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REFERENCE LINKING PLATFORM OF KOREA S&T JOURNALS
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Journal of the Korean Society of Manufacturing Process Engineers
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Journal DOI :
The Korean Society of Manufacturing Process Engineers
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Volume & Issues
Volume 14, Issue 6 - Dec 2015
Volume 14, Issue 5 - Oct 2015
Volume 14, Issue 4 - Aug 2015
Volume 14, Issue 3 - Jun 2015
Volume 14, Issue 2 - Apr 2015
Volume 14, Issue 1 - Feb 2015
Selecting the target year
Cycle Reduction Simulation for Turning Process
Kim, Sun-Ho ; Cho, Hang-Deuk ; Kim, Tae-Ho ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 1~8
DOI : 10.14775/ksmpe.2015.14.1.001
Productivity of machining using machine tools is affected by cutting conditions such as cutting speed, feedrate and depth. However, undesirable conditions that lengthen the machining cycle and shorten the tool life occur frequently because determination of cutting condition is known to depend on human experience. This paper presents a method of cycle reduction by removing undesirable conditions. For cycle reduction, maximum cutting load is determined using commercial FEM simulation code. The feedrate in the NC program is altered based on a predetermined cutting load value. To make a decision on the proposed effectiveness, a simulation is performed for the brake hub parts of an automobile. From the evaluation, it was found that the cycle reduction was under 15%.
A Study on the CAE Analysis of Bed of Multi-Tasking Machine for Automotive Power Train Shafts
Cho, Jun-Hyun ; Moon, Dong-Ju ; Lee, Jong-Chan ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 9~14
DOI : 10.14775/ksmpe.2015.14.1.009
To build a high precision machine tool and increase its productivity, structural analysis needs to be carried out for vibration and stiffness of the machine tools before any detailed design. Therefore, in this paper, static and dynamic analysis is carried out to evaluate 8-axis multi tasking machining beds for automotive power train shafts; then, selection of an appropriate device is made for application to bed design. The results of structural and modal analysis confirmed the structural characteristics of the 8-axis multi tasking machine for automotive power train shaft beds: and the second shape bed is the safest is considered secure.
Manufacturing on the Door Built-in Metal Pattern using Electroforming with Hologram
Kwon, Hyuk Hong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 15~20
DOI : 10.14775/ksmpe.2015.14.1.015
I developed a high-quality metal door with a hologram-pattern design using a high-speed electroforming process. In this study, the major processes were master production, conducting grant, nickel-sulfamate acid electroforming, ablation treatment, and final dressing. The processing system was provided with a nickel sulfamate pole, and a rotary-pole PP-plating jig in a circular tank. This approach could reduce defects and errors, as much as possible, by its use of a hologram pattern to create the master of a metal door. The thin-sheet metal-creation process for the door built-in metal pattern using electroforming with hologram was successful.
Comparison of the Contact Characteristics for Sealing strips of the Tsunami Damper
Seo, Ji-Hwan ; Kim, Byung-Tak ; Chin, Do-Hun ; Yoon, Moon-Chul ; Kwak, Jae-Seob ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 21~28
DOI : 10.14775/ksmpe.2015.14.1.021
A Tsunami damper, which is installed on the outer wall of a nuclear power plant, is usually used as a ventilation window of the machine room, but can serve as a device for preventing flooding of the machine room when large waves flow over the outer wall. The sealing strip, which is inserted between the casing and the blades, plays an important role in maintaining a watertight environment. In this study, in order to ensure an effective watertight performance of the tsunami damper, FE analysis is conducted to compare the contact characteristics of sealing strips with three different section shapes. In the analysis, the casing and the blade of Tsunami damper are assumed to be rigid bodies; the sealing strip is assumed to be a flexible body. The stress, the strain, and the contact pressure are investigated to examine the sealing performance of each model.
Development of Rubber Sleeve for Reduction of End-mark in Cold Rolled Steel Sheet
Kim, Soon-Kyung ; Kim, Dong-Keon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 29~35
DOI : 10.14775/ksmpe.2015.14.1.029
In this study, a FEM analysis is undertaken of a rubber sleeve which is mounted onto a spreading mandrel so as to avoid marking the first wrappings of coils (known as the 'end-mark'), as occasionally occurs when a concentrated load is placed on the edge of a steel sheet, significantly reducing its quality. A commercial numerical package, ANSYS, was utilized to analyze the structural behavior of the rubber sleeve. In general, the strain of the sleeve increases as the thickness of the rubber layer (H) covering the tubes increases, thus also increasing the surface of the sleeve for a constant boundary condition, and decreasing the pitch (P) between each tube, resulting in an increase in the strain on the surface of the sleeve for all rubber thickness conditions tested here. In a comparison of two different materials, rubber and urethane, when H=3 mm and P=1.1D, the maximum total deformations in these cases are 0.12669 mm and 0.086623 mm, respectively.
Optimization of Injection Molding Design Using Two-Characteristic Value Function Methodology
Park, Jong-Cheon ; Kim, Kyung-Mo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 36~43
DOI : 10.14775/ksmpe.2015.14.1.036
Optimizing multiple design characteristics which are usually in conflict with each other in the injection molding process is frequently becoming a critical problem for designers who work in this area. The purpose of this work is to develop an automated design methodology for optimizing two such design characteristics found in injection-molded parts. A value function based on decision-making theory is used as a means of evaluating the performance of a two-characteristic design alternative. Also, a design space reduction algorithm based on Taguchi's orthogonal arrays is utilized to discover an optimal design alternative. Verification of the developed design methodology is carried out for an actual model with two design characteristics, the weld line and the gate location, to be optimized in computer simulation experiments.
Minimization of Warpage of Injection Molded Parts using Dynamic Robust Design
Kim, Kyung-Mo ; Park, Jong-Cheon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 44~50
DOI : 10.14775/ksmpe.2015.14.1.044
This paper presents a heuristic process-optimization procedure for minimizing warpage in injection-molded parts based on the dynamic robust design methodology. The injection molding process is known to have intrinsic variations of its process conditions due to various factors, including incomplete process control facilities. The aim of the robust design methodology advocated by Taguchi is to determine the optimum design variables in a system which is robust to variations in uncontrollable factors. The proposed procedure can determine the optimal robust conditions of injection molding processes at a minimum cost through a trade-off strategy between the degree of warpage and the packing time.
Investigation of Abnormal Wear of Jig in Electric Resistance Welding
Kim, Sun-Ho ; Cho, Hang-Deuk ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 51~56
DOI : 10.14775/ksmpe.2015.14.1.051
This paper presents an investigation of abnormal wear of a contact jig between a nail and a nail fixture in electric resistance welding. To perform an analysis on the abnormal wear phenomenon, several methods are provided. Based on the theory of electric resistance welding, are analyzed. Using microscopic analysis, surface craters are observed. In the measurement of the electric current flow in the nail fixture, the current flow distribution is measured. From several analyses, the cause of abnormal wear in the contact jig is measured using the electric discharge of high current density at the inflow point of the electric supply to the nail fixture. An alternative shape for normal wear is proposed.
Study on the Reduction of Wet-Brake Noise
Koo, Ja-Ham ; Kwon, Soon-Hong ; Chung, Sung-Won ; Park, Jong-Min ; Choi, Won-Sik ; Kim, Jong-Soon ; Kwon, Soon-Goo ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 57~62
DOI : 10.14775/ksmpe.2015.14.1.057
The wet brakes used on a forklift often produce noise upon engagement. The elimination or reduction of this squeal noise is an important task for the improvement of the comfort of those operating these machines. In this paper, a test rig was developed for the testing of brake noise, and the squeal noise was measured with this apparatus. Automatic transmission fluid and grooves in the material of the friction-plate pad were found to be the main factors causing squeal noise. In order to identify the characteristics of this type of noise, signal analyses of the noise were conducted using different frequency spectra. The experimental results showed that the viscosity of the automatic transmission fluid and the groove pattern on the friction-plate pad largely affected the reduction of the wet brake squeal noise made by an industrial forklift.
Development of Protective Device for Quadcopter on Impact
Na, Yeong-Min ; Park, Jong-Kyu ; Lee, Hyun-Seok ; Kang, Tae-Hun ; Park, Tae-Gone ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 63~69
DOI : 10.14775/ksmpe.2015.14.1.063
Recently, research and interests in pilotless and radio-controlled quadcopters have increased due to military, hobby, and air-photo applications. However, quadcopters are fragile and can very easily to break when they crash. Therefore, it is necessary to create a protective device such that these devices can protect the main board, motor, and propellers from outside impacts. In this paper, a protective device for a quadcopter is designed in the form of a circle to disperse shock. Also, a dropping and impact simulation was performed to verify that the quadcopter can be efficiently protected when using the proposed device, created with the commercial finite element software Solidworks.
Drilling Characteristics of PVC Materials
Byun, J.Y. ; Park, Na-Ram ; Chung, S.W. ; Kwon, S.H. ; Kwon, S.G. ; Park, J.M. ; Kim, J.S. ; Choi, Won-Sik ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 70~77
DOI : 10.14775/ksmpe.2015.14.1.070
This paper develops and evaluates a mechanical machining process which involves drilling on PVS material. According to the material, two treatment experiments were conducted, one involving drilling in a wet condition or using a lubricant and one involving drilling in a dry condition with no lubricant. Drilling in a dry condition showed better performance in terms of the cutting time than in the wet condition. Otherwise, the wet condition has several advantages. The lubricant influenced the burr diameter size and minimized the temperature on the surface of the work piece. During the wet condition drilling process, a smaller burr diameter size was noted as compared to the dry condition. The temperature showed a linear correlation with the drill bit size, where a least-square analysis provided an
valuewhichexceeded 0.95. The wet condition required more cutting time than the dry condition. In this condition, the water provides a lubrication effect. A thin layer between the cutting edges and the surface of the work piece is formed. The chip formation is affected by the drilling depth. The color on the tips of the chips was darker than in the initial condition. No correlation between the drilling depth and the bore roughness was noted, but the variation of the cutting speed or the RPM influenced the roughness of the bore. The optimum cutting speed ranged from 40 RPM to 45 RPM in the condition which provided the finest roughness surface.
The Effect of Behavior Fatigue Crack Propagation on 2-Axle Load Frequency
Kim, Sang-Hee ; Li, Jing-Hua ; Choi, Seong-Dae ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 78~84
DOI : 10.14775/ksmpe.2015.14.1.078
The stress state acting on mechanical parts and structures is generally mixed stress. This complex stress state, which is subject to changes in the environment, will produce many. Cars running on roads with different road conditions will subject the automotive parts to combined stress state. In the x direction and the y direction, a different amplitude and frequency of the fatigue load can be present. However, the load amplitude for Mode I and Mode II in a 2-axis fatigue test is limited to a constant ratio; the load frequency is always the same for any mode. In this paper, it is verified how the variation of the load frequency for mode II affects the behavior of fatigue crack propagation under mixed mode.
Structural Analysis and Design of Small Wind Turbine Blade
Choi, Du-Soon ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 85~91
DOI : 10.14775/ksmpe.2015.14.1.085
Wind turbine blades represent a key component of wind turbines, which extract energy from the wind. In the present study, the structural design of a small wind turbine blade is undertaken using a numerical analysis. The reliability of numerical results is verified through a comparison with the full-scale structural test data of a current blade. To modify the blade design, the blade was divided into several sections and the effect of the thickness of each section was investigated in a numerical analysis. Finally, the modified blade was designed with a lightweight and high-strength.
Carrier Design by Temperature Distribution Analysis in Chamber of ITO Deposition Inline Sputter
Lee, Sang-Jae ; Choi, Ju-Ran ; Choi, Seong-Dae ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 92~97
DOI : 10.14775/ksmpe.2015.14.1.092
The design of the glass-carrier was studied using simulations of the temperature distribution of an ITO deposition inline-sputter process. The temperature distribution was simulated in Heating Chamber 7, and in the ITO Deposition Chambers 8 and 9. The temperature distribution of the glass sheets was low in both the lower and upper lines. Moreover, it was observed that the temperature in Chamber 8 significantly affected the temperature in Chamber 9, and that the latter was hotter. The rear of the chambers were subjected to more heating than the fronts, so the temperature range at the back was wider. Redesigning the shape of the carrier made it possible to load more glass sheets on the glass carrier, and to make deposits on the ITO glass at higher temperature, over a wider area.
An experimental study on the Vortex nozzle for generating micro-bubble by air self-suction
Kwak, Gu Tae ; Park, Sang Hee ; Kim, Chang Su ; U, Sang Yul ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 98~104
DOI : 10.14775/ksmpe.2015.14.1.098
This experiment was a study of a Vortex nozzle designed to produce micro-bubbles due To investigate air self-suction and the generation of micro-bubble by the Vortex nozzle, the dimensions of air intake region, the nozzle shape, and the nozzle exit diameter (
)werevaried. The air self-suction rate was ~1,000 to 2,000 cc/min at the orifice nozzle (7 mm), and ~100 and ~22 cc/min at the sector nozzles (9.2 and 12.3 mm, respectively). The most bubbles were detected in the orifice nozzle, but bubbles less than
were found in the 12.3-mm sector nozzle. The dissolved oxygen in the tank water was much greater in Case 2 than in Case 1, at both the orifice and sector nozzles. Moreover, the reduction rate of dissolved oxygen was found to be less at the sector nozzles, than at the orifice nozzle.
Development of Hybrid Composite Die for the Production of the Supercapacitor
Kwon, Hyuk Hong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 105~110
DOI : 10.14775/ksmpe.2015.14.1.105
In this study, a high-speed procedure to be used in composite molding technology is developed for the production of a hybrid supercapacitor in a progressive and revolutionary current in a production system, as are the related operating conditions. Mold parts with solid modeling, the ease of programming of future mold product designs, tolerance management, and pre-explode tests by the building of a progressive die design system using Cimatron_E10 Die Design Software for the strip layout are done. The capacity of the super-hybrid composite mold design will save time and money through its verification of the manufacture of molds. We plan to apply this to future related products for production cost savings of more than 30% achieved by considering the components of the production costs, labor, and material costs of production as compared to conventional production methods.
Rescue Lift Development Using Structural Analysis
Son, In-Soo ; Kim, Chang-Ho ; Bae, Sung-Ho ; Lee, Joon-Yong ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 111~116
DOI : 10.14775/ksmpe.2015.14.1.111
There has been a string of negligent accidents at the seaside. In addition, there is a shortage of professional equipment to deal with these negligent accidents at present. The purpose of this paper is to assess the development of a rescue lift using a structural analysis. The critical load of a support pipe on the rescue lift is investigated in this paper. The stability of the rescue lift is also determined in a structural analysis. In the critical load analysis, the effects of variations in the pipe length and the ratio of the moment of inertia are investigated. The total weight of the developed rescue lift is approximately 20.7kg, and the lift passed the load tests.
A Development of High-Precision Chamfering Tool Set
Kim, Chul ; Choi, Yong-Hoon ; Sho, Byung-Hwan ; Kim, Chang-Ho ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 117~122
DOI : 10.14775/ksmpe.2015.14.1.117
There has been a string of negligent accidents at the seaside, and there is presently a shortage of professional equipment to deal with such accidents. The purpose of this paper is to assess the development of a rescue lift. The critical load of a support pipe, and the stability of the rescue lift, were investigated using structural analysis. Critical-load analysis was used to study the effects of variations in the pipe length and the ratio of the moment of inertia. The total weight of the developed rescue lift is approximately 20.7 kg, and the lift passed the load tests.
Development of the Optimized Angle Head for Internal Shape Machining Using Five-Axis Machine Tool
Hwang, Jong-Dae ; Kim, Jae-Hyun ; Cho, Young-Tae ; Jung, Yoon-Gyo ; Ko, Hae-Ju ;
Journal of the Korean Society of Manufacturing Process Engineers, volume 14, issue 1, 2015, Pages 123~129
DOI : 10.14775/ksmpe.2015.14.1.123
In general, recent critical studies of five-axis machine have tended to center on the question of effective machining to realize complex shape parts. However, the hydrostatic bearing and journal bearing, both of which are involved in the complex process of dividing the processing of internal precision-shape machining, must be optimized. Although the angle head is designed to machine the internal shape as it approaches the inner diameter of the work piece, research on the angle head in five-axis machining has received only minimal attention in domestic industries. In this study, an angle head which is optimized for effective internal shape machining is developed. In pursuit of this purpose, 3D and 2D designs of the angle head for five-axis machining are devised. Reliability is secured through static performance tests and machining accuracy evaluations of the angle head in keeping with the machining accuracy standard of 0.2mm for hydrostatic bearings.