane-based parameters such as pore shape correction factor, surface tension and contact angle, and system-based parameters, such as volumetric concentration factor and total volume of system. In this paper, three different hollow fibers were used to perform the pressure decay test. With identical initial test pressure applied, their pressure decay tendency were different from each other. This finding can be explained by the micro-structure disparity of those membranes which is verified by FESEM images of those membranes. More specifically, FESEM images revealed that three hollow fibers have asymmetry, deep finger, shallow finger pore shape, respectively. In addition, sensitivity analysis was conducted on five parameters mentioned above to elucidate their relation to determination of initial test pressure and upper control limit. In case of initial pressure calculation, the pore shape correction factor has the highest value of sensitivity. For upper control limit determination, system factors have greater impact compared to membrane-based parameters.

• Journal of Korean Association for Spatial Structures
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• v.10 no.2
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• pp.45-60
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• 2010

Nonlinear problems for membrane structures are very sensitive in convergence procedure in nonlinear iterations. Therefore many researchers have suggested a lot of ideas in published papers. In this study, authors are trying to get easier solution for taking membrane shape by initial stresses from substitution of the membrane to line elements. To obtain nonlinear stiffness, the nonlinear finite element method is used for both membrane and cable elements, and only geometric nonlinear terms are taken for shape analysis. By some examined models, we can find that the substituted models show better results to get, initial shape in which the concentrating phenomenon is removed at edge parts.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.4
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• pp.118-124
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• 2016

In this paper, the model to develop the forming process for turbine seal is suggested. And numerical approach for the shape design of the turbine seal is examined. Because of the thin thickness of the turbine seal, the seal is easily fractured in the manufacturing process. The main factors of the seal manufacturing consist of addendum angle and dedendum angle, fillet on the addendum face, number of the gear teeth, sheet initial location and gear initial location, rake and vertical clearance. The structure and shape of seal are modeled using the commercial 3D mechanical design program, CATIA(V5/R20). Also, rolling process to manufacture the turbine seal is analyzed using DEFORM$^{TM}$-3D(V11), commercial forming analysis software and runs under PC workstation. This study focused on the shape design of turbine seal. Through this research, the main factors to make the turbine seal for airplane turbine engine can be obtained. This study results are reflected to the shape design for turbine seal.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 1998.10a
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• pp.266-273
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• 1998

The object of this study is shape finding and cutting pattern generation of membrane structures under the following assumptions: (1) material is linearly elastic (2) stress state is plane stress. Cable and membrane structures should introduce the nonlinear analysis considering geometric nonlinearity because these structures deform largely under the external loads. The analysis procedure is consisted of three steps considering geometric nonlinearity unlike any other structures. First step is the shape finding analysis to determine the initial equilibrium shape. Second step is the stress-deformation analysis to investigate the behaviors of structures under various external loads. Once a satisfactory shape has been found, a cutting pattern based on the shape finding analysis may be generated from the view point of construction. In this paper, after shape finding analysis, cutting pattern determination procedure using weighted least-square minimization flattening method and some results are presented.