• 한국자동차공학회논문집
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• 제14권6호
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• pp.95-103
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• 2006

Wheel treads of E.M.U. are usually under a heavy thermal load by brake frictional heat between wheel and brake shoe and damaged by repeated thermal and mechanical loads. To examine the cause of wheel tread damage of E.M.U.'s in service running, a systematic approach has been used. This study is composed of three parts. Frictional heat analysis was conducted in the first part by finite element method. Two kinds of brake shoes in service were considered. In the second part, experimental study was carried out on a brake dynamometer. Temperatures were measured for the two brake shoes. And experimental study in service running E.M.U.'s was performed. Wheel and brake shoe temperatures were measured by using thermocouples and temperature indicating strips. Finally metallurgical characteristics were examined by a SEM/EDS and the cause of the wheel damage was analyzed. It seems that aggregated ferrous component is a main cause of the wheel tread damage.

• 한국자동차공학회논문집
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• 제9권1호
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• pp.122-130
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• 2001

In order to improve the efficiency of the design process and the quality of the resulting design, this study proposes a design method for determining design variables of an automotive wheel-bearing unit of double-row angular-contact ball bearing type by using a genetic algorithm. The desired performance of the wheel-bearing unit is to maximize system life while satisfying geometrical and operational constraints without enlarging mounting spae. The use of gradient-based optimization methods for the design of the unit is restricted because this design problem is characterized by the presence of discrete design variables such as the number of balls and standard ball diameter. Therefore, the design problem of rolling element bearings is a constrained discrete optimization problem. A genetic algorithm using real coding and dynamic mutation rate is used to efficiently find the optimum discrete design values. To effectively deal with the design constraints, a ranking method is suggested for constructing a fitness function in the genetic algorithm. A computer program is developed and applied to the design of a real wheel-bearing unit model to evaluate the proposed design method. Optimum design results demonstrate the effectiveness of the design method suggested in this study by showing that the system life of an optimally designed wheel-bearing unit is enhanced in comparison with that of the current design without any constraint violations.

• 한국정밀공학회지
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• 제33권4호
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• pp.257-264
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• 2016

Solid state joining techniques are increasingly applied in a wide range of industrial applications. Friction welding is a solid state welding technique that is used to join similar or dissimilar materials. In this study, friction welding was applied to rotor shaft composed of a disk and a shaft. The disk and shaft were manufactured by hot forging and rolling, respectively. The aim of the study was to predict the structural characteristics during hot forging and friction welding process for rotor shaft of turbo charger. The structural characteristics were determined by heat input and heat affected zone (HAZ) during a short cycle time. Thus, transient FE analysis for hot forging and friction welding was based on heat transfer. The results were used to predict structural characteristics during hot forging and friction welding processes. The prototype of rotor shaft was manufactured by the result-based process parameters.

• Tribology and Lubricants
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• 제16권1호
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• pp.39-45
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• 2000

In this paper, the effects of shaft and bearing flexibilities are investigated for the accurate modeling of a shaft-bearing system supported by ball bearings. Generally, rolling bearings are modeled by simple rigid pin-joint in the mechanical design. However, they can no longer be modeled by ideal boundary conditions in the advanced applications because the rigid pin-joint model cannot satisfy the current trends of mechanical design decreasing mass and reducing volume. Consequently the flexible support model of ball bearing is investigated using the static analysis module developed by A .B. Jones and T. A. Harris. A simple two-bearing system, supported by two deep groove ball bearings and radially loaded on the shaft midway between the bearings, is utilized to validate the coupled model of shaft-bearing system. Numerical computations using the model indicate that the shaft span length, locating/floating bearing arrangements and applied bearing size are significant factors in determining the mechanical behaviors. The flexible support model of ball bearing can be escaped to over-estimate in the bearing fatigue life. The proposed simple design formulation obtained by numerical simulations can approximately predict a rate of bearing life reduction as a function of shaft span length/shaft diameter (L/d).

• Tribology and Lubricants
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• 제23권3호
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• pp.103-108
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• 2007

In this paper, the optimized design and strength analysis have been presented based on the finite element and Taguchi's experimental methods. The stress, strain and displacement characteristics of OPC drum tubes are affected by rolling contact pressures between an OPC drum tube and a paper, design parameters of an aluminum tube and material properties. The OPC drum tubes with nine different geometrical models are analyzed for design parameters that are related to the outer diameter, the thickness, and the length of an aluminum tube for a toner cartridge. The optimized design parameters for an aluminum tube may be selected as the outer diameter of 28 mm, the thickness of 0.8 mm, and the length of 220 mm. But the currently used aluminum tube for a laser printer is fairly optimized based on the Taguchi's design analysis. The calculated FEM results showed that the affection ratio of the design parameter t, which may control the strength of an aluminum tube, is the most influential parameter among the length and an outer diameter of a tube.

• 소성∙가공
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• 제20권1호
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• pp.42-47
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• 2011

Recently, with the merits of simplicity, ease of mass production and cost effectiveness, a roll-to-roll (R2R) forming process is tried to be employed in the manufacturing of the circuit board, barrier ribs and other electronic device. In this study, the roll-to-roll process for the forming of micro-pattern in electronic device panel is designed and analyzed. In the preliminary experiments, two major defects, i.e., crack near the dimple wall and wrinkling on outside region of dimple, are found. The study on the crack prevention is carried out in previous works by authors. In this study, the cause of wrinkling and modification of tooling to prevent the wrinkling is studied. The main cause of wrinkling is considered to be the uneven material flow along the rolling direction. To reduce or to retard the wrinkling initiation, a dummy shape on outside the pattern is introduced. From the finite element analysis results, it is shown that the dummy shape can reduce the uneven material flow significantly. Finally the effect of dimensions of the dummy shape on material flow is investigated and the optimum dimensions are found.

• 대한기계학회논문집A
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• 제33권9호
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• pp.982-989
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• 2009

Parallel Kinematic Mechanism (PKM) is a device to perform the various motion in three-dimensional space and it calls for six degree of freedom. For example, Parallel Kinematic Mechanism is applied to machine tools, medical equipments, MEMS, virtual reality devices and flight motion simulators. Recently, many companies have tried to develop new Parallel Kinematic Mechanism in order to improve the cycle time and the precisional tolerance. Parallel Kinematic Mechanism uses general universal joint and spherical joint, but such joints have accumulated tolerance problems. Therefore, it causes position control problem and dramatically life time reduction. This paper focused on the rolling element to improve sliding precision in new sliding ball joint development. Before the final design and production, it was confirmed that new sliding ball joint held a higher load and a good geometrical structure. FEM analysis showed a favorable agreement with tensile and compressive testing results by universal testing machine. In conclusions, a new sliding ball joint has been developed to solve a problem of accumulated tolerance and verified using tensile and compressive testing as well as FEM analysis.

• 대한산업공학회지
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• 제27권1호
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• pp.61-68
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• 2001

A rotor system is composed of a rotating shaft with supporting bearings. The rotor system is widely used in every rotating machinery such as the turbine generator and the high precision machine tools. A negligible error or malfunction in the rotor, however, can cause a catastrophic failure in the system then result in the environmental and economic disasters. A diagnosis of the rotor system is important in preventing these kinds of failures and disasters. Up to now, many researchers have devoted in the development of diagnosing tools for the system. The basic principles behind the tools are to retrieve the data through the sensors for a specific state of the system and then to identify the specific state through the heuristic methods such as neural network, fuzzy logic, and decision matrix. The proper usage of the heuristic methods will enhance the performance of the diagnostic procedure when together used with the statistical signal processing. In this paper, the methodologies in using the above 3 heuristic methods for the diagnostics of the rotor system are established and also tested and validated for the data retrieved from the rolling element bearing and journal bearing supported system.

• 한국추진공학회:학술대회논문집
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• 한국추진공학회 2003년도 제21회 추계학술대회 논문집
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• pp.261-266
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• 2003

포일 베어링은 공기의 점성과 포일 형태의 구조물을 이용하는 비접촉 베어링으로서, 구름베어링에 비하여 별도의 윤활장치가 필요 없고, 무한수명이 가능하며, 구름베어링을 사용할 수 없는 초고속 회전체와 50$0^{\circ}C$ 이상의 고온 환경에도 적용이 가능하다는 장점이 있다. 최근에는 전통적으로 널리 사용되어 왔던 소형 터보기기 분야뿐만 아니라, 소형 가스터빈 엔진과 같이 극한 온도 조건에서도 작동할 수 있는 포일 베어링에 대한 연구가 활발하게 진행되고 있다. 본 논문에서는 포일 공기 베어링 원리에 대한 소개와 함께, 현재 당사에서 볼베어링을 사용하여 개발 중인 65마력급 무인기용 터보샤프트 엔진의 고온부 베어링으로 적용하기 위한 가능성 연구를 수행하였다.

• 유공압시스템학회논문집
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• 제7권1호
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• pp.1-5
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• 2010

This paper presents the experimental results of the radial piston type oil pump with new mechanism for a metal diaphragm hydrogen compressor. Generally, metal diaphragm type hydrogen compressor systems are operated by oil hydraulic power. In this system an oil compensating pump has been demanded to compensate for a leakage oil head chamber. The metal diaphragm type hydrogen compressor consists of an oil compensating pump, commonly used hydraulic piston pump and driven by main crank shaft. The radial piston type oil compensating pump with new rolling contacted piston mechanism is developed and experimented. The developed piston element of the radial piston pump consists of piston, steel ball, return spring, two check valves, eccentric cam and ball racer. In this study, designed 4 type pistons as and orifice hole. Operating characteristics and pressure ripple characteristics are tested under no load to 60bar loaded with every 20bar increasing step and pressure ripple and flow rate are experimentally investigated.