• Journal of the Korean Society for Precision Engineering
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• v.30 no.12
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• pp.1303-1312
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• 2013

We report an ultra-precision lathe designed to machine micron-scale features on a large-area roll mold. The lathe can machine rolls up to 600 mm in diameter and 2,500 mm in length. All axes use hydrostatic oil bearings to exploit the high-precision, stiffness, and damping characteristics. The headstock spindle and rotary tooling table are driven by frameless direct drive motors, while coreless linear motors are used for the two linear axes. Finite element method modeling reveals that the effects of structural deformation on the machining accuracy are less than $1{\mu}m$. The results of thermal testing show that the maximum temperature rise at the spindle outer surface is approximately $0.5^{\circ}C$. Finally, performance evaluations of the error motion, micro-positioning capability, and fine-pitch machining demonstrate that the lathe is capable of producing optical-quality surfaces with micron-scale patterns with feature sizes as small as $20{\mu}m$ on a large-area roll mold.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.25 no.11
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• pp.1594-1605
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• 2001

In this study, a numerical simulation was developed which was capable of predicting the characteristics of NO formation in pilot scale combustor adopting the air-staged burner flame. The numerical calculation was constructed by means of establishing the mathematical models fur turbulence, turbulent combustion, radiation and turbulent nitric oxide chemistry. Turbulence was solved with standard k-$\xi$ model and the turbulent combustion model was incorporated using a two step reaction scheme together with an eddy dissipation model. The radiative transfer equation was calculated by means of the discrete ordinates method with the weighted sum of gray gases model for CO$_2$and H$_2$O. In the NO chemistry model, the chemical reaction rates for thermal and prompt NO were statistically averaged using the $\beta$ probability density function. The results were validated by comparison with measurements. For the experiment, a 0.2 MW pilot multi-air staged burner has been designed and fabricated. Only when the radiation was taken into account, the predicted gas temperature was in good agreement with the experimental one, which meant that the inclusion of radiation was indispensable for modeling multi-air staged gas flame. This was also true of the prediction of the NO formation, since it heavily depended on temperature. Subsequently, it was found that the multi-air staged combustion technique might be used as a practical tool in reducing the NO formation by controlling the peak flame temperature.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.1
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• pp.81-88
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• 2020

In this paper, the performances of the electrical characteristics of the Fused Deposition Modeling (FDM) 3D-printed flexible resistance sensor was evaluated. The FDM 3D printing flexible resistive sensor is composed of flexible-material thermoplastic polyurethane and a conductive PLA (carbon black conductive polylactic acid) polymer. While 3D printing, polymer filaments heat up quickly before being extruded and cooled down quickly. Polymers have poor thermal conductivity so the heating and cooling causes unevenness, which then results in internal stress on the printed parts due to the rapidity of the heating and cooling. Electrical resistance measurements show that the 3D-printed flexible sensor is unstable due to internal stress, so the 3D-printed flexible sensor resistance curve does not match the increases and decreases in the displacement curve. Therefore, annealing was performed to eliminate the mismatch between electrical resistance and displacement. Annealing eliminates residual stress on the sensor, so the electrical resistance of the sensor increases and decreases in proportion to displacement. Additionally, the resistance is lowered in comparison to before annealing. The results of this study will be very useful for the fabrication of various devices that employ 3D-printed flexible sensor that have multiple degrees of freedom and are not limited by size and shape.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.9
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• pp.1189-1194
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• 2013

The Intermediate Heat Exchanger (IHX) of a Very High Temperature Reactor (VHTR) is a core component that transfers the high heat of $950^{\circ}C$ generated in the VHTR to a hydrogen production plant. The Korea Atomic Energy Research Institute manufactured a lab-scale prototype of a Printed Circuit Heat Exchanger (PCHE) as a candidate for an IHX. In this study, as a part of a high-temperature structural integrity evaluation of the lab-scale PCHE prototype made of SUS316L, we carried out high temperature structural analysis modeling and macroscopic thermal and elastic structural analysis for the lab-scale PCHE prototype under helium experimental loop (HELP) test conditions as a precedent study prior to the performance test in HELP.

• Journal of Korea Foundry Society
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• v.33 no.5
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• pp.193-203
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• 2013

The Ni-base superalloy CM247LC was directionally solidified (DS) using the Bridgman-type furnace to understand the effect of the chill plate on the microstructural evolution, such as dendrite arm spacing, microporosity, and MC-type carbide. The DS process was also modeled by the PROCAST to predict the solidification rate, thermal gradient, and resultant cooling rate in the entire length of the DS specimen. Due to the quenching effects of chill plate, four distinct areas were found to form in the specimen, in which the solidification rate was changed, during DS at a given withdrawal rate of 0.083 mm/s. Among the microstructural features investigated, the dendrite arm spacings and average size of the MC-type carbide near the chill plate were found to be influenced by the quenching effect of the chill plate. However, no significant influence was found on the size and volume fraction of microporosity, and the volume fraction of the MC-type carbide. The relationship between the microstructural features and the solidification variables was also analyzed and discussed on the basis of a combination of experimental and modeling results.

• International Journal of Fluid Machinery and Systems
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• v.10 no.3
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• pp.240-253
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• 2017

Latin hypercube sampling is widely used design-of-experiment technique to select design points for simulation which are then used to construct a surrogate model. The exploration/exploitation properties of surrogate models depend on the size and distribution of design points in the chosen design space. The present study aimed at evaluating the performance characteristics of various surrogate models depending on the Latin hypercube sampling (LHS) procedure (sample size and spatial distribution) for a diverse set of optimization problems. The analysis was carried out for two types of problems: (1) thermal-fluid design problems (optimizations of convergent-divergent micromixer coupled with pulsatile flow and boot-shaped ribs), and (2) analytical test functions (six-hump camel back, Branin-Hoo, Hartman 3, and Hartman 6 functions). The three surrogate models, namely, response surface approximation, Kriging, and radial basis neural networks were tested. The important findings are illustrated using Box-plots. The surrogate models were analyzed in terms of global exploration (accuracy over the domain space) and local exploitation (ease of finding the global optimum point). Radial basis neural networks showed the best overall performance in global exploration characteristics as well as tendency to find the approximate optimal solution for the majority of tested problems. To build a surrogate model, it is recommended to use an initial sample size equal to 15 times the number of design variables. The study will provide useful guidelines on the effect of initial sample size and distribution on surrogate construction and subsequent optimization using LHS sampling plan.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.34 no.7
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• pp.89-96
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• 2006

The combustion temperature in gas generator should be kept below around 1,000K to avoid any possible thermal damages to turbine blade by adopting either fuel rich or oxidizer rich combustion. Thus, non-equilibrium chemical reaction dominates in the gas generator. Meanwhile, Kerosene is a compounded fuel mixed with various types of hydrocarbon elements and difficult to model the chemical kinetics. This study focus to model the non-equilibrium chemical reaction of kerosene/LOX with detailed kinetics developed by Dagaut using PSR(Perfectly stirred reactor) assumption. Also, droplet evaporation time is taken into account by calculating for the residence time of droplet and by decoupling reaction temperature from the reactor temperature. In Dagaut’s surrogate model for kerosene, chemical kinetics of kerosene consists of 1592 reaction steps with 207 chemical species. The comparison of calculation results with experimental data could provide very reliable and accurate numbers in the prediction of combustion gas temperature, species fraction and other gas properties.

• Tribology and Lubricants
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• v.32 no.4
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• pp.113-118
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• 2016

As an economic, high quality, and highly reliable gear with low noise and low vibration is demanded, an overall finite element analysis regarding a gear is required. Also, an infrared thermography test, which is a quantitative testing technique, is demanded for safety and longer lifespan of gear products. In order to manufacture a gear product or to determine safety of a gear being used, it is necessary to precisely determine ingredients of a material constituting a gear and detect any internal defect. This study aims to realize a design that minimizes the spur gear displacement with respect to power during its rotation and ensures the spur gear control capacity by using a 3D model and the midasNFX program. This facilitates the assessment of the possibility of cracking by evaluating the stress intensity and focusing on the integrity of the spur gear. We prepare the specimen of the spur gear based on the possibility of cranking as per the result of the structural interpretation from an infrared ray thermal measuring technique. After cooling the spur gear, we perform experiments using thermography and halogen lamps and analyze the temperature data according to the results of the experiment. In the experiment which we use thermography after cooling, we find a rise in the temperature of the room. As a result, the defective part show temperatures lower than their surroundings while the normal parts have temperatures higher than the defective parts. Therefore, it possible to precisely identify defective part owing to its low temperature.

• Journal of Korean Society of Water and Wastewater
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• v.34 no.3
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• pp.183-190
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• 2020

Although membrane bio-reactor (MBR) has been widely applied for wastewater treatment plants, the membrane fouling problems are still considered as an obstacle to overcome. Thus, many studies and commercial developments on mitigating membrane fouling in MBR have been carried out. Recently, high voltage impulse (HVI) has gained attention for a possible alternative technique for desalting, non-thermal sterilization, bromate-free disinfection and mitigation of membrane fouling. In this study, it was verified if the HVI could be used for mitigation of membrane fouling, particularly the internal pore fouling in MBR. The HVI was applied to the fouled membrane under different conditions of electric fields (E) and contact time (t) of HVI in order to investigate how much of internal pore fouling was reduced. The internal pore fouling resistance (R_f) after HVI induction was reduced as both E and t increased. For example, R_f decreased by 19% when the applied E was 5 kV/cm and t was 80 min. However, the R_f decreased by 71% as the E increased to 15 kV/cm under the same contact time. The correlation between E and t that needed for 20% of R_f reduction was modeled based on kinetics. The model equation, E^1.54t = 1.2 × 10³ was obtained by the membrane filtration data that were obtained with and without HVI induction. The equation states the products of En and t is always constant, which means that the required contact time can be reduced in accordance with the increase of E.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.10
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• pp.1283-1288
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• 2012

A process heat exchanger (PHE) in a nuclear hydrogen system is a key component for transferring the considerable heat generated in a very high temperature reactor (VHTR) to a chemical reaction that yields a large quantity of hydrogen. A performance test on a medium-scale PHE prototype made of $Hastelloy^{(R)}$-X is scheduled in a small-scale gas loop at the Korea Atomic Energy Research Institute. In this study, as a preliminary study before carrying out the performance test in the gas loop, high-temperature structural analysis modeling and macroscopic thermal and structural analysis of the medium-scale PHE prototype by imposing the established displacement boundary constraints were carried out under the gas loop test condition. The results obtained in this study will be compared with the performance test results of the medium-scale PHE prototype in the gas loop.