• International Journal of Automotive Technology
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• v.4 no.4
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• pp.193-201
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• 2003

The problem of brake judder is typically caused by defects of quality manufacturing. DFSS (Design for six sigma) is a design process for quality improvement. DFSS will result in more improved but less expensive quality products. This paper presents an implementation of DFSS for quality improvement of the brake judder of heavy-duty trucks. Carrying out 5 steps of DFSS, the major reasons for defects of quality are found. The numerical approximation of the brake system is derived by means of the response surface method. Its quality for brake judder is improved by using the sigma based robust design methodology. Results are compared between the conventional deterministic optimal design and the proposed sigma based robust design. The proposed one shows that manufacturing cost may increase as the quality level increase. The proposed one, however, is more economical in aspect of the overall cost since the probability of failure dramatically goes down.

• Journal of the Korea Institute of Military Science and Technology
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• v.15 no.1
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• pp.93-100
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• 2012

In this paper, the deterministic optimal design for the tail plane made of composite materials is conducted under the deterministic loading condition and compared with that of the metallic materials. Next, the reliability analysis with five random variables such as loading and material properties of unidirectional prepreg is conducted to examine the probability of failure for the deterministic optimal design results. The MATLAB programing is used for reliability analysis combined with FEA S/W(COMSOL) for structural analysis. The laminated composite is assumed to the equivalent orthotropic material using classical laminated plate theory. The response surface methodology and importance sampling technique are adopted to reduce computational cost with satisfying the accuracy in reliability analysis. As a result, structural weight of composite materials is lighter than that of metals in deterministic optimal design. However, the probability of failure for the deterministic optimal design of the tail plane structures is too high to be neglected. The sensitivity of each variable is also estimated using probabilistic sensitivity analysis to figure out which variables are sensitive to failure. The computational cost is considerably reduced when response surface methodology and importance sampling technique are used. The study of the computationally inexpensive method for reliability-based design optimization will be necessary in further work.

• International Journal of Aeronautical and Space Sciences
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• v.18 no.4
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• pp.780-787
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• 2017

The propellant grain configuration is a design variable that determines the shape and performance of a solid rocket motor. Grain configuration variables have complicated effects on the motor performance; so the global optimization problem has to be solved in order to design the configuration variables. The grain performance has been analyzed by means of the grain burn-back and internal ballistic analysis, and the optimization technique searches for the configuration variables that satisfy the requirements. The deterministic and stochastic optimization techniques have been applied for the grain optimization, but the results are imperfect. In this study, the optimization design of the configuration variables has been performed using the hybrid optimization technique, which combines those two techniques. As a result, the hybrid optimization technique has proved to be efficient for the grain optimization design.

• Journal of Korean Society of Steel Construction
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• v.16 no.6 s.73
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• pp.819-832
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• 2004

This study describes an efficient and facile method for configuration optimum design of structures. One of the ways to achieve numerical shape representation and the selection of design variables is using the design element concept. Using this technique, the number of design variables could be drastically reduced. Isoparametric mapping was utilized to automatically generate the finite element mesh during the optimization process, and this made it possible to easily calculate the derivatives of the coordinates of generated finite element nodes w.r.t. the design variables. For the structural analysis, finite element analysis was adopted in the optimization procedure, and two different techniques(the deterministic method, a modified method of feasible direction; and the stochastic method, a genetic algorithms) were applied to obtain the minimum volumes and section areas for an efficient configuration optimization procedure. Futhermore, spline interpolation was introduced to present a realistic optimum configuration that meet the manufacturing requirements. According to the results of several numerical examples(steel structures), the two techniques suggested in this study simplified the process of configuration optimum design of structures, and yielded improved objective function values with a robust convergence rate. This study's applicability and capability have therefore been demonstrated.

• International Journal of Aeronautical and Space Sciences
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• v.17 no.2
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• pp.268-283
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• 2016

Aircraft manufacturing companies have to consider multiple derivatives to satisfy various market requirements. They modify or extend an existing aircraft to meet new market demands while keeping the development time and cost to a minimum. Many researchers have studied the derivative design process, but these research efforts consider baseline and derivative designs together, while using the whole set of design variables. Therefore, an efficient process that can reduce cost and time for aircraft derivative design is needed. In this research, a more efficient design process is proposed which obtains global changes from local changes in aircraft design in order to develop aircraft derivatives efficiently. Sensitivity analysis was introduced to remove unnecessary design variables that have a low impact on the objective function. This prevented wasting computational effort and time on low priority variables for design requirements and objectives. Additionally, uncertainty from the fidelity of analysis tools was considered in design optimization to increase the probability of optimization results. The Reliability Based Design Optimization (RBDO) and Possibility Based Design Optimization (PBDO) methods were proposed to handle the uncertainty in aircraft conceptual design optimization. In this paper, Collaborative Optimization (CO) based framework with RBDO and PBDO was implemented to consider uncertainty. The proposed method was applied for civil jet aircraft derivative design that increases cruise range and the number of passengers. The proposed process provided deterministic design optimization, RBDO, and PBDO results for given requirements.

• 한국전산유체공학회:학술대회논문집
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• 2004.10a
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• pp.187-191
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• 2004

The conventional reliability based design optimization(RBDO) methods require high computational cost compared with the deterministic design optimization(DO) methods. To overcome the computational inefficiency of RBDO, single loop methods have been proposed. These need less function calls than that of RBDO but much more than that of DO. In this study, the approximate reliability method is proposed that the computational requirement is nearly the same as DO and the reliability accuracy is good compared with that of RBDO. Using this method, the 3-D viscous aerodynamic shape design optimization with uncertainty is performed very efficiently.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.3-11
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• 2008

Robust design pioneered by Dr. G. Taguchi has been applied to versatile engineering problems for improving quality. Since 1980s, the Taguchi method has been introduced to numerical optimization, complementing the deficiencies of deterministic optimization, which is often called the robust optimization. In this study, the robust optimization strategy is proposed by considering the robustness of objective and constraint functions. The statistics of responses in the functions are surrogated by kriging models. In addition, objective and/or constraint function is represented by the probability of success, thus facilitating robust optimization. The mathematical problem and the two-bar design problem are investigated to show the validity of the proposed method.

• Transactions of the Korean Society of Automotive Engineers
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• v.12 no.2
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• pp.123-130
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• 2004

The automobile suspension system is composed of parts that affect performances of a vehicle such as ride quality, handling characteristics, straight performance and steering effort, etc. Moreover, by using the finite element analysis the cost for the initial design step can be decreased. In the design of a suspension system, usually system vibration and structural rigidity must be considered simultaneously to satisfy dynamic and static requirements simultaneously. In this paper, we consider the weight reduction and the increase of the first eigen-frequency of a suspension part, the upper control arm, especially using topology optimization and size optimization. Firstly, we obtain the initial design to maximize the first eigen-frequency using topology optimization. Then, we apply the multi-objective parameter optimization method to satisfy both the weight reduction and the increase of the first eigen-frequency. The design variables are varying during the optimization process for the multi-objective. Therefore, we can obtain the deterministic values of the design variables not only to satisfy the terms of variation limits but also to optimize the two design objectives at the same time. Finally, we have executed reliability based optimal design on the upper control arm using the Monte-Carlo method with importance sampling method for the optimal design result with 98％ reliability.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.38 no.11
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• pp.1067-1074
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• 2010

In this study, RBDO(Reliability Based Design Optimization) was performed for a supersonic double-wedge inlet. By considering uncertainty of design with given design space, the pressure recovery was transformed into the probabilistic constraint while the inlet drag was considered as a deterministic objective function. To save computational analysis cost and to search good design space, Latin-Hypercube design of experiment and the Kriging model were incorporated and then RBDO was performed. Monte-Carlo simulation was performed to verify the accuracy of AFORM(Advanced First Order Reliability Method). It was found that AFORM result agreed very well with the Monte-Carlo simulation result. The system reliability was guaranteed by considering uncertainty of the design variables. In case of considering diverse uncertainty of system design, RBDO was found to be useful.

• Transactions of the Society of Information Storage Systems
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• v.4 no.1
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• pp.6-12
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• 2008

The paper deals with the numerical analysis and design optimization of polysilicon micro thermal flexure actuator. The deflection of a thermal actuator is implicitly related to the actuation time so that such deflection is to be maximized under the consideration of structural performances such as maximum stress and natural frequencies. At first, the structural formulation of a thermal actuator is reviewed, and its CAE based simulation is performed to verify the numerical model. A parametric study is then conducted to identify the mainly effective design variables. Finally, the design of a micro thermal actuator is explored in the context of deterministic optimization and reliability based design optimization in the present study.