• Steel and Composite Structures
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• v.34 no.5
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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.

• Information Systems Review
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• v.7 no.2
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• pp.117-128
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• 2005

This study proposes an integrated monitoring system for data reliability improvement in a steel manufacturing industry. The data obtained from existing steel manufacturing process is not micro data which is gathered at the occurring point, but average value (macro data) which is gathered from the occurring point to ending point. This kind of macro data is not only difficult for a detailed analysis for an error causing factor, but it might cause a fatal influence as well on the quality of produced goods even if the error is within an error tolerance. And during the process of steel production, thousands of data is produced in a second, thus requiring database plan to manage abundant amount of data. Therefore, the following proposed system is capable of collecting as well as analyzing all the data generated from the process of product production. And the system was able to raise the efficiency of the database server by planning the database to handle large capacity data. Also, by applying web-based technology, inquiries and analysis of data with no limit on time and space was possible with PC connected to the intranet. Hence, the system was able to work on effective quality improvement of manufactured products, plus able to raise the reliability of the product. Also, accumulated data from long period of time was used for fundamental material for new controlling model, operation technology, and new product development.

• Environmental and Resource Economics Review
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• v.23 no.3
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• pp.453-472
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• 2014

Analyzing the effects of carbon emissions trading, which is scheduled to be introduced in Korea in 2015, requires an accurate assessment of $CO_2$ abatement costs by both industries and firms. Firms faced with regulatory constraints are unlikely to minimize their production costs due to rising production costs caused by allocative inefficiency of inputs. The use of a distance function would results in underestimation of $CO_2$ abatement costs, because it fails to capture the allocative distortion costs. Recognizing the disadvantage of the previous approach, first, this paper tests for allocative efficiency of input for the Korean steel industry over the period 1990-2010, then derives the marginal $CO_2$ abatement costs by applying a cost function approach. The hypothesis of allocative efficiency in inputs is rejected and the steel industry pays an annual average cost of 92,000 won in removing an additional ton of $CO_2$ over the sample period.

• Korean Journal of Heritage: History & Science
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• v.35
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• pp.138-158
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• 2002

To compare and analyze technical system related to manufacturing of ironware during the period of the Three Kingdoms, an analysis was conducted on the minute system of metalwork, as study objects, of the remains of the Mt. Wolpyeong fortress wall in Daejeon in the period of capital during the era of the Three Kingdoms in the 5th century, the Sanwol-ri remains in the 6th century in Gunsan and the remains of ironware excavated from the great ancient tomb of Hwangnam of the Silla dynasty in the 5th century. The result of analysis shows that in the most of the casting products, the minute system of white cast iron were contained. While the iron part of decarbonization was in the system by casting as white cast iron in the central part, on the surface layer it was turned out that comparatively uniform 100% pearlite system of about 1~2mm degree was existing. The part of pearlite on the surface layer was caused by decarbonization, which appears in all the parts of blade front end and handle. Therefore, it was found that the iron part of decarbonization was manufactured by casting, and then was processed at the high temperature by decarbonization. For the products of forging, after processing the products on the basis of pure iron for materials, they manufactured the ironware that raises the strength by carbonizing that keeps carbon infiltrated on the necessary part, by the method of black smith welding that add pure iron to steel, or by varying the method of heat processing onto the part required of strength. Though limited, we could understand that the technical systems for manufacturing skill of ironware in the areas of Baekje and Silla were different each other. In the technical system for Hwangnam great ancient tomb in the Silla area, it is found that they had raised the strength on the necessary part by applying the steelmaking method of carbonizing in the last stage of production of products, in the meantime in Baekje area, it appears that they had produced steel in advance in the first stage of production of the products, and used the produced steel only to the necessary part.

• Journal of the Korean Society for Heat Treatment
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• v.36 no.1
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• pp.22-32
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• 2023

In general, when scrap is dissolved in an electric arc furnace, the amount of electric furnace steel dust (EAFD) generated is about 1.5% of the scrap charge amount, and the electric furnace steel dust collected by the bag filter is charged into the Rotary Kiln or Rotary Hearth Furnace (RHF), and the zinc component is recovered as crude zinc oxide, at which time a clinker of Fe-Base is generated. In this research, first, for the efficient resource conversion of electric furnace steel dust, a reduction and roasting experiment was conducted and the reaction kinetics was examined. As a result of the experiment, it was observed that the reduction and roasting reaction was actively conducted in the range of 1100~1150℃, and melting occurred in the range of 1250℃. In the past, this clinker was widely used as a roadbed material for road construction and an Fe-Source for cement production, but in recent years, it has been mainly reclaimed due to strengthening environmental standards. However, landfill treatment is by no means a desirable treatment method due to environmental pollution caused by leachate, expensive landfill costs, and waste of Fe resources. Therefore, in order to more actively recycle the Fe component in the clinker, first of all the clinker was pulverized into an optimal particle size, and anthracite and binder (starch) were added to the magnetic material obtained by specific gravity and magnetic separation for briquet. As a experimental results, it was possible to efficiently separate clinker as Fe component and other slag component by specific gravity and magnetic force. As a results of loading and dissolving the manufactured briquet clinker in an electric arc furnace, it was observed that the unit of power and production yield were clearly improved and the carbon addition effect in molten metal was also somewhat.

• Design & Manufacturing
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• v.9 no.1
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• pp.5-8
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• 2015

The company Daewoo Precision Industries imported fine blanking press of 40 tons from Switzerland with fine blanking tool in order to produce the fuse part of bomb in 1978 at first in Korea. About 1985 the first fine blanking tool for producing the door lock parts was manufactured in the company Gold Star (now LG). And then this technology was grown up with the growth of automobile industries in Korea. Now 31 companies are closely related to the fine blanking technology and there are total 146 fine blanking presses in Korea. The developments of fine blanking technology in industries have been oriented to the production of precise fine blanking parts, the reduction of die roll height on fine blanking parts, the production of complex fine blanking parts with progressive fine blanking tool including forming and forging technology, the production of high-strength steel fine blanking parts and so on. Some R&D activities in KITECH were introduced.

• Structural Engineering and Mechanics
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• v.74 no.2
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• pp.255-266
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• 2020

The main requirements of modern welded metal structures are the load-carrying capacity (safety), fitness for production, and economy. The primary objective of attaching longitudinal stiffeners is to improve the buckling strength of relatively thin compression panels. This paper gives several comparisons for stiffened plates with different loadings (static, dynamic), different shape of stiffeners (flat, L-shape, trapezoidal), different steel grades, and different welding technologies (SMAW, GMAW, SAW), different costs to show the necessity of a combination of design, fabrication and economic aspects. Safety and fitness for production are guaranteed by fulfilling the design and fabrication constraints. The economy is achieved by minimizing the cost function. It is shown that the optimum sizes depend on the welding technology, the material yield stress, the profile of the stiffeners, the load cycles and the place of the production.

• Proceedings of the Korean Institute of Building Construction Conference
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• 2012.11a
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• pp.115-117
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• 2012

Task based modeling is essential in a construction operation simulation modeling. It allows dealing with local variables or delay factors that affect productivity and improves the reusability of existing operation models. An operation model can secure reality only if it reflects the real construction processes by effectively dealing with zoning issue. However, system users have some difficulties in modeling a construction operation that is consisted of several processes having different production units. Zoning is a major modeling issue when the task based modeling method is implemented using the existing discrete event simulation systems. This paper highlights the difficulty and presents a new method that complements the zoning issues attributed to different production units. The method is described in detail by presenting the flow of entities. It is confirmed that the zoning method effectively deals with the unbalance of production units between processes and facilitates to model an operation model having processes with different production units. The "Zoning module" contributes to increasing accuracy of simulation result.

• Journal of Navigation and Port Research
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• v.33 no.8
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• pp.563-572
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• 2009

The steel industry, as the national representative strategic industry of our country, has played the motive power for the economic growth of Korea in 1970s as the positive support of the government and the management endeavor of the private were harmonized. However, in case of our country, we have mostly relied on import of the raw materials for the steel industry, and as the weight of the imported raw materials is heavy, the steel industry is the industry whose transport burden is big as it is called 'transport industry'. So, the transport rationalization will be the important task of the steel industry. This study has analyzed the economic efficiency per the transport route (container ship vs bulk ship) of the sea transport related to import/export of the steel scrap on the level acquiring the stable supply of the steel scrap. For this, this study firstly researched the status of domestic/foreign steel industry. And analyzed the world crude steel production volume, steel scrap consumption volume and world steel scrap trading structure. Also, in order to compare the transport logistics expenses between two transport devices, namely, container ship and bulk ship, this study calculated the logistics expenses per ton by using the traffic hours and traffic expenses items as the imported/exported scrap freights of 'D' company.

• Journal of the Korean GEO-environmental Society
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• v.12 no.3
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• pp.5-12
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• 2011

In this paper, after studying structural performance for the representative corrugated steel plate used in Korea, we proposed the optimum shape for section of corrugated steel plate considering a width of steel plates that can be produced currently in the factory. Using AISI(1986) in examination for the performance of the corrugated steel plate, we determined the mechanical limit of the optimum sections considering shear force and bending moment of corrugated steel plate and also determined the geometric limit of them considering formability, shapes and ratio between width of steel plate before forming and that after forming. As a result of examination for performance of steel plate applying algorithm for searching optimal sections algorithm developed in this study to the existing representative corrugated steel plate, allowable force and moment of inertia indicated the maximum values at bending radius 76mm and internal bending angle $50^{\circ}$. And as an application result of the optimum design system that used SS490 with 1,550mm of width and 4,700mm of length considering current production situation in Korea, we developed the new section with more than 2 times of structural performance comparing with existing corrugated steel plate.