• Transactions of Materials Processing
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• v.31 no.3
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• pp.143-150
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• 2022

The purpose of this study was to investigate an innovative hydroforming process for the cost-effective manufacturing of double layered tube with circumferentially corrugated patterns. Conventional double pipe heat exchanger has relatively poor heat transfer efficiency because of the limited contact area resulting from the concentrically arranged simple cylindrical structure. As a promising alternative to enhance heat transfer efficiency, double layered tube with corrugated internal pattern was considered in this study. To fabricate corrugated inner tube, innovative tube hydroforming system was developed. The customized loading paths were established using the simulated forming pressure and contracting stroke at various bar diameters. Experimentally obtained cross-sectional profiles were analyzed to evaluate the reliability and applicability of the hydroformed tube with various patterns. The results demonstrate that the proposed hydroforming process can be a feasible alternative for manufacturing high-performance double-tube heat exchangers.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.8
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• pp.76-83
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• 2010

Metallic sandwich panels with pyramidal truss structures are high-stiffness and high-strength materials with low weight. In particular, bulk structures have enough space for additional multi-functionalities. In this work, in order to fabricate 3-D structures efficiently, Layered Manufacturing Method (LMM) which was composed of three steps, including crimping process, stacking process and bonding process using rapid infrared brazing, was proposed. The joining time was drastically reduced by employing infrared brazing of which heating rate and cooling rate were faster than those of conventional furnace brazing. By controlling the initial cooling rate slowly, the bonding strength was improved up to the level of strength by conventional vacuum brazing. The observation of infrared brazed specimens by optical microscope and SEM showed no defect on the joining sections. The experiments of 1-layered pyramidal structures and 2-layered pyramidal structures subject to 3-point bending were conducted to determine structural advantages of multilayered structures. From the results, the multi-layered structure has superior mechanical properties to the single-layered structure.

• Korean Journal of Computational Design and Engineering
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• v.11 no.3
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• pp.223-233
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• 2006

Layered manufacturing(LM) is emerging as a new technology that enables the fabrication of three dimensional heterogeneous objects such as Multi-materials and Functionally Gradient Materials (FGMs). Among various types of heterogeneous objects, more attention has recently paid on the fabrication of FGMs because of their potentials in engineering applications. The necessary steps for LM fabrication of FGMs include representation and process planning of material information inside an FGM. This paper introduces a new process planning algorithm that takes into account the processing of material information. The detailed tasks are discretization (i.e., decomposition-based approximation of volume fraction), orientation (build direction selection), and adaptive slicing of heterogeneous objects. In particular, this paper focuses on the discretization process that converts all of the material information inside an FGM into material features like geometric features. It is thus possible to choose an optimal build direction among various pre-selected ones by approximately estimating build time. This is because total build time depends on the complexity of features. This discretization process also allows adaptive slicing of heterogeneous objects to minimize surface finish and material composition error. In addition, tool path planning can be simplified into fill pattern generation. Specific examples are shown to illustrate the overall procedure.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.2
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• pp.8-14
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• 2014

Many kinds of robots and machines have been developed to replace human laborin industrial and medical fields, as well as domestic life. In these applications, the device sneed to obtain environmental data using diverse sensors. Among such sensors, the tactile sensor is important because of its ability to get information regarding surface texture and force through the use of mechanical contact. In this research, a simple tactile sensor was developed using the direct writing of pressure sensitive material and layered fabrication of photocurable material. The body of the sensor was fabricated using layered fabrication, and pressure sensitive materials were dispensed between the layers using direct writing. We examined the line fabrication characteristics of the pressure sensitive material according to nozzle dispensing conditions. A simple $4{\times}4$ array flexible tactile sensor was successfully fabricated using the proposed process.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.6 s.183
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• pp.187-195
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• 2006

FDM, SLS, and EOS processes are the layered manufacturing processes far functional prototypes. In this paper, bench mark tests of those processes were carried out using various materials. The test includes mechanical properties, such as tensile and compressive strengths, hardness, impact strength, and heat resistance, and surface roughness, shape and dimensional accuracy, manufacturing time, and manufacturing costs. It is verified that SLS method is advantageous in surface roughness and manufacturing time, EOS method in shape accuracy, and FDM method is great in manufacturing costs.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.1 s.256
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• pp.113-120
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• 2007

Design optimization of layered plates bonding process is conducted by considering uncertainties in a manufacturing process, in order to reduce the crack failure arising due to the residual stress at the surface of the adherent which is caused by different thermal expansion coefficients. Robust optimization is peformed to minimize the mean as well as its variance of the residual stress, while constraining the distortion as well as the instantaneous maximum stress under the allowable reliability limits. In this optimization, the dimension reduction (DR) method is employed to quantify the reliability such as mean and variance of the layered plate bonding. It is expected that the DR method benefits the optimization from the perspectives of efficiency, accuracy, and simplicity. The obtained robust optimal solution is verified by the Monte Carlo simulation.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2006.04a
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• pp.836-840
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• 2006

Design optimization of layered plates bonding process is conducted to achieve high product quality by considering uncertainties in a manufacturing process. During the cooling process of the sequential sub-processes, different thermal expansion coefficients lead to residual stress and displacement. thus resulting in defects on the surface of the adherent. So robust process optimization is performed to minimize the residual stress mean and variation of the assembly while constraining the distortion as well as the instantaneous maximum stress to the allowable limits. In robust process optimization, the dimension reduction (DR) method is employed to quantify both reliability and quality of the layered plate bonding. Using this method. the average and standard deviation is estimated. Response surface is constructed using the statistical data obtained by the DRM for robust objectives and constraints. from which the optimum solution is obtained.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.4
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• pp.97-103
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• 2012

This study investigates thermal insulation properties of multi layer materials depending on thickness of air layers. Numerical analysis on the heat flow of different insulating materials was conducted to identify whether their temperature distributions demonstrate the reduced rate of heat transfer conclusively or not. Analytical model is divided into two categories. One is to distinguish temperature distribution of the air-layer materials from the non-air layer ones. The other is to compare the efficacy between eight-layered insulating materials with no air-layer contained and three-layered insulating materials which include an air-layer definitely. In the latter case, the identical thickness is assigned to each material. The effect of thermal insulation by including an air-layer is verified in the first analytical model. The result of the second model shows that the insulation of the eight-layered materials is coterminous at the three-layered ones with an air-layer and the thermal insulation of the two materials is imperceptible. The benefits of cost and energy saving are anticipated if air-layers are efficiently incorporated in multi layer insulating materials in a greenhouse.

• Transactions of Materials Processing
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• v.22 no.1
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• pp.17-22
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• 2013

Tube hydroforming is a technology that utilizes hydraulic pressure to form a tube into desired shapes inside die cavities. Due to its advantages, such as weight reduction, increased strength, improved quality, and reduced tooling cost, single-layered tube hydroforming is widely used in industry. However in some special applications, it is necessary to produce multi-layered tubular components which have corrosion resistance, thermal resistance, conductivity, and abrasion resistance. In this study, a hollow forming process to fabricate a part from multi-layered tubes for structural purposes is proposed. To accomplish a successful hydroforming process, an analytical model that predicts optimal load path for various parameters such as tube material properties, thickness of tubes, diameter of holes and the number of holes was developed. Tubular hydroforming experiments to fabricate a hollow part were performed and the optimal loading path developed by the analytical model was successfully verified. The results show that the proposed hydroforming process can effectively produce hollow parts with multi-layered tube without defects such as wrinkling or fracture.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2003.05a
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• pp.1048-1055
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• 2003

This paper proposes a new method of solving integrated problems that consist of several sub-problems in a symmetric multi-layered structure, and also demonstrate the applicability of the method. The proposed method is named Symmetric Multi-layered Coevolutionary Algorithm (SMCA). The SMCA imitates partly the natural process of endosymbiotic evolution, which is a special type of coevolution. The SMCA is applied to the process planning problem in flexible manufacturing system (FMS), taking account of the flexibility of machine, tool, process, and sequence. To do this, SMCA's components are studied and its strategies are developed to improve the performance. The proposed algorithm is compared with the existing ones in terms of solution quality. The experimental results confirm the effectiveness of our approach.