• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.7
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• pp.60-66
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• 2020

In order to improve fatigue life of transmission gear carburizing is normally used. Carburizing is a very good process to achieve low cost and high performance. The machined gears are heated up to carburizing temperature and then cooled rapidly in an oil bath to produce high surface hardness. The gears may undergo excessive thermal distortion during heating and rapid cooling. In order to predict the distortion during heating and rapid cooling, a coupled thermo-mechanical simulation is needed. In the current research, the simulation of heating and cooling was performed. The results show that the thermal distortion and the residual stresses are well predicted by the coupled simulation. In addition, induction heating and rapid cooling simulation is carried out to predict the thermal distortion. The amount of distortion is compared. It is shown that induction heating is very effective to reduce thermal distortion.

• Tunnel and Underground Space
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• v.31 no.6
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• pp.593-609
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• 2021

We proposed a numerical method for the thermo-mechanical behavior of rock fracture using a grain-based distinct element model (GBDEM) and simulated thermally induced fracture slip. The present study is the benchmark simulation performed as part of DECOVALEX-2023 Task G, which aims to develop a numerical method to estimate the coupled thermo-hydro-mechanical processes within the crystalline rock fracture network. We represented the rock sample as an assembly of Voronoi grains and calculated the interaction of the grains (blocks) and their interfaces (contacts) using a distinct element code, 3DEC. Based on an equivalent continuum approach, the micro-parameters of grains and contacts were determined to reproduce rock as an elastic material. Then, the behavior of the fracture embedded in the rock was characterized by the contacts with Coulomb shear strength and tensile strength. In the benchmark simulation, we quantitatively examined the effects of the boundary stress and thermal stress due to heat conduction on fracture behavior, focusing on the mechanism of thermally induced fracture slip. The simulation results showed that the developed numerical model reasonably reproduced the thermal expansion and thermal stress increment, the fracture stress and displacement and the effect of boundary condition. We expect the numerical model to be enhanced by continuing collaboration and interaction with other research teams of DECOVALEX-2023 Task G and validated in further study experiments.

• Tunnel and Underground Space
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• v.11 no.3
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• pp.257-269
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• 2001

Numerical simulation is performed to understand the structural behavior of an underground radwaste repository, assumed to be located at the depth of 500 m, in a granitic rock mats, in which a fault intersects the roof of the repository cavern. Two dimensional universal distinct element code, UDEC is used in the analysis. The numerical model includes a granitic rock mass, a canister with PWR spent fuels surrounded by the compacted bentonite inside the deposition hole, and the mixed bentonite backfilled in the rest of the space within the repository cavern. The structural behavior of three different cases, each case with a fault of an angle of $33^{\circ},\;45^{\circ},\;and\;58^{\circ}$ passing through the cavern roof-wall intersection, has been compared. And then fro the case with the $45^{\circ}$ fault, the hydro-mechanical, thermo-mechanical, and thermo-hydro-mechanical interaction behavior have been studied. The effect of the time-dependent decaying heat, from the radioactive materials in PWR spent fuels, on the repository and its surroundings has been studied. The groundwater table is assumed to be located 10m below the ground surface, and a steady state flow algorithm is used.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.98-103
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• 2008

This paper is to discuss distribution of welding residual stresses of a ferritic low alloy steel nozzle with dissimilar metal weld using Alloy 82/182. Two dimensional (2D) thermo-mechanical finite element analyses are carried out to simulate multi-pass welding process on the basis of the detailed and fabrication data. On performing the welding analysis generally, the characteristics on the heat input and heat transfer of weld are affected on the weld residual stress analyses. Thermal analyses in the welding heat cycle process is very important process in weld residual stress analyses. Therefore, heat is rapidly input to the weld pass material, using internal volumetric heat generation, at a rate which raises the peak weld metal temperature to $2200^{\circ}C$ and the base metal adjacent to the weld to about $1400^{\circ}C$. These are approximately the temperature that the weld metal and surrounding base materials reach during welding. Also, According to the various ways of appling the weld heat source, the predicted residual stress results are compared with measured axial, hoop and radial through-wall profiles in the heat affected zone of test component. Also, those results are compared with those of full 3-dimensional simulation.

• International Journal of Naval Architecture and Ocean Engineering
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• v.10 no.2
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• pp.141-152
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• 2018

The heating process such as line heating, triangular heating and so on is widely used in plate forming of shell plates found in bow and stern area of outer shell in a ship. Local shrinkage during heating process is main physical phenomenon used in plate forming process. As it is well appreciated, the heated plate undergoes the change in material and mechanical properties around heated area due to the harsh thermal process. It is, therefore, important to investigate the changes of physical and mechanical properties due to heating process in order to use them plate the design stage of shell plates. This study is concerned with the development of formula of plastic hardening constitutive equation for steel plate on which line heating is applied. In this study the stress correction formula for the heated plate has been developed based on the numerical simulation of tension test with varying plate thickness and heating speed through the regression analysis of multiple variable case. It has been seen the developed formula shows very good agreement with results of numerical simulation. This paper ends with usefulness of the present formula in examining the structural characteristic of ship's hull.

• Laser Solutions
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• v.9 no.1
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• pp.9-16
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• 2006

Glass is one of brittle materials. Generally, brittle material is weak for tensile stress but strong for compression stress. Laser breaking of glass used this brittle characteristics. Laser breaking of glass was simulated to optimize breaking condition by using commercial FEM code MARC which is applicable to thermo-mechanical coupling analysis. Various shapes of heat sources were applied to the analysis and the distance between heating and cooling source were varied for each simulation. The shapes of heat sources were circle, single and double ellipse and the distance was varied from 0mm to 30mm. Moving heat sources were designed on the basis of experimental condition. As a result, double elliptic shape of heat source was the most suitable among them in laser breaking of glass. And it should be useful to determine optimal condition of laser breaking for glass.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.11
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• pp.7667-7671
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• 2015

Recently, Zinc coating is often used with environment friendly features and high performance. Generally The coating temperature is one of main factors for determining coating thickness and coating ability, so the optimal coating temperature is strongly required. In this paper, the thermo-flow simulation considering the air flow inside the coating rooms for analyzing the temperature distributions of Zinc spray coating room was performed. Two spray coating rooms, preheating room and drying room were all modeled by SolidWorks program and the temperature distributions were analyzed by Flow simulation program. The analysis results were verified with the measured data by thermal image camera. The characteristics of temperature distributions of the first spray room and the second spray room were understood and the results showed that the temperatures of two spray coating room were low compared with the target temperature $25^{\circ}C$. To the exclusion of heater addition, the simulation with all the same conditions exclusive the exhaust fan was performed, which showed that the temperatures of the first and the second spray rooms increased by $6.2^{\circ}C$ and $5.8^{\circ}C$. This analysis can be applicable for designing a new spray coating room for improving performance.

• Nuclear Engineering and Technology
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• v.53 no.9
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• pp.2937-2952
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• 2021

A typical three-dimensional finite element model for a fuel assembly is established, which is composed of 16 monolithic U-10Mo fuel plates and Al alloy frame. The distribution and evolution results of temperature, displacement and stresses/strains in all the parts are numerically obtained and analyzed with a self-developed code of FUELTM. The simulation results indicate that (1) the out-of-plane displacements of Al alloy side plates are mainly attributed to the bending deformations; (2) enhanced out-of-plane displacements appear in fuel plates adjacent to the outside Al plates, which results from the occurred bending deformations due to the applied constraints of outside Al plates; (3) an intense interaction of fuel foil with the cladding occurs near the foil edge, which appears more heavily in the fuel plates adjacent to the outside Al plates. The maximum first principal stresses in the fuel foil are similar for all the fuel plates and appear near the fuel foil edge; while, the through-thickness creep strains of fuel foil in the fuel plate near the central region of fuel assembly are larger, and the induced creep damage might weaken the fuel skeleton strength and raise the fuel failure risk.

• Ocean Systems Engineering
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• v.13 no.4
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• pp.367-384
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• 2023

Herein, we present the design and development of an efficient finite element analysis model for thermal plate forming in shipbuilding. Double curvature shells in the ship building industries are primarily formed through the thermal forming technique. Thermal forming involves heating of steel plates using heat sources like oxy-acetylene gas torch, laser, and induction heating, etc. The differential expansion and contraction across the plate thickness cause plastic deformation and bending of plates. Thermal forming is a complex forming technique as the plastic deformation and bending depends on many factors such as peak temperature, heating and cooling rate, depth of heated zone and many other secondary factors. In this work, we develop an efficient finite element analysis model for the thermo-mechanical analysis of thermal forming. Different simulations are reported to study the effect of various parameters affecting the process. Temperature dependent properties are used in the analysis and the finite element analysis model is used to identify the critical flame velocity to avoid recrystallization of plate material. A spring connected plate is modeled for structural analysis using spring elements and that helps in identifying the resultant shapes of various thermal forming patterns. Finally, detailed simulation results are reported to establish the efficacy, applicability and efficiency of the designed and developed finite element analysis model.

• Structural Engineering and Mechanics
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• v.48 no.6
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• pp.757-774
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• 2013

An integrated simulation tool for multilayer stepped pyramidal structures is presented. The tool, based on a semi-analytical mathematical strategy, is able to calculate the temperature distributions and thermal stresses at the interfaces between the layers of such structures. The core of the thermal solver is the analytical simulator for power electronic devices, DJOSER, which has been supplemented with a mechanical solver based on the finite-element method. To this end, a new ele-ment is proposed whose geometry is defined by its mean surface and thickness, just as in a plate. The resulting mechanical model is fully three-dimensional, in the sense that the deformability in the direction orthogonal to the mean surface is taken into account. The dedicated finite element code developed for solving the equilibrium problem of structures made up of two or more superimposed plates subjected to thermal loads is applied to some two-layer samples made of silicon and copper. Comparisons performed with the results of standard finite element analyses using a large number of brick elements reveal the soundness of the strategy employed and the accuracy of the tool developed.