• Proceedings of the KSME Conference
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• 2000.11b
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• pp.192-198
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• 2000

Three dimensional thermal cycle analysis of the plunger is carried out in repeated forming process of the TV glass, which is continued work of two dimensional analysis where an efficient method has been proposed. The plunger undergoes temperature fluctuation during a cycle due to the repeated contact and separation from the glass, which attains a cyclic steady state having same temperature history at every cycle. Straightforward analysis of this problem brings about more than 90 cycles to get reasonable solution. An exponential function fitting method is proposed, which finds exponential function to best approximate temperature values of 3 consecutive cycles, and new cycle is restarted with the fitted value at infinite time. Number of cases are analyzed using the proposed method and compared to the result of straightforward repetition, from which one finds that the method always reaches nearly convergent solution within $9{\sim}12$ cycles, but turns around afterwards without further convergence. Two step use is found most efficient, in which the exponential fitting is carried out fer the first 12 cycles, followed by simple repetition, which shows fast convergence expending only 6 additional cycles to get the accuracy within 2 error. This reduces the computation cycle remarkably from 90 to 18, which is 80% reduction. From the parametric studies, one reveals that the overall thermal behavior of the plunger in terms of cooling parameters and time is similar to that of 2 dimensional analysis.

• Tribology and Lubricants
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• v.31 no.4
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• pp.148-156
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• 2015

In the study, a design process for ensuring optimal clearance in a fuel injection pump(FIP) is suggested. Structure analysis and hydrodynamic lubrication analysis are performed to determine the optimal clearance. The FIP is simulated using Hypermesh, Abaqus 6.12 to evaluate the reduction of clearance when the maximum supply pressure is applied. The reduction in clearance is caused by the difference in the deformations between the barrel and plunger. When the deformation of the plunger is larger than that of the barrel, a reduction in clearance at the head part occurs. On the other hand, the maximum clearance reduction equals the maximum deformation in the stem part, because the deformation of barrel does not occur in this region. The clearance of FIP should be designed to be larger than maximum reduction of clearance in order to avoid contact between the plunger and barrel. In addition, the two-dimensional Reynolds equation is used to evaluate lubrication characteristics with variations of viscosity, clearance and nozzle for a laminar, incompressible, unsteady state flow. The equation is discretized using the finite difference method. The lubrication characteristics of FIP are investigated by comparing film parameter, which is the ratio of the minimum film thickness and surface roughness. The optimal clearance of FIP is to be designed by considering the maximum reduction in clearance, lubrication characteristics, machining limits and tolerance of clearance.

• Journal of the Korean Institute of Gas
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• v.26 no.4
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• pp.1-8
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• 2022

DME, a clean fuel that is being studied as an alternative fuel for diesel engines, can reduce exhaust gas, which is the one of the crucial problems of diesel engines, and has a very high cetane number and high oxygen content. DME is a fuel has properties similar with LPG and can use the infrastructure of LPG. In this study, The target was to build a database of basic data on the mass flow rate discharged for the performance evaluation of the plunger-type high pressure pump. In this study, the mass flow rate of the DME plunger type high pressure pump was analyzed by changing the common rail pressure and the motor rotation speed. The experimental conditions were the common rail pressure was changed from 300 to 500 bar and the motor rotation speed was changed from 300 to 1000 rpm. In addition, basic mass flow data were constructed to high-pressure pumps for DME. As a result of the experiment, in both cases the mass flow rate was increased.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.3
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• pp.285-293
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• 2016

The high velocity oxygen fuel(HVOF) thermal spray is a kind of surface modification techniques to produce the sprayed coating layer. This process is to form the coating layer after spraying the powder to molten or semi-molten state by the ultra-high speed at the high-temperature heat source and conflicting with a substrate. The efficiency of thermal spraying is dropped, however, because the semi-molten powder in a spray process become a factor that degrades the mechanical property by the formed pore within the coating layer. Therefore, it is necessary to melt completely the thermal spray powder in order to produce the coating layer with an optimal adhesive force. In this study, to improve the wear resistance, corrosion resistance and heat resistance, the plungers of high-speed and ultra-high pressure reciprocating hydraulic pumps used in ironworks are manufactured with STS $420J_2$ and are coated by the powders of WC-Co-Cr and WC-Cr-Ni including the WC of high hardness using a HVOF thermal sprayer developed in this laboratory. These are called by the surface-modified plungers. The surface roughness, hardness, and surface and cross-sectional microstructure of these two surface-modified and conventional ceramic plungers are measured and compared before operation with after operation for 100 days. It is found that the values of centerline average surface roughness and maximum height for conventional ceramic plunger are 9.5 to 10.8 and 5.2 to 5.7 times higher than those of surface-modified ones coated by WC-Co-Cr and WC-Cr-Ni because the fine tops and bottoms on surface roughness curve of conventional ceramic plunger are approximately 100 times higher than those of surface-modified ones. In addition, the pores and scratches in the surface microstructure are considerably formed in the order of conventional ceramic, WC-Cr-Ni and WC-Co-Cr surface-modified plungers. The greater the WC content of high hardness powder is less the change in the plunger surface.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.659-660
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• 2009

• Journal of Korea Foundry Society
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• v.30 no.4
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• pp.126-129
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• 2010

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2007.06a
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• pp.15-16
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• 2007

• Journal of Advanced Marine Engineering and Technology
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• v.30 no.1
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• pp.58-64
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• 2006

This work focuses on reducing the noise and vibration levels of an LPi fuel pump, which are generated from the dynamic motions of pump elements and non-uniform flow of fuel. The noise and vibration levels increase as the revolution speed of the cam goes up. The fuel pump consists of five cavity cells, plungers and diaphragms, which are driven by the cam. The optimal design of the cam profile is performed to decrease the accelerations of moving Parts and to obtain a smooth hydraulic force through a dynamic analysis of a cam-plunger mechanism. The cam-Plunger with a cavity is modeled as a 2 degrees of freedom system having non-linear contacts, the cam profile being represented in terms of Fourier series in order to determine the optimal shape of the cam. From the optimized cam Profile, the acceleration of the diaphragm is reduced in $78\%$, the hydraulic force becoming smoother in case that the hydraulic force is rapidly dropped.

• Journal of Advanced Marine Engineering and Technology
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• v.35 no.4
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• pp.460-467
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• 2011

Cavitation phenomena during the spill process of the Bosch type fuel injection pump for medium-speed diesel engine were investigated by optical observations. Typically, these phenomena can cause a surface damage with material removal or round-off at the plunger and barrel port etc., and may shorten their expected life time. The images, which were recorded with high speed CCD camera and borescope, show that the plunger damage is mainly affected by fountain-like cavitation generated before the end of delivery. And the damages of barrel port and deflector are caused by jet-type cavitation generated after end of delivery.

• Proceedings of the KSME Conference
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• 2000.04b
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• pp.252-257
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• 2000

An efficient method is developed for mold thermal cycle analysis in repeated forming process, which is well suited to the analysis in TV glass production. plunger, which is a mold to press-form the glass, undergoes temperature fluctuation during a cycle due to the repeated contact and separation from the glass, which attains a cyclic steady state in the end. If analyzed straightforwardly of this problem, it leads to more than 80 cycles to get reasonable solution, and it is yet hard to setup stopping creteria due to extremely slow convergence. An exponential fitting method is proposed to solve the problem, where an exponential function is found to best approximate temperature values of 3 consecutive cycles, and new cycle is restarted with the function value at infinite time. From numerical implementation, it is found that the method reduces the number of cycles dramatically to only $6{\sim}15$ cycles to reach accurate solution within $1^{\circ}$ error. A system for the analysis is contructed, in which the thermal analysis is performed by commercial software ANSYS, and the fitting of the result is done by IMSL library.