• 대한산업공학회지
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• 제29권1호
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• pp.21-31
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• 2003

Determination of operational dimensions and tolerances is complex if there exist inconsistencies between operational and design specifications. Dimension and tolerance charts (D&T charts) have been used to establish the relationships among operational dimensions in complex machining. This chart proves that individual operations can be harmonized when they are interconnected. However, it is hard to generate the chart manually. Because operational dimensions and tolerances must meet the design specifications, the dimensions and tolerances of interconnected operations have to be verified serially for economical operations. In this paper, the chart is automatically generated from the interconnected operations. More importantly, all operational dimensions and tolerances displayed in the chart have been verified by using LP to meet the design specifications. Finally, the chart is converted to an operational routing sheet that contains a detailed process plan along with cutting speed, feed rate, and operational references based on material hardness, surface finish, and tool nose radius.

• Steel and Composite Structures
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• 제34권5호
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• pp.681-698
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• 2020

The paper addresses contribution to the modeling and optimization of major machinability parameters (cutting force, surface roughness, and tool wear) in finish dry hard turning (FDHT) for machinability evaluation of hardened AISI grade die steel D₃ with PVD-TiN coated (Al₂O₃-TiCN) mixed ceramic tool insert. The turning trials are performed based on Taguchi's L₁₈ orthogonal array design of experiments for the development of regression model as well as adequate model prediction by considering tool approach angle, nose radius, cutting speed, feed rate, and depth of cut as major machining parameters. The models or correlations are developed by employing multiple regression analysis (MRA). In addition, statistical technique (response surface methodology) followed by computational approaches (genetic algorithm and particle swarm optimization) have been employed for multiple response optimization. Thereafter, the effectiveness of proposed three (RSM, GA, PSO) optimization techniques are evaluated by confirmation test and subsequently the best optimization results have been used for estimation of energy consumption which includes savings of carbon footprint towards green machining and for tool life estimation followed by cost analysis to justify the economic feasibility of PVD-TiN coated Al₂O₃+TiCN mixed ceramic tool in FDHT operation. Finally, estimation of energy savings, economic analysis, and sustainability assessment are performed by employing carbon footprint analysis, Gilbert approach, and Pugh matrix, respectively. Novelty aspects, the present work: (i) contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-60 HRC, (ii) demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing ceramic tool in hard turning processes considering technological, economical and ecological aspects, which are helpful and efficient from industrial point of view, (iii) provides environment friendliness, cleaner production for machining of hardened steels, (iv) helps to improve the desirable machinability characteristics, and (v) serves as a knowledge for the development of a common language for sustainable manufacturing in both research field and industrial practice.

• 한국도로학회논문집
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• 제10권3호
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• pp.97-107
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• 2008

고속도로 및 국도 등의 인터체인지 유출부에 대한 설계기준과 연구 내용은 주로 변이구간, 감속차로, 곡선반경, 유출각 및 노즈부의 형상 등 자동차와 도로 기하구조간의 운동역학적인 관점의 안전성 확보만 주요 관심사였다. 따라서 본 연구에서는 차량 주행속도 특성에 초점을 맞추어 첫째 현행 설계기준의 이론적 의미를 해석하고, 둘째, 유출부 완화곡선에서 차량의 주행속도 및 교통사고 특성을 살펴보았고, 셋째, 기존의 인터체인지 유출 램프부 최소곡선반경의 부적합성을 검토한 후 운전자의 완화 곡선부 주행특성에 맞는 새로운 완화곡선 설계방법을 제시하였고 그 결과를 산출하여 기존방법과 비교 검토한 결과 유출램프 완화 곡선부 설계속도 50km/h, 40km/h의 경우기존의 원심력과 구심력이 평형을 이루는 최소곡선반경에서 관성력이 커져 교통사고의 위험이 높아진다는 것을 확인할 수 있었고 새로이 제안한 감속주행 완화곡선에서는 기존의 완화곡선보다 관성력이 작아지고 곡선은 커져 기존보다 안전한 곡선으로 확인되었다.