• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.531-534
• /
• 2008

A new forming process of the large-size forging within the limit of forming loads is developed by introducing the drawing process, which usually used to apply to sheet forming. For the development of the forming process, corresponding numerical simulation are carried out. The approach is based on the Taguchi method, and utilize the DOE for design of FEM analyses. In this study, the important factors are chosen at first, and then the concept of signal-to-nose(S/N) rate is applied to evaluate the formability of large size forging-products, and each value of the design parameter is determined.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.41 no.3
• /
• pp.181-186
• /
• 2017

Single point incremental forming (SPIF) is a sheet-forming technique. It is a die-less sheet metal manufacturing process for rapid prototyping and small batch production. The Critical parameters in the forming process include tool diameter, step depth, feed rate, spindle speed, etc. In this study, these parameters and the die shape corresponding to the Varying Wall Angle Conical Frustum(VWACF) model were used for forming 0.8mm in thick Al5052-O sheets. The Taguchi method of Experiments of Design (DOE) and Grey relational optimization were used to determine the optimum parameters in SPIF. A response study was performed on formability, spring back, and thickness reduction. The research shows that the optimum combination of these parameters that yield best performance of SPIF is as follows: tool diameter, 6mm; spin speed, 60rpm; step depth, 0.3mm; and feed rate, 500mm/min.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.15 no.8
• /
• pp.4729-4735
• /
• 2014

To protect the environment, the regulation of emissions from off-road engines which are relatively neglected, is being reinforced. This paper deals with the robust design of off-road diesel engines considering the emission characteristics. Measurements of the NOx and PM levels based on the DOE were carried out. The injector hole number, injection timing and EGR rate were selected as the control factors. The orthogonal arrays table $L_9(3^3)$ was made from 2 or 3 levels for each factor and measurements of emissions were accomplished based on the table. The small-the-better SN ratio according to the Taguchi method was evaluated. The ANOVA (analysis of variance) for the SN ratio was conducted. The injection timing on the NOx emissions and the EGR rate on the PM have the largest effect on the low-load operation condition. The confidence levels of the control factors were more than 90%.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
• /
• 2009.10a
• /
• pp.130-136
• /
• 2009

The goal of this paper is to develop a standard side mirror geometry that will perform well across multiple vehicles. One of the important performance attributes of a side mirror is the amount of wind noise generated under the flow conditions on a car. PowerFLOW can be used for Computer Aided Testing of the aeroacoustics performance of a design in addition to directing design modifications based on a detailed analysis of the flow structures responsible for the noise generation. Alternatively, a Design of Experiment (DOE) approach is useful to explore the design space without any a-priori assumptions of the effects of design parameter changes. Some general design guidelines regarding the significant mirror geometry factors will be determined which may help to reduce vehicle development time and cost in the future. The results of this research will also allow us to estimate the trade-off between cost saving and performance optimum related to using a standard mirror shape for different vehicles.

• Journal of Computational Design and Engineering
• /
• v.3 no.1
• /
• pp.63-70
• /
• 2016

Deep drawing is a forming process in which a blank of sheet metal is radially drawn into a forming die by the mechanical action of a punch and converted to required shape. Deep drawing involves complex material flow conditions and force distributions. Radial drawing stresses and tangential compressive stresses are induced in flange region due to the material retention property. These compressive stresses result in wrinkling phenomenon in flange region. Normally blank holder is applied for restricting wrinkles. Tensile stresses in radial direction initiate thinning in the wall region of cup. The thinning results into cracking or fracture. The finite element method is widely applied worldwide to simulate the deep drawing process. For real-life simulations of deep drawing process an accurate numerical model, as well as an accurate description of material behavior and contact conditions, is necessary. The finite element method is a powerful tool to predict material thinning deformations before prototypes are made. The proposed innovative methodology combines two techniques for prediction and optimization of thinning in automotive sealing cover. Taguchi design of experiments and analysis of variance has been applied to analyze the influencing process parameters on Thinning. Mathematical relations have been developed to correlate input process parameters and Thinning. Optimization problem has been formulated for thinning and Genetic Algorithm has been applied for optimization. Experimental validation of results proves the applicability of newly proposed approach. The optimized component when manufactured is observed to be safe, no thinning or fracture is observed.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.30 no.6 s.249
• /
• pp.728-733
• /
• 2006

The reduction of the Vehicle interior noise has been the main interest of NVH engineers. The driver's perception on the vehicle noise is affected largely by psychoacoustic characteristic of the noise as well as the SPL. In particular, the HVAC sound among the vehicle interior noise has been reflected sensitively in the side of psychology. In previous study, we have developed to verify identification of source for the vehicle HVAC system through multiple-dimensional spectral analysis. Also we carried out objective assessments on the vehicle HVAC noises and subjective assessments have been already performed with 30 subjects. In this study, the linear regression models were obtained for the subjective evaluation and the sound quality metrics. The regression procedure also allows you to produce diagnostic statistics to evaluate the regression estimates including appropriation and accuracy. Appropriation of regression model is necessary to $R^2$ value and F-value. And testing for regression model is necessary to independence, homoscedesticity and normality. Also we selected optimum layout of damping material using Taguchi method. As a result of application, sound quality is improved more quietly, powerfully, even though costly, and smoothly.

• Journal of the Korean Society for Precision Engineering
• /
• v.28 no.3
• /
• pp.370-376
• /
• 2011

Recently, the application range of plastic gears is widely expanding by the development of engineering plastics with good mechanical properties. Plastic gears have excellent performances such as light weight, water resistance and vibration absorbing ability for metallic gears. In this study, the optimization of injection molding process was done for the large disk type plastic gears of auto phoropter. Design Of Experiment (Taguchi method) was adopted to find a tendency of molding conditions that influence the flatness of disk type gear. Four main factors for molding conditions were selected based on injection temperature, filling time, packing pressure and mold temperature. Also, Filling, packing and cooling analyses were carried out to evaluate Z directional deflection of large disk type gear by using the simulation software (Moldflow) based on the DOE. From the results, it was found that the injection temperature and packing pressure are the most sensitive parameters for the Z directional deflection of large disk type gears.

• Transactions of Materials Processing
• /
• v.18 no.8
• /
• pp.633-639
• /
• 2009

Remarkable progress had been made in both technology and production of optical elements including aspheric lens. In the past, precision optical glass lenses were produced through multiple processes such as grinding and polishing, but mass production of aspheric lenses requiring high accuracy and having complex profile was rather difficult. Against such a background, the high-precision optical GMP process was developed with an eye on mass production of precision optical glass pasts by molding press. This GMP process can produce with precision and good repeatability special form lenses such as for cameras, video cameras, aspheric lenses for optical items. In this study, Design Of Experiment(Taguchi method) was adopted to find a tendency of molding conditions that influence formability. Three main factors for molding conditions were selected based on pressure at pressing stage and temperature, pressure at cooling stage. Also, the DOE was carried out and the interference patterns were measured to evaluate the formability of GMP process. From the results, it was found that the cooling pressure is the most sensitive parameter for progressive GMP process.

• Korean Journal of Materials Research
• /
• v.25 no.7
• /
• pp.322-329
• /
• 2015

The magnitude of wear should be at a minimum for numerous automobile and aeronautical components. In the current work, composites were prepared by varying the cenosphere content using the conventional stir casting method. A uniform distribution of particles was ensured with the help of scanning electron microscopy (SEM). Three major parameters were chosen from various factors that affect the wear. A wear test was conducted with a pin-on-disc apparatus; the controlling parameters were volume percentages of reinforcement of 5, 10, 15, and 20%, applied loads of 9.8, 29.42, and 49.03 N, and sliding speeds of 1.26, 2.51, and 3.77 m/s. The design of the experiments (DOE) was performed by varying the different influencing parameters using the full factorial method. An analysis of variance (ANOVA) was used to analyze the effects of the parameters on the wear rate. Using regression analysis, a response curve was obtained based on the experimental results. The parameters in the resulting curve were optimized using the Genetic Algorithm (GA). The GA results were compared with those of an alternate efficient algorithm called Neural Networks (NNs).

• Transactions of Materials Processing
• /
• v.30 no.6
• /
• pp.291-300
• /
• 2021

Currently, starting with electric vehicles, the application of ultra-high-strength steel sheets and light metals has expanded to improve mileage by reducing vehicle weight. At a time when internal combustion engine vehicles are rapidly changing to electric vehicles, the application of ultra-high-strength steel is expanding to satisfy both weight reductions and the performance safety of the chassis parts. There is an urgent need to improve the quality of parts without defects. It is particularly difficult to estimate the part formability through the finite element method (FEM) in the burring operation, so product design has been based on the hole expansion ratio (HER) and experience. In this study, design of experiment (DOE), analysis of variance (ANOVA), and regression analysis were combined to optimize the formability by adjusting the process variables affecting the burring formability of ultra-high-strength steel parts. The optimal variables were derived by analyzing the influence of variables and the correlation between the variables through FE analysis. Finally, the optimized process parameters were verified by comparing experiment with simulation. As for the main influence of each process variable, the initial hole diameter of the piercing process and the shape height of the preforming process had the greatest effects on burring formability, while the effect of a lower round of punching in the burring process was the least. Moreover, as the diameter of the initial hole increased, the thickness reduction rate in the burring part decreased, and the final burring height increased as the shape height during preforming increased.