• KIEE International Transactions on Electrophysics and Applications
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• v.3C no.1
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• pp.1-4
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• 2003

This paper presents an attempt to develop probabilistic multistress life models to evaluate the lifetime characteristics of epoxy-encapsulated magnet wire with heavy build polyurethane enamel. A set of accelerated life tests were conducted over a wide range of pulsating voltages, temperatures, and frequencies. Samples of fine gauge twisted pairs of the encapsulated magnet wire were tested us-ing a pulse endurance dielectric test system. An electrical-thermal lifetime function was combined with the Weibull distribution of lifetimes. The parameters of the combined Weibull-electrical-thermal model were estimated using maximum likelihood estimation. Likewise, a generalized electrical-thermal-frequency life model was also developed. The parameters of this new model were estimated using multiple linear regression technique. It was found in this paper that lifetime estimates of the two proposed probabilistic multistress life models are good enough. This suggests the suitability of using the general electrical-thermal-frequency model to estimate the lifetime of the encapsulated magnet wire over a wide range of voltages, temperatures and pulsating frequencies.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.224-229
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• 2010

During the multi-pass wire drawing process, wires suffer a great amount of plastic deformation that is through the cross-section. This generates tensile residual stress at surface of drawn wires. The generated residual stress on surface is one of the problems for quality of wires so that prediction and reduction of residual stresses is important to avoid unexpected fracture. Therefore, in this study, the effect of process variables such as semi-die angle, bearing length and reduction ratio on the residual stress was evaluated through Finite Element Analysis. Based on the results of the Analysis, a prediction model was established for predicting residual stress on the surface of high carbon steel(AISI1072, AISI1082). To identify the effectiveness of the proposed model, X-ray diffraction is used to measure the residual stresses on the surface. As the result of the comparison between calculated residual stresses and measured residual stresses, the model could be used to predict residual stresses in cold drawn wire.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2002.05a
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• pp.460-465
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• 2002

The nonlinear vibration of the CRT shadow mask is analyzed in consideration of the V-shaped tension distribution and the effect of wire impact damping. The reduced order FEM model of the shadow mask is obtained from dynamic condensation for the mass and stiffness matrices. Damping wire is modeled using the lumped parameter method to effectively describe its contact interactions with the shadow mask. The nonlinear contact-impact model is composed of spring and damper elements, of which parameters are determined from the Hertzian contact theory and the restitution coefficient, respectively. The analysis model of the shadow mask with damping wires is experimentally verified through impact tests of shadow masks performed in a vacuum chamber. Using the validated analysis model of the shadow mask with damping wires, the‘design of experiments’technique is applied to search fur the optimal damping wire configuration so that the vibration attenuation of the shadow mask is maximized.

• Transactions of Materials Processing
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• v.22 no.8
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• pp.470-476
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• 2013

The aim of the current study was to predict shape recovery behavior of Ni-Ti shape memory alloy (SMA) wire after loading-unloading and after wire drawing. The superelasticity of SMA was analyzed by a hyper-elastic model for the Mullins effect using ABAQUS. Firstly, tensile tests and loading-unloading tests of the Ni-Ti SMA wire with a diameter 1.0 mm were performed using an MTS servo-hydraulic tester. The parameters for the Mullins effect were computed by ABAQUS based on curve-fitting of the loading-unloading test data. The proposed FE-model predicted the shape recovery of Ni-Ti SMA after wire drawing. Finally, the effectiveness of the model was verified by drawing experiments. The wire drawing experiments using the Ni-Ti SMA were conducted on a drawing machine(1ton, 50mm/s). In order to evaluate the shape recovery of Ni-Ti SMA, the drawn wires are annealed for 30min at $450^{\circ}C$.

• Journal of Welding and Joining
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• v.24 no.5
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• pp.67-73
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• 2006

Laser welding is suitable for welding to the aluminum alloy sheet. In order to apply the aluminum laser welding to production line, parameters should be optimized. In this study, the optimal welding condition was searched through the genetic algorithm in laser welding of AA5182 sheet with AA5356 filler wire. Second-order polynomial regression model to estimate the tensile strength model was developed using the laser power, welding speed and wire feed rate. Fitness function for showing the performance index was defined using the tensile strength, wire feed rate and welding speed which represent the weldability, product cost and productivity, respectively. The genetic algorithm searched the optimal welding condition that the wire feed rate was 2.7 m/min, the laser power was 4 kW and the welding speed was 7.95 m/min. At this welding condition, fitness function value was 137.1 and the estimated tensile strength was 282.2 $N/mm^2$.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.1
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• pp.263-270
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• 1995

The use of the shape memory alloy, Nitinol wire, is investigated as an actuator for enhancing the damping in structural vibration systems. The first-order mathematical model of the Nitinol wire is obtained from the experimental data for an actuator. Finite element method is utilized for the strain gage sensor model, which is installed at the root of cantilever beam. A simple system, cantilever beam, is built as a flexible structural system to implement a control law with the Nitinol wire actuator. The system model including sensor and actuator is derived, which agrees with the experimental results. The actuator dynamics is augmented with the system so as to design PI controller and the one of robust controllers, LQG/LTR controller, and the control laws are implemented experimentally. The experimental study shows the feasibility of utilizing the Nitinol wire as an actuator for the purpose of vibration control.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.10
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• pp.1359-1366
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• 2010

Recently, many electronic control techniques for vehicles have been developed and applied. One of the technologies can be X-by-wire such as throttle-by-wire, brake-by-wire, steer-by-wire, and etc, in which most of mechanical parts are replaced into electrical wire and actuators. In this study, the effect of throttle-by-wire and brake-by-wire control systems on vehicle velocity control, especially in a school zone, are taken into consideration. The number of accidents reported in school zones is higher than that in other places. The reason for this is that many vehicle drivers do not obey speed limit regulations. Moreover, some of the students are careless while crossing the streets. Therefore, in this study, we attempt to develop a method using throttle-by-wire and brake-by-wire control systems for automatically reducing the vehicle speed such that it will be within the speed limit. First, an engine model and a transmission system model are developed for a specific vehicle model. Second, speed reduction is carried out such that the reduction follows a pre-designed cubic spline trajectory; the trajectory is determined such that rapid deceleration, which causes discomfort to the driver and passengers, can be prevented, for which a fuzzy-PID control algorithm is applied for the trajectory following control. Finally, simulation results are presented to verify the performance of the proposed speed reduction control system.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.10
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• pp.1069-1077
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• 2015

In tunnel excavation using blast, the wire saw rock cutting method generates a discontinuity perimeter around the center cut, and thus prevents blast vibration propagation to reduce vibration and noise. Therefore, the method is expected to be easy to use and economical compared with other methods. In this paper, the cutting mechanism of wire saw in tunnel excavation is investigated. A model describing the changes in cutting depth and wire saw shape inside a rock during cutting is established and validated for this purpose. Through a simulation using the model, the important characteristics of wire saw cut are investigated, and the influences of cutting conditions, such as wire saw tension, wire saw speed, feed speed, depth, and diameter of boring, on cutting performance are also examined. A method to improve the cutting performance is proposed based on the results.

• Smart Structures and Systems
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• v.16 no.3
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• pp.415-433
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• 2015

Tendon failures in bonded post-tensioned bridges over the last two decades have motivated ongoing investigations on various aspects of unbonded tendons and their monitoring methods. Recent research shows that change of strain distribution in anchor heads can be useful in detecting wire breakage in unbonded construction. Based on this strain variation, this paper develops a damage detection model that enables an automated tendon monitoring system to identify and locate wire breaks. The first part of this paper presents an experimental program conducted to study the strain variation in anchor heads by generating wire breaks using a mechanical device. The program comprised three sets of tests with fully populated 19-strand anchor head and evaluated the levels of strain variation with number of wire breaks in different strands. The sensitivity of strain variation with wire breaks in circumferential and radial directions of anchor head in addition to the axial direction (parallel to the strand) were investigated and the measured axial strains were found to be the most sensitive. The second part of the paper focuses on formulating the wire breakage detection framework. A finite element model of the anchorage assembly was created to demonstrate the algorithm as well as to investigate the asymmetric strain distribution observed in experimental results. In addition, as almost inevitably encountered during tendon stressing, the effects of differential wedge seating on the proposed model have been analyzed. A sensitivity analysis has been performed at the end to assess the robustness of the model with random measurement errors.

• Journal of Welding and Joining
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• v.18 no.5
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• pp.41-48
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• 2000

Dynamic behaviors of the GMAW system are simulated using the short-circuit transfer model and the characteristic equations fir the power supply, wire system and arc. The conventional wire equation, which relates the rate change of the wire extension to the wire feed rate and melting rate, is modified to include effects of the molten drop attached at the wire tip. The modified wire equation describes behaviors of the GMAW system more precisely and provides information about the initial bridge volume for short-circuit transfer. The proposed short-circuit model predicts the variation of parameters such as the current, voltage, short-circuit frequency and time considering the effects of the surface tension and electromagnetic force due to current. The calculated results are in broad agreements with the experimental results under the argon shielding condition.