• Journal of Advanced Marine Engineering and Technology
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• v.32 no.2
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• pp.306-314
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• 2008

General metal welding occurs distortion. Also, reducing distortion is required much cost. Therefore, the purpose of this study is optimization of welding conditions to reduce distortion in welding of monolithic rack housing for modular steering gear. Firstly, heat source for welding was chosen arc and laser. Secondly, it investigated optimizing welding conditions in bead welding by arc and laser heat source, and welding conditions in fillet welding was optimized with welding shapes. Finally, it was measured temperature distribution of welds by infrared camera and angle distortion in fillet welding. As a result, laser welding was superior to arc welding on distortion.

• Macromolecular Research
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• v.17 no.10
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• pp.797-806
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• 2009

The mechanical and thermal behaviors of polyamide-6/clay nanocomposites were studied using the continuum-based, micromechanical models such as Mori-Tanaka, Halpin-Tsai and shear lag. Mechanic-based model prediction provides a better understanding regarding the dependence of the nanocomposites' reinforcement efficiency on conventional filler structural parameters such as filler aspect ratio ($\alpha$), filler orientation (S), filler weight fraction (${\Psi}_f$), and filler/matrix stiffness ratio ($E_f/E_m$). For an intercalated and exfoliated nanocomposite, an effective, filler-based, micromechanical model that includes effective filler structural parameters, the number of platelets per stack (n) and the silicate inter-layer spacing ($d_{001}$), is proposed to describe the mesoscopic intercalated filler and the nanoscopic exfoliated filler. The proposed model nicely captures the experimental modulus behaviors for both intercalated and exfoliated nanocomposites. In addition, the model prediction of the heat distortion temperature is examined for nanocomposites with different filler aspect ratio. The predicted heat distortion temperature appears to be reasonable compared to the heat distortion temperature obtained by experimental tests. Based on both the experimental results and model prediction, the reinforcement efficiency and heat resistance of the polyamide-6/clay nanocomposites definitely depend on both conventional (${\alpha},\;S,\;{\Psi}_f,\;E_f/E_m$) and effective (n, $d_{001}$) filler structural parameters.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.6
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• pp.111-118
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• 2014

Aluminum lithium alloys are new materials developed for lightweight aircraft parts. However, as compared with conventional aluminum alloys in high-speed machining, problems such as tool wear, machining distortion, and cutting ability arise. This study presents the machining distortion characteristics of an Al-Li alloy wing tip in relation to the cutting heat in high-speed machining. A machining experiment was conducted with high-speed machining equipment for an evaluation of the machining distortion characteristics, with each machining stage temperature change of the workpiece machining surface, and the inside and outside temperature changes of the equipment measured. By measuring the amount of distortion of the workpiece before and after machining, the cutting heat was analyzed with regard to its effect on machining distortion in the product.

• Journal of Sensor Science and Technology
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• v.19 no.5
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• pp.375-384
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• 2010

In this paper, we proposed a new shaft distortion correction system having an adaptive PID controller using displacement sensors, which is adaptively reflecting variations of shaft strength owing to irregular heat treatment during an annealing process and sensitivity to the seasonal temperature changes. Generally, the shafts are annealed by heat treatment in order to enlarge the strength of the shaft, which causes an distortion of a shaft such as irregular bending of the shaft. In order to correct such a distortion of the shaft, a mechanical pressure is properly impacted to the distorted shaft. However, the strength of every shaft is different from each other owing to irregular annealing and seasonal temperature changes. Especially, the strength of a thin shaft such as a car transmission shaft is much more sensitive than that of a thick shaft. Therefore, it is very important for considering the strength of each shaft during correction of the car transmission shaft distortion in order to generate proper mechanical pressure. The conventional PID controller for the shaft distortion correction system does not consider each different strength of each shaft, which causes low productivity. Therefore, we proposed a new PID controller considering variations of shaft strength caused by seasonal temperature changes as well as irregular heat treatment and different cooling time. Three displacement sensors are used to measure a degree of distortion of the shaft at three different location. The proposed PID controller generates adaptively different coefficients according to different strength of each shaft using appropriately obtained pressure times from long-term experiments. Consequently, the proposed shaft distortion correction system increases the productivity about 30 % more than the conventional correction system in the real factory.

• Journal of the Society of Naval Architects of Korea
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• v.44 no.6
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• pp.598-604
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• 2007

The purpose of this study is to establish the predictive method of welding distortion and residual stress for the channel I butt SA (submerged arc) weldment using FEA. In order to do it, the heat input model for the weldment was defined as the combined heat source with the surface heat flux of gaussian distribution and volumetric heat source uniformly distributed within weld groove by comparing the shapes of molten pool and temperature distribution obtained by FEA with those of experiments. The arc efficiency of SA welding for two-dimensional FE analysis was evaluated as 0.85. The welding distortion and residual stress of the weldment obtained by FEA and heat input model proposed have a good agreement with those obtained by experiment. Based on the results, it was suggested that the proper heat input model should be required to evaluate the welding distortion for weldment.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 2001.11a
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• pp.341-349
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• 2001

Heat distortion of the non-contacting mechanical face seal is affected by friction heat between primary seal and seal sheet. The fluid or gas in mechanical face seal maintains operating gap, cooling friction heat and lubricates at the face of seal. So we designed face of seal for inclined face. inclined face of seal improves fluid or gas flow at the face of seal and it increases circumferential velocity at outer radius of the seal so temperature of the seal is decreased by low heat transfer coefficient at there. In this paper, inclined face seal are analysed numerically using finite element method for proof improve inclined face seal performance. Angle of the incline face used for FEA is from 50$^{\circ}$to 90$^{\circ}$and for explaining the effects of inclined face in seal, we get temperature, face distortion, and stress in the seal with variable operating gap and rotating speeds. Result of analysis shows that angle of the incline face is 60$^{\circ}$come to good thermal distortion characteristics.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2006.11a
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• pp.189-192
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• 2006

The purpose of this study is to evaluate the welding distortion at the channel I butt SA weldment. In order to do it, the heat input model for the weldment was defined as combined heat source with the surface heat flux of gaussian mode and volume heat source uniformly distributed within weld groove on the basis of comparing the shapes of molten pool and temperature distribution obtained by FEA and experiment. The arc efficiency of SA welding for 2 dimensional FE analysis was determined as 0.85. The results of welding distortions at the weldment obtained by FEA and heat input conditions proposed have a good agreement with those obtained by experiment. Based on the results, it was suggested that the proper heat input model should be required to evaluate the welding distortion for weldment.

• Journal of Welding and Joining
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• v.30 no.5
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• pp.57-63
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• 2012

The purpose of this study is to evaluate the welding distortion of the circular type lap joint in STS304L of 0.7mm thickness by using FEA. In order to do it, a heat input model for GTA welding process with non-consumable electrode was established through comparing the molten pool shapes and temperature distributions obtained by both FEA and experiment. With the heat input model, the welding distortion of the circular type lap joint was evaluated by 3-D FEA. From FEA results, it was found that 3-D FEA with proper heat input model can be used for the evaluation of the excessive distortion of the circular type lap joint of STS304L thin plate. In addition, the root cause of the excessive distortion in the weld was also identified as the excessive compressive residual stress in the tangential direction of the weld.

• Proceedings of the KWS Conference
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• 2002.10a
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• pp.661-667
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• 2002

Welding-induced buckling distortion is one of the most problematic concerns in both design and fabrication of welded thin-plate structures. This paper deals with experimental and numerical results of the welding-induced longitudinal and/or buckling distortion occurring in welding of 6mm-thick AH36 high strength steel plates. Effects of the heat input and the plate size on the distortion were experimentally evaluated for square plates. Bead-on-plate welding was performed with the submerged arc welding process along the middle line of plate specimens. Experimental results showed that the longitudinal distortion made a single curvature in the plate, and the distortion magnitude along the weld centerline was proportional to the heat input and the plate size. The experimental results were used to examine the validity of the numerical simulation procedure for welding-induced distortion where the longitudinal distortion mode and magnitude were numerically quantified. Three-dimensional, large deformation, welding simulations were performed for selected weld models. Numerical results of the distortion mode and magnitude were in a good agreement with experimental ones. Depending on the presence of halting the distortion growth during the cooling cycle of welding, the condition discriminating buckling distortion from longitudinal distortion was established. Eigenvalue analyses were performed to check the buckling instability of tested plates with different sizes subjected to different heat inputs. The perturbation load pattern for the analysis was extracted from longitudinal inherent strain distributions. Critical buckling curve from the eigenvalue analyses revealed that the buckling instability is manifested when plate size or heat input increases.

• Fibers and Polymers
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• v.7 no.4
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• pp.358-366
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• 2006

Thermotropic liquid crystal polymer (TLCP)-reinforced poly(butylene terephthalate) (PBT) composites were prepared by melt processing. The improvement in the mechanical properties and the processability of the PBT/TLCP composites was attributed to the reinforcing effect by TLCP phase and its well distribution in the PBT matrix. X-ray diffraction results demonstrated that a slow cooling process leads to the thicker lamellar structures and the formation of more regular crystallites in the composites. The incorporation of TLCP improves not only the tensile strength and flexural modulus but also the heat distortion temperature (HDT) of the PBT/TLCP composites. The HDT values of the composites were dependent on TLCP content. The improvement in the HDT values of the PBT/TLCP composites may be explained in terms with the increased flexural modulus, the development of more regular crystalline structures, and the enhancement of the ability of the composites to sustain the storage modulus by TLCP phase. In addition, the simple additivity rule makes it possible to predict the HDT values of the PBT/TLCP composites.