• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.186-192
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• 2002

As industry is developed, the faster transportation of freight train is demanded. The optimum design of a structure requires the determination of economical member size and shape of a structure which will satisfy the design conditions and the functions. In this study, it is attempted to minimize the dead weight of bogie frame. From the numerical results in the shape and size optimization of the bogie frame, it is known that the weight can be reduced up to 17.45% with the displacement, stress, first natural frequency and critical buckling-load constraints. The first natural frequency and the critical buckling load of the optimized model is larger than that of the lowest design value. Stress and displacement conditions are also satisfied within the design conditions. From the results, the optimal model is stable and useful for the improvement of railway carriages.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.88-94
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• 2014

The under-drive brake piston is an essential part in the automatic transmissions of automobiles. This component is manufactured by forging after blanking from S55C plate with a thickness of 6mm. It is difficult to design the plate forging process using a thick plate approach since there will be limited material flow as well as large press loads. Furthermore, the under-drive brake piston has a complex shape with a right angle step, which often results in die unfill and abrupt increase in press load. To overcome these obstacles, a separate die for filling material sufficiently to the corner of the right angle step is proposed. However, this approach induces an uncontrolled workpiece surface between the dies, resulting in flash. This excess flash degrades the tool life in the final machining after cold forging as well as increases the cycle time to obtain the net-shape of the part. In the current study, we propose an optimum process design using a conventional die shaped with the benefit of finite element analysis. This approach enhanced the process efficiency without sacrificing the dimensional accuracy in the forged part. As the result, the optimum plate forging process was done with a two stage die, which reduces weight of by 6% compared with previous process for the under-drive brake piston.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.06a
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• pp.49-54
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• 2006

During most of manufacturing processes of auto-body panels, the trimming line should be designed in advance prior to flanging. It is an important task to find a feasible trimming line to obtain a precise final part shape after flanging. This paper proposes a new fast method to find feasible trimming line based on one-step analysis. The basic idea of the one-step analysis is to seek for the nodal positions in the initial blank from the final part, and then the distribution of strain, stress and thickness in the final configuration can be calculated by comparing the nodal position in the initial blank sheet with the one of the final part. The one-step analysis method is able to predict the trimming line before flanging since the desired product shape after flanging can be defined from the final configuration and most of strain paths are simple during the flanging process. Finally, designers can obtain a discrete trimming line from the boundary of the developed meshes after one-step analysis and import it into CAD system in the early design stage. The proposed method has been successfully applied to two basic curve flanging processes demonstrating many advantages.

• Journal of Korean Society of Steel Construction
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• v.23 no.4
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• pp.465-474
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• 2011

In this study, a microgenetic algorithm was used to find the optimum cross-section and shape of dome structures. The allowable stress and Euler buckling stress were considered constraints when the weight of the trusses was minimum. The design optimization of the truss structures involved arriving at the optimum sizes of the cross-section and geometric coordinate. The features of the proposed method, which helped in the modeling of and application to the optimal design of truss structures, were demonstrated using the microgenetic algorithm, by solving sample problems.

• Journal of Mechanical Science and Technology
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• v.14 no.9
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• pp.1005-1012
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• 2000

Numerical optimization techniques combined with a three-dimensional thin-layer Navier-Stokes solver are presented to find an optimum shape of a stator blade in an axial compressor through calculations of single stage rotor-stator flow. Governing differential equations are discretized using an explicit finite difference method and solved by a multi-stage Runge-Kutta scheme. Baldwin-Lomax model is chosen to describe turbulence. A spatially-varying time-step and an implicit residual smoothing are used to accelerate convergence. A steady mixing approach is used to pass information between stator and rotor blades. For numerical optimization, searching direction is found by the steepest decent and conjugate direction methods, and the golden section method is used to determine optimum moving distance along the searching direction. The object of present optimization is to maximize efficiency. An optimum stacking line is found to design a custom-tailored 3-dimensional blade for maximum efficiency with the other parameters fixed.

• Structural Engineering and Mechanics
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• v.68 no.1
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• pp.121-130
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• 2018

This study deals with optimum geometry design of laterally loaded piles in a Winkler's medium through the Fully Stressed Design (FSD) method. A numerical algorithm distributing the mass by means of the FSD method and updating the moment by finite elements is implemented. The FSD method is implemented here using a simple procedure to optimise the beam length using an approach based on the calculus of variations. For this aim two conditions are imposed, one transversality condition at the bottom end, and a one sided constraint for moment and mass distribution in the lower part of the beam. With this approach we derive a simple condition to optimise the beam length. Some examples referred to different fields are reported. In particular, the case of laterally loaded piles in Geotechnics is faced.

• Transactions of Materials Processing
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• v.7 no.4
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• pp.393-399
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• 1998

For minimizing wall thickness thinning of circular shells, a new stamping technology, the deep draw-ing process combined with ironing is approached and investigated. The design requirements for the deep drawing shells are to keep the optimum wall thickness with max. 10 percent thickness thinning of the initial blank thickness, to make uniform thickness strain distribution for the wall of circular shell and to improve the shape accuracy for the roundness and concentricity. In order to check the validity and effectiveness of proposed work, a sample process design is applied to a circular shell needed for a 4multi-stepped deep drawing. Through experiments, the variations of the thickness strain distribution in each drawing process are observed. Also a series of experiments are performed to investigate optimum process variables such as the geometry of tooling, radius and drawing rate. In particular, the advantage of current approach with ironing is shown in contrast to the conventional deep drawing process. From the results of proposed method, the optimum value of process variables are obtained, which contribute more uniform thickness strain distribution and better quality in the drawn product.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.1
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• pp.1-9
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• 2016

Optimum cross-sectional shape of an automotive disc brake was developed based on FEM thermal analyses and the Taguchi method. Frictional heat flux and convection heat transfer coefficients were first calculated using equations and applied to the disc to calculate accurate temperature distribution and thermal deformations under realistic braking conditions. Maximum stress was generated in an area with highest temperature under pads and near the hat of ventilated disc and vanes. The SN ratio from Taguchi method and MINITAB was applied to obtain the optimum cross-sectional design of a disc brake on the basis of thermal deformations. The optimum cross-section of a disc can reduce thermal deformation by 15.2 % compared to the initial design.

• The KSFM Journal of Fluid Machinery
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• v.11 no.1
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• pp.52-60
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• 2008

Staggered dimples printed on opposite walls of an internal cooling channel are formulated numerically and optimized to enhance heat transfer performance. Nusselt number and friction factor based objectives are considered and a weighted average surrogate model is used to approximate the data generated by numerical simulation. The dimpled channel shape is defined by three geometric design variables, and the design point within design space are selected using Latin hypercube sampling. A weighted-sum method for multi-objective optimization is applied to integrate multiple objectives into a single objective. By the optimization, the objective function value is improved largely and heat transfer rate is increase much higher than pressure loss increase due to shape deformation. Channel with vertically non-symmetric optimum dimples is tested and found that the best appears if dimples on opposite wall are displaced by one quarter of dimple spacing.

• Journal of Magnetics
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• v.20 no.2
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• pp.193-200
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• 2015

Direct-acting solenoid valves are used in the automotive industry due to their simple structure and quick response in controlling the flow of fluid. We performed an optimization study of response time in order to improve the dynamic performance of a direct-acting solenoid valve. For the optimal design process, we used the commercial optimization software PIAnO, which provides various tools for efficient optimization including design of experiments (DOE), approximation techniques, and a design optimization algorithm. 35 sampling points of computational experiments are performed to find the optimum values of the design variables. In all cases, ANSYS Maxwell electromagnetic analysis software was used to model the electromagnetic dynamics. An approximate model generated from the electromagnetic analysis was estimated and used for the optimization. The best optimization model was selected using the verified approximation model called the Kriging model, and an optimization algorithm called the progressive quadratic response surface method (PQRSM).