• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.476-479
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• 2005

In this study, the process parameters in powder compaction are optimized for getting high relative densities. To find optimized parameters, the analytic models of powder compaction are firstly prepared by 2-dimensional rod arrays with random green densities using a quasi-random multi-particle array. Then, using finite element method, the changes in relative densities are analyzed by varying the size of the particle, the amplitude of cyclic compaction, and the coefficient of friction, which influence the relative density in cyclic compactions. After the analytic function of relative density associated process parameters are formulated by aid of the response surface method, the optimal conditions in powder compaction process are found by the grid search method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.441-444
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• 2009

In this research, a hot and cold combined forging process for manufacturing net-shape one-way clutch bearing outer race of an automobile automatic transmission unit is developed. The process is composed of hot forging for manufacturing an optimized gear-like perform and precision cold forging for sizing the perform into final net-shape product. Finite element simulation techniques are applied to find the optimized process designs including blank and die shapes. The predictions and experiments are compared, revealing that they are in good agreement with each other. The dimensional test showed that the important dimensional requirements on gear tooth-like shape of the forged product were fulfilled.

• Journal of Applied Reliability
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• v.15 no.4
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• pp.248-255
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• 2015

Purpose : The purpose of this research is to develop the optimized method and process in the reliability-growth target setting, especially for complex and repairable system (or products) such as vehicle and airplane, construction equipment. Method : A reliability-growth test plan specifies a scenario to achieve the planned reliability value (or reliability target). The major elements in test planning are reliability-growth starting time and reliability level at that time, reliability-growth rate and reliability-growth target. All of them except a reliability target can be referred to the previous development data and reference researches. The reliability target level is directly influencing to test period (or time) which is related to test and warranty cost together. There are a few researches about the reliability target setting method and but showing the limitations to consider the views of engineering, business and customer together. There is no research how to handle the target setting process in detail. Result : We develop the optimized method and systematic process in reliability target setting with considering such views. This research also establish the new concept as production capability which means company (or supplier) capability to product its products. Conclusion : In this research result, we apply the new method to a few projects and can set the reasonable test planning. The developing results is showing the good balance between the developing cost and warranty cost at market.

• Proceedings of the Materials Research Society of Korea Conference
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• 2011.10a
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• pp.24.2-24.2
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• 2011

Ru is used as a bottom electrode capacitor in dynamic random access memories (DRAMs) and ferroelectric random access memories (FRAMs). The surface of the Ru needs to be planarized which is usually done by chemical mechanical polishing (CMP). Ru CMP process requires chemical slurry consisting of abrasive particles and oxidizer. A slurry containing NaIO4 and alumina particles is already proposed for Ru CMP process. However, the stability of the slurry is critical in the CMP process since if the particles in the slurry get agglomerated it would leave scratches on the surface being planarized. Thus, in the present work, the stability behavior of the slurry using a suitable anionic polyelectrolyte is investigated. The parameters such as slurry pH, polyelectrolyte concentration, adsorption time and the sequence of addition of chemicals are optimized. The results show that the slurry is stable for longer time at an optimized condition. The polishing behavior of the Ru using the optimized slurry is also investigated.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.1
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• pp.123-129
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• 2015

In general, recent critical studies of five-axis machine have tended to center on the question of effective machining to realize complex shape parts. However, the hydrostatic bearing and journal bearing, both of which are involved in the complex process of dividing the processing of internal precision-shape machining, must be optimized. Although the angle head is designed to machine the internal shape as it approaches the inner diameter of the work piece, research on the angle head in five-axis machining has received only minimal attention in domestic industries. In this study, an angle head which is optimized for effective internal shape machining is developed. In pursuit of this purpose, 3D and 2D designs of the angle head for five-axis machining are devised. Reliability is secured through static performance tests and machining accuracy evaluations of the angle head in keeping with the machining accuracy standard of 0.2mm for hydrostatic bearings.

• 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.

• Transactions of Materials Processing
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• v.20 no.4
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• pp.273-278
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• 2011

Employing the TRIZ problem solving technique, a hybrid-type center plate for the molten carbonate fuel cell(MCFC) was developed for the purpose of improving gas sealing and maintenance. The manufacturing method of the hybrid-type center plate was divided into a trimming operation and a two-step bending process. In the latter, a modified punch shape was used to reduce springback. Using finite element(FE) simulations, bending stresses in the thickness and the in-plane directions were computed and the bending conditions were optimized. The optimized results of the two-step bending process were used as a basis for the design of the trimming process of the hybrid-type center plate. Finally, the external manifold-type center plate and the hybrid-type center plate were fabricated using a die set that accounts for the optimized conditions. It was found that the numerical simulation results were in good agreement with the experiments.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.4
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• pp.100-106
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• 2022

Topology optimization is applied for the optimal design of various products to ensure weight reduction and productivity improvement. Reducing the weight of the mold while maintaining its rigidity can ensure shortening of the production cycle, stabilization of the mold temperature, and reduction of mold material costs. In this study, a topology optimization technique was applied to the optimal design of the injection mold, and a topology-optimized model of the mold was obtained. First, the injection mold for the square specimens was modeled. Subsequently, a structural analysis was performed by implementing a load condition generated during the injection molding process. Topology optimization was performed based on the structural analysis results, and the models of the initial and topology-optimized designs were manufactured at 1/4 magnification using a 3D printer. Consequently, compared with the existing model, the weight of the topology-optimized model decreased by 9.8%, and the manufacturing time decreased by 7.61%.

• Journal of Computational Design and Engineering
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• v.1 no.4
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• pp.256-265
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• 2014

Energy efficiency is an essential consideration in sustainable manufacturing. This study presents the car fender-based injection molding process optimization that aims to resolve the trade-off between energy consumption and product quality at the same time in which process parameters are optimized variables. The process is specially optimized by applying response surface methodology and using non-dominated sorting genetic algorithm II (NSGA II) in order to resolve multi-object optimization problems. To reduce computational cost and time in the problem-solving procedure, the combination of CAE-integration tools is employed. Based on the Pareto diagram, an appropriate solution is derived out to obtain optimal parameters. The optimization results show that the proposed approach can help effectively engineers in identifying optimal process parameters and achieving competitive advantages of energy consumption and product quality. In addition, the engineering analysis that can be employed to conduct holistic optimization of the injection molding process in order to increase energy efficiency and product quality was also mentioned in this paper.

• Korean Institute of Interior Design Journal
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• v.14 no.6 s.53
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• pp.202-211
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• 2005

The future of design relies much on and is only ensured by the fundamental understanding of the dynamics between the ecosystem of nature and that of humans; therefore, having an eco-mind is essential. This study establishes ecological design strategies coinciding with the furniture design process and the furniture product life cycle in production, distribution, and end-of-life. In addition, it provides an overall direction with guidelines for ecological furniture design. The presented strategies focus on the Development of a New Concept; the Optimized Use of Physical Materials-functionality and utility; the Optimized Production; the Optimized Distribution System; and the Optimized End-of-life System. Through taking these steps, we can not only preserve our natural environment and Improve our lives, but also create optimal furniture design which corresponds and integrate with the ecosystem.