• Structural Engineering and Mechanics
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• v.89 no.5
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• pp.467-477
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• 2024

Manufacturing industries, now-a-days, focus mostly on redesigning of the products for reducing cost and lead-time via detailed analysis of its composition and constructional design regarded as the Reverse Engineering (RE) process that involves the acquisition of relevant data of the original product, analysis for its functional use and finally, reproduction of the design for improving the functionality. In the present work, a new model based on optimization at different steps of RE, is proposed to redesign a structural component, which is subjected to severe tensile stress while in service. The component under study is an accessory namely, hitch bracket, attached to the rear axle of a tractor to connect it to the plough. The methodology includes building of a 3D Computer Aided Design (CAD) model from the scanned data of the existing component with the help of 3D scanner. Computer Aided Engineering (CAE) analysis is carried out on the CAD model with existing load conditions by Finite Element Analysis (FEA). Topological optimization is carried out giving rise to a modified/optimized design of the component. It is observed that the performance of the modified component improves significantly with simultaneous weight reduction without affecting its functional use and the manufacturing process setup.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.6
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• pp.117-124
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• 2017

In this study, we investigated the optimization of process conditions by using the Six Sigma process, design of experiment (DOE) method and response surface method (RSM) to resolve dimensional deviation and appearance problems arising from the shortened process time of the mobile phone rear cover. The analysis of the trivial many was performed by 2-sample T-test and cooling time, and mold temperature and packing pressure were selected as the vital fews affecting the overall width of the product. The optimal conditions of the process were then studied using the DOE and the RSM. We analyzed the improvement effects by applying the selected optimal conditions to the production process and the results showed that the difference between the mean value and target value of the overall width stood at 0.01 mm, an improvement of 88.89% compared to current process that fell within the range of standard dimension. The short-term process capability stood at $4.77{\sigma}$, which implied an excellent technology level despite a decrease by $0.22{\sigma}$ compared to the current process. The difference in process capability decreased by $2.44{\sigma}$ to $0.41{\sigma}$, showing a significant improvement in management capability. Ultimately, the process time of the product was shortened from 18.3 seconds in the current process to 13.65 seconds, resulting in a 34.07% improvement in production yield.

• Journal of the Korean Society for Precision Engineering
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• v.6 no.4
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• pp.71-83
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• 1989

The optimization in the machining process has been a long-standing goal of the manufacturing community. The optimization is composed of two main subjects;one is to select an optimum cutting condition, and the other is to detect the emergency situation and take necessary actions in real-time base. This paper proposes a reliable and practical guide system whose purpose is the optimization of cutting conditions, and the detection of tool failure in the machining process. The optimal cutting conditions are determined through the estimation of tool wear rate and the establishment of access- ible field from the measured cutting temperature and force. Tool breakage is detected by the normal force component acting on minor flank face extracted from on-line sensed feed force and radial force. In experiments, the proposed guide system has proved availability for the decision of reliable cutting conditions for the given tool-work system and the detection of tool breakage in ordinary cutting environments.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.5
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• pp.107-112
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• 2015

Increased productivity and cost reduction have emerged as the main goals of the industry due to the development of the machinery industry, and mechanical materials with excellent properties with the development of the machine tool industry are widely used in machine parts or structures. In addition, the cutting process of production plays a pivotal role in the production technology. Studies on cutting have involved a lot of research on the material, the cutting tool, the processing conditions, and numerical analysis. Due to the development of the computer through numerical analysis, cutting conditions, the assessment of cutting performance, and cutting quality could be predicted. This research uses the creation of the material model and AdvantEdge Production module for the NC code analysis. To improve the productivity, this research employs the optimization method to reduce cutting time.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.55-61
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• 2012

The structure of winch brake disk was successfully designed and developed based on sizing optimization. In this research, static analysis was performed by commercial software ANSYS v12.0. To simulate the working process of disk brake, the real properties of materials and working conditions were considered. Based on the results of the static structural analysis, the existing designs of the brake discs were optimized. Among existing designs, there are three cases that have achieved an efficient light weight around 200g. As a result, the optimized weight of each case was 3.41kg, 3.42kg, and 3.44kg, respectively. Finally, through prototyping and performance testing, the stability of the optimized brake disc was verified. Although, this free-fall winch brake disk had been developed in design and evaluation techniques, more detailed plans for developing the disk brake structure were also proposed as a further study based on this research.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.1
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• pp.63-69
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• 2017

The golden section search method is widely used to optimize a single design variable in many fields due to its superior advantages of search. In this paper, a new direct search method is proposed by modifying the search structure of the golden section search method; thus, it can be adapted in the optimization of a single design variable for the injection molding process. This proposed method is applied to determine an optimal gate position for the injection molding of a bezel of an automated teller machine for minimizing the injection pressure. Thus, an optimal gate position where the injection pressure is decreased by 4.5 MPa to that of the initial position was obtained with a small number of simulations. It is anticipated that the current proposed search method can be utilized as a practical tool for optimizing single variables for injection molding design.

• Journal of Korean Institute of Industrial Engineers
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• v.18 no.1
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• pp.47-62
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• 1992

This paper describes a procedure for optimizing the route selection and production conditions in alternate process plans under a cellular manufacturing environment. The type of production is mainly production-to-order which deals with unexpected products as the changes factor. The flexible cellular manufacturing can be viewed as a complete unification of both flexible manufacturing process and flexible production management. The integrated problem for designing flexible cellular manufacturing associated with determining the optimal values of the machining speeds, overtime, and intercell flow is formulated as Nonlinear Mixed Integer Programming(NMIP) in order to minimize total production change cost. This is achieved by introducing the marginal cost analysis into the NMIP, which will compute the optimal machining speed, overtime, intercell flow, and routing. The application of this procedure offers greater flexibility to take advantage of the cellular manufacturing due to the optimum use of resources. A solution procedure for this problem was developed and a numerical example is included.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.19 no.4
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• pp.469-475
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• 2010

The objective of this study is to integrate reliability analysis into shape optimization problem using the evolutionary structural optimization (ESO) in the application example. Reliability-based shape optimization is formulated as volume minimization problem with probabilistic stress constraint under minimization max. von Mises stress and allow stress. Young's modulus, external load and thickness are considered as uncertain variables. In order to compute reliability index, four methods, i.e., reliability index approach (RIA), performance measure approach (PMA), single-loop singlevector (SLSV) and adaptive-loop (ADL), are used. Reliability-based shape optimization design process is conducted to obtain optimal shape satisfying max. von Mises stress and reliability index constraints with the above four methods, and then each result is compared with respect to numerical stability and computing time.

• Industrial Engineering and Management Systems
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• v.4 no.1
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• pp.54-67
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• 2005

This paper provides an evaluation of an optimization-based, multiple-input double-output (MIDO) run-to-run (R2R) control scheme for general semiconductor manufacturing processes. The controller in this research, termed adaptive dual response optimizing controller (ADROC), can serve as a process optimizer as well as a recipe regulator between consecutive runs of wafer fabrication. In evaluation, it is assumed that the equipment model could be appropriately described by a pair of second-order polynomial functions in terms of a set of controllable variables. Of practical relevance is to consider a drifting effect in the equipment model since in common semiconductor practice the process tends to drift due to machine aging and tool wearing. We select a typical application of R2R control to chemical mechanical planarization (CMP) in semiconductor manufacturing in this evaluation, and there are five different CMP process scenarios demonstrated, including mean shift, variance increase, and IMA disturbances. For the controller, ADROC, an on-line estimation technique is implemented in a self-tuning (ST) control manner for the adaptation purpose. Subsequently, an ad hoc global optimization algorithm based on the dual response approach, arising from the response surface methodology (RSM) literature, is used to seek the optimum recipe within the acceptability region for the execution of next run. The main components of ADROC are described and its control performance is assessed. It reveals from the evaluation that ADROC can provide excellent control actions for the MIDO R2R situations even though the process exhibits complicated, nonlinear interaction effects between control variables, and the drifting disturbances.

• Korean Journal of Computational Design and Engineering
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• v.15 no.5
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• pp.325-332
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• 2010

A lens system for mobile phone cameras is comprised of various lenses and designed so as to satisfy design requirements for responses such as a modular transfer function (MTF). However, it is difficult to manufacture and assemble camera modules to maintain the same performance compared with the designed camera modules, because of uncertainty. We should always design a lens system by considering uncertainty that can be caused by errors in the manufacturing and assembly process of mobile phone cameras. The robust optimization offers tools of making robust decisions with the consideration of design parameters, uncontrollable parameters, and the variance of the system. Using an efficient reliability analysis method and an optimization algorithm, we obtained robust optimization results that maximize the mean of MTF and minimize the standard deviation and proposed a new robust design process for a lens system.