• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.4
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• pp.104-112
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• 2017

In the sand casting process, the flow of liquid metal affects the quality of casting products and their die life. To determine the optimal bush part design process, this study performed various analyses using commercial finite element analysis S/W. The simulation focused on the molten metal behaviors during the mold filling and solidification stages of sand casting. This study aims to develop methods to reduce the cost and increase the tool life of the continuous hot zinc plating roll.

• Journal of Korea Foundry Society
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• v.13 no.1
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• pp.81-93
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• 1993

It is well-known that the analysis of elasto-plastic thermal stress and deformation are substantially important in optimal design of metal casting mould. The unsteady state thermal stress and deformation generated during the solidification process of ingot and mould have been analyzed by two dimensional thermal elasto-plastic theories. Distributions of temperature, stress and relative displacement of the mould are calculated by the finite element method and compared with experimental results. In the elasto-plastic thermal stress analysis, compressive stress occurred at the inside wall of the mould whereas tensile stress occurred at outside wall. A coincidence between the analytical and experimental results is found to be fairly good, showing that the proposed analytical method is reliable.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.2
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• pp.114-120
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• 2008

This study is to compare and analyze the material flow, deformation characteristics, and forming load of flange by means of similitude experimental method of model material using plasticine. In order to find optimal forming conditions, prototype experiments were designed to investigate forming characteristics of general-purpose flange under various working conditions. As a result of prototype experiments, billet thickness and gap-height ratio was found to be the most influential experimental parameter in flange forming. Forming loads from prototype experiments were compared to the results of finite element analysis after conducting estimation of forming loads of real material. Results of prototype experiments based on model material techniques are expected to be used as a basic data of die design f3r the development of products and process.

• Design & Manufacturing
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• v.17 no.1
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• pp.27-32
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• 2023

In this paper, we intend to predict the mass of the spiral using CAE and machine learning. First, We generated 125 data for the experiment through a complete factor design of 3 factors and 5 levels. Next, the data were derived by performing a molding analysis through CAE, and the machine learning process was performed using a machine learning tool. To select the optimal model among the models learned using the learning data, accuracy was evaluated using RMSE. The evaluation results confirmed that the Support Vector Machine had a good predictive performance. To evaluate the predictive performance of the predictive model, We randomly generated 10 non-overlapping data within the existing injection molding condition level. We compared the CAE and support vector machine results by applying random data. As a result, good performance was confirmed with a MAPE value of 0.48%.

• Transactions of Materials Processing
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• v.4 no.3
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• pp.214-221
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• 1995

In the paper, we have proposed a new method to determine the initial billet for the forged products using a function approximation in the neural network. The architecture of neural network is a three-layer neural network and the back propagation algorithm is employed to train the network. By utilizing the ability of function approximation of a neural network, an optimal billet is determined by applying the nonlinear mathematical relationship between the aspect ratios in the initial billet and the final products. The amount of incomplete filling in the die is measured by the rigid-plastic finite element method. The neural network is trained with the initial billet aspect ratios and those of the unfilled volumes. After learning, the system is able to predict the filling regions which are exactly the same or slightly different to the results of finite element simulation. This new method is applied to find the optimal billet size for the plane strain rib-web product in cold forging. This would reduce the number of finite element simulation for determining the optimal billet size of forging product, further it is usefully adapted to physical modeling for the forging design.

• Design & Manufacturing
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• v.16 no.4
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• pp.17-23
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• 2022

Recently, several studies are being conducted to achieve a curvature of 180° or more for the edge of the display glass. The thermocompression molding process is applied to the manufacture of curved glass, and high hardness G5 graphite is used as the mold material to withstand the impact applied to the mold. G5 graphite has high hardness and strong brittleness, which makes tool wear and surface damage easy during machining. Therefore, the demand for diamond-coated tools with good mechanical properties is increasing in the G5 machining field. In this study, the optimal cutting conditions and machinability of a nanodiamond (NCD) coated ball end mill being developed by a tool manufacturer were analyzed and evaluated. For this purpose, the same test was performed on the microdiamond (MCD) coated ball end mill and compared together. In summary, the machinability of MCD and NCD coated tools showed better cutting performance at a cutting speed of 282 m/min, a feed rate of 1,400 mm/min, and a radial depth of cut of 0.08 to 0.1 mm.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.6
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• pp.73-81
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• 2014

In this paper, multiple gate locations and process conditions under concern are automatically optimized by considering robustness to minimize the injection pressure required to mold an automotive dashboard. Computer simulation-based experiments using orthogonal arrays(OA) and a design-range reduction algorithm are consolidated into an iterative search scheme, which is then used as a tool for the optimization process. The robustness of a design is evaluated using an OA-based simulation of process fluctuations due to noise as well as the signal-to-noise ratio. The optimal design solution for the automotive dashboard shows that the robustness of the injection pressure is significantly improved when compared to the initial design. As a result, both the die clamping force and the pressure distribution in the part cavity are also much improved in terms of their robustness.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.8
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• pp.1468-1484
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• 1992

In the present paper forward projection is proposed as a new approach to determine the preform shape in rib-web type forging. In the forward projection technique an optimal billet is determined by applying some mathematical relationship between geometrical trials in the initial billet shape and the final products. In forward projection a volume difference between the desired product shape and the final computed shape obtained by the rigid-plastic finite element method is used as a measure of incomplete filling of working material in the die. At first linear inter-/extrapolation is employed to find a proper trial shape for the initial billet and the method is successfully applied to some cases of different aspect ratios of the initial billet. However, when the initial guesses are not sufficiently near the optimal value linear inter-/extrapolation does not render complete die filling. For more general application, a fuzzy system is used in the forward projection technique in order to determine the initial billet shape for rib-web type forging. It has been thus shown that the fuzzy system is more reliable for the preform design in the rib-web type forging process.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.10 no.10
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• pp.2577-2582
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• 2009

A rivet which can fasten two parts is one of an important mechanical elements. In this study, the process design of a blind revet is implemented using finite element method in order to manufacture it which can resist high vibration and has strong coherence between two parts. Considering plastic flow, ease of manufacture, high strength, material loss, and so forth, an optimal four-stage process is proposed by finite element analysis and process design rules. In addition, the finite element simulation results such as shape of the forged rivet, strain distribution and forging load are investigated for the usefulness of the forging process of the blind rivet. These results will be contributed to the forging process design and the die design of the blind rivet.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.2
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• pp.177-185
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• 2001

This study shows the process design and forming analysis of permalloy shielding can that support the automobile multi-display parts to indicate the accurate information of car. This study is particularly important, since the strain and thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite thickness of permalloy shielding can is known to affect the magnetic properties such as coercivity and permeability quite sensitively. The objective functions are strain and thickness deviation. The punch radius, die radius and blank holding force are considered as design parameters. Orthogonal array (OA) table and characteristics are applied to neural network (NN) as train data. After training, the optimal and robust condition of design parameters is selected. This study shows the correlation between the design methodology of NN and the statistical design of experiments (DOE) approach.