• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.6
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• pp.84-90
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• 2010

This paper presents the shape optimization process for the automotive wheel bearing seal lip using the finite element method and the response surface method. First, to predict performance of the bearing seal lip, we used the non-linear finite element analysis. And then, we compared the analysis results with the test results to verify the finite element model. The objective function in optimizing process was obtained from results of the mud slurry test, which is one of many tests for evaluating performance of wheel bearing. After the mud slurry test for the four models which have the similar cross-sectional shape, we measured the wear area of the seal lip and the moisture content in grease. The objective function has been chosen by comparing the results of mud slurry test and characteristics of seal lip, such as contact force, contact area, contact pressure, and interference. Finally, within limited design parameters, we suggested the optimized shape of seal lip, which is expected to improve the wear and the sealing effect of it.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.3
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• pp.381-386
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• 2003

Gradually engineering designers are determined based on computer simulations. Modeling of the computer simulation however is too expensive and time consuming in a complicate system. Thus, designers often use approximation models called metamodels, which represent approximately the relations between design and response variables. There arc general metamodels such as response surface model and kriging metamodel. Response surface model is easy to obtain and provides explicit function. but it is not suitable for highly nonlinear and large scaled problems. For complicate case, we may use kriging model that employs an interpolation scheme developed in the fields of spatial statistics and geostatistics. This class of into interpolating model has flexibility to model response data with multiple local extreme. In this study. metamodeling techniques are adopted to carry out the shape optimization of a funnel of Cathode Ray Tube. which finds the shape minimizing the local maximum principal stress Optimum designs using two metamodels are compared and proper metamodel is recommended based on this research.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.19 no.11
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• pp.1151-1157
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• 2009

Ensuring both product quality and reducing material cost are important issue for the design of the piping system of an air conditioner outdoor unit. This paper describes a shape optimization that achieves mass reduction of an air conditioner piping system while satisfying two design constraints on resonance avoidance and the maximum stress in the pipes. In order to obtain optimized design results with various analysis fields considered simultaneously, an automated multidisciplinary analysis system was constructed using PIAnO v.2.4, a commercial process integration and design optimization(PIDO) tool. As the first step of the automated analysis system, a finite element model is automatically generated corresponding to the specified shape of the pipes using a morphing technique included in HyperMesh. Then, the performance indices representing various design requirements (e.g. natural frequency, maximum stress and pipe mass) are obtained from the finite element analyses using appropriate computer-aided engineering(CAE) tools. A sequential approximate optimization(SAO) method was employed to effectively obtain the optimum design. As a result, the pipe mass was reduced by 18 % compared with that of an initial design while all the constraints were satisfied.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.186-192
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• 2002

As industry is developed, the faster transportation of freight train is demanded. The optimum design of a structure requires the determination of economical member size and shape of a structure which will satisfy the design conditions and the functions. In this study, it is attempted to minimize the dead weight of bogie frame. From the numerical results in the shape and size optimization of the bogie frame, it is known that the weight can be reduced up to 17.45% with the displacement, stress, first natural frequency and critical buckling-load constraints. The first natural frequency and the critical buckling load of the optimized model is larger than that of the lowest design value. Stress and displacement conditions are also satisfied within the design conditions. From the results, the optimal model is stable and useful for the improvement of railway carriages.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.441-442
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• 2006

It is attempted to find out the optimal shape of U-type bellows using the finite element analysis. The design factors, mountain height, length, thickness, and the number of convolutions are considered and the proper values are chosen fur the simulation. The results show that as the number of convolutions reduces, the volume decreases while the stress increases. However, as the number of convolutions increases, the volume increases above the standard volume and the stress obviously increases. In addition, the effect of the thickness of bellows on the stress is very large. Both of the mass and stress are decreasing at a certain lower value region. Also, we investigated shape optimization with considering maximum stress distribution tendency.

• International Journal of Precision Engineering and Manufacturing
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• v.9 no.4
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• pp.16-21
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• 2008

The demand for three-dimensional (3D) shape measurements is increasing in a variety of fields, including the manufacture of molds and dies. The most popular technology for 3D shape measurement is the coordinate measuring machine (CMM) with a contact trigger probe. Although a CMM provides a high degree of accuracy, it is inefficient due to its long measuring time. It also has difficulty measuring soft objects that can be deformed by the touch of the contact probe. In addition, a CMM cannot digitize areas that are difficult to reach, and cannot capture very minute details on the surface of complex parts. For these reasons, optical non-contact measurement techniques are receiving more attention since they eliminate most of the problems associated with contact methods. Laser scanning is emerging as one of the more promising non-contact measurement techniques. This paper describes various acquisition considerations for laser scanning, including the accuracy of the 3D scan data, which depends on the charge-coupled device (CCD) gain and noise. The CCD gain and noise of a 3D laser scanner are varied while keeping the other conditions constant, and the measurement results are compared to the dimensions of a standard model. The experimental results show that a considerable time savings and an optimum degree of accuracy are possible by selecting the proper CCD gain and noise.

• Transactions of Materials Processing
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• v.18 no.1
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• pp.52-58
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• 2009

Generally, a vertical rolling process is used to achieve extensive width reduction in hot strip mill. However, it is impossible to avoid the defects such as dog-bone and edge-seam defect. The sizing press process has been developed in response to the defects mentioned above. Especially, this study is carried out to investigate the deformation of slab by two-step sizing press. The deformation behavior of slab in the sizing press process is more favorable than that in conventional vertical rolling edger. The FE-simulation is applied to predict the deformation behavior of the slab. In this paper, the several causes of the asymmetrical deformation are mentioned for the purpose of understanding of the anvil shape. Load, dog-bone and edge-seam defect are discussed in width sizing process considering the anvil shape. And to reduce the problems generated at rougher mill just after sizing press, these are studied in this paper. The deformation behavior of slabs and optimum anvil shape are obtained by rigid-plastic finite element analyses and neural network.

• Proceedings of the Korean Institute of Navigation and Port Research Conference
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• v.2
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• pp.329-334
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• 2006

Rail clamps are mechanical components installed to fix the container crane to its bottoms from wind blast or slip. Rail clamps should be designed to survive the harsh wind loading condition. In this study, the jaw structure that is one part of wedge-typed rail clamp is optimized, considering strength under the severe wind loading condition. According to the classification of structural optimization, the structural optimization of a jaw belongs to shape optimization. In the conventional structural optimization methods, they have difficulties in defining complex shape design variables and preventing mesh distortions. To overcome the difficulties, the metamodel using kriging interpolation method is introduced, replacing true response by approximate one. This research presents the shape optimization of a jaw using iterative kriging interpolation models and simulated annealing algorithm. The new kriging models are iteratively constructed by refining the former kriging models. This process is continued until the convergence criteria are satisfied. The optimum results obtained by the suggested method are compared with those obtained by the DOE (design of experiments) and VT (variation technology) methods built in ANSYS WORKBENCH.

• Transactions of Materials Processing
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• v.17 no.6
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• pp.393-400
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• 2008

Springback is one of the most difficult phenomena to analyze and control in sheet forming. Most of traditional springback control methods rely on experiences of skilled workers in industrial fields. This study focuses on prediction and generation of optimum reconfigurable die surfaces to control shape errors originated by springback. For this purpose, a deformation transfer function(DTF) was combined with finite element analysis of the springback in the 2D sheet forming model of elastic-perfectly plastic materials under the condition without blank holder. The results showed shape errors within 1% of the objective shape, which were comparable with analytically predicted errors. In addition to this theoretical analysis, DTF method was also applied to 2D and 3D sheet forming experiments. The experimental results showed ${\pm}0.5$ mm and ${\pm}1.0$ mm shape error distribution respectively, demonstrating that reconfigurable die surfaces were predicted well by the DTF method. Irrespective of material properties and sheet thickness, the DTF method was applicable not only to FEM simulation but also to 2D and 3D elasto-reconfigurable die forming. Consequently, this study shows that springback can be controlled effectively in the elasto-RDF system by using the DTF method.

• Journal of Korean Association for Spatial Structures
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• v.1 no.1 s.1
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• pp.143-155
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• 2001

Generally, truss design has been determined by the designer's experience and intuition. But if we perform the most economical structural design we must consider not only cross-sections of members but also configurations(howe, warren and pratt types etc.) of single truss as the number of panel and truss height. The purpose of this study is to develope automated optimum design techniques for steel truss structures considering cross-sections of members and shape of trusses simultaneously. As the results, it could be possible to find easily the optimum solutions subject to design conditions at the preliminary structural design stage of the steel truss structures. In this study, the objective function is expressed as the whole member weight of trusses, and the applied constraints are as stresses, slenderness ratio, local buckling, deflection, member cross-sectional dimensions and truss height etc. The automated optimum design algorithm of this study is divided into three-level procedures. The first level on member cross-sectional optimization is performed by the sequential unconstrained minimization technique(SUMT) using dynamic programming method. And the second level about truss height optimization is applied for obtaining the optimum truss height by three-equal interval search method. The last level of optimization is applied for obtaining the optimum panel number of truss by integer programming method. The algorithm of multi-level optimization programming technique proposed in this study is more helpful for the economical design of plane trusses as well as space trusses.