Engine components subjected to cyclic thermal and mechanical loads may experience low-cycle or high-cycle fatigue failures. In particular, both of these failures can easily occur in aluminum cylinder heads, which are exposed to high temperatures and combustion pressures. Predicting the fatigue characteristics of the cylinder head are very important in the design stage of engine development. In this study, a finite element analysis was performed to predict the low-cycle thermal fatigue around exhaust ports of the cylinder head. Temperature distributions are obtained through the heat transfer analysis considering thermal cyclic test. The analysis result involves large plastic deformations, indicating compressive stresses at high temperatures and subsequently turn into tensile stresses at cold conditions. And the results showed that the critical regions such as exhaust port with large plastic strains coincided well with crack locations from thermal cyclic test. Next, design changes were made to the critical areas of the exhaust ports, and the results showed that the durability was improved by about 60% over the initial model and there were no problems in the thermal fatigue test.
In order to commercialize large diameter PP pipes, the cutting work was attempted with the cutting machine (∅18″and AL120 cutter, 2100 r.p.m) used for the conventional PE or PVC pipe(∅1200 mm, t 70), but the cutting work was failed because the material of “PP pipe” melted and sticked to the surface of the wheel-cutter. In order to find the optimal structure and number of blades for wheel-cutters, an experimental investigation the temperature measurement of specimen and wheel-cutter and the visualization of cutted specimen surface and chip shape were carried out during and after experiment. In addition, modelings for cutting and heat transfer mechanisms have been developed for theoretical analysis. The theoretical and experimental results were in good agreement. The results show that the appropriate structure and the rotational speed of wheel-cutter are W60 and 650 rpm for the large diameter PP pipe cutting machine.
In this study, quality keywords of frequent mention of failures were extracted by analyzing the field operational data of main battle tanks recorded for about 5 years. As a result of the data analysis, the leaf spring assembly of the crew hatches corrosion and failure was frequently occurred. FEA(Finite Element Analysis) and tests were performed to analyze the cause of the failure, and it was confirmed that durability of the leaf spring was insufficient. Therefore a design modification study was conducted to improve durability of the leaf spring, and FEA and durability tests demonstrated the improvement. As a result, the durability of leaf spring was improved at least 3.3 times compared to before improvement. This study will contribute to suggesting the use of data analysis in the defense area and improving the operability of the main battle tanks.
The purpose of this study is to investigate the interrelationship of how the ship's wave resistance performance changes with the change of the longitudinal position of the section line in the ship's lines, and to find a way to use it in the hull-form design. To this end, we developed a hull-form automatic change algorithm that can maintain the proper hull-form while moving the section lines in the longitudinal direction, and the computer program for a numerical analysis was developed to apply the developed algorithm. By applying the developed hull-form automatic change algorithm and the wave resistance performance prediction program, the numerical analysis package was constructed. The numerical analysis was carried out for the passenger ship. Numerical analyzes were carried out by moving the section lines of the passenger ship in the longitudinal direction, and the results were compared with each other. Based on the numerical results, we attempted to investigate the correlation between the section line movement and the wave resistance performance.
The objective of this study is to optimize the diameter of tubular shaft yoke and solid shaft yoke, which are the core components of Al IMS for xEV. The processes of both products were designed totally 6 steps to manufactured the shaft part and the yoke part. The diameter of solid shaft yoke and tubular shaft yoke were changed from 20mm to 25mm and from 30mm to 35mm, respectively. Al 6082 was applied to the material of both products. The friction condition between die and material was employed Oil_Cold (Aluminum) with reference to the library in the program. The results were analyzed and compared in terms of effective stress, effective strain, and nodal velocity characteristics. The effective strain value for manufacturing the yoke part was higher than the shaft part because its part has a complex geometry. The value of nodal velocity was also higher with high effective strain region. However, in 6 stage process of tubular shaft yoke, although it had the high effective strain value, the nodal velocity value was the lowest due to the piercing process. The effect of shaft part diameter on effective stress in the tubular shaft was difficult to observe, however, in the solid shaft yoke, when the shaft part of one increased, the effective stress value was increased due to the larger yoke size.
With the current increase in national income, consumers are favoring expensive home appliances. Many aluminum parts are used to improve the appearance of TV products. However, many losses are incurred due to production defects. There are many flaws in the bending process. This study studied the improvement of bending defects during fault handling. The material used is an aluminum alloy (6063), and the product is a serrated component on the surface of an aluminum part. After the bending process, it was identified how the sawtooth area was twisted. Then, while bending, experimented to find the main cause of the defect. The study tried to find maximum effectiveness with a minimum experiment using 6 sigma techniques. The experiment showed that there were many defects depending on the bending speed of the part and the distance it was fixed. The experiment used a method of finding optimal conditions by combining variables from each item. As a result, the failure was minimized when the distance between the two axes was maintained at 4.5-5mm and the bending speed was maintained at 15mm/sec. The component fixation force has a fixed hook in the middle of the product, and therefore it is found that changes in the amount of byte for the fixed part do not result in significant improvements in the defect.
The research model of panel data analysis in this study was used as the dependent variables and the business characteristics of the welding industry were reflected in the research model for systematic analysis of the effect of welding technology on the welding industry. As a result of the existing research, the domestic welding technology is seriously encroaching on the domestic welding industry between the United States, Japan and China. There is no quantitative statistical analysis on this aspect. In this study, the panel data analysis is used to indicate differences in explanatory power by numerical values of POLS model, fixed effect and random effect. And the prior studies on the current status of welding industry related to arc welding, special welding, multiple welding, welding and bonding technology are applied by the panel data analysis. Therefore, the problems of existing research are diagnosed while presenting the future research directions.
sesses the finishing capabilities for application to high-precision machining. Because Ti-6AL-4V (Eli) is widely used in applications where it is exposed to the human body, the industrial grinding oil that is commonly used in the magnetic abrasive finishing process was replaced by vegetable oils; the processing performances of these different grinding oils were compared and verified. The characteristics of magnetic abrasive finishing were also investigated according to the temperature of the material. The experimental results show that olive oil yields a surface roughness improvement of 87%. Also, in terms of the roundness and the amount of material removal, the performance was excellent. This demonstrates the possibility of replacing the conventional industrial oil for grinding. Furthermore, when olive oil was used at different temperatures, the finishing characteristics at room temperature were the most excellent. SEM and EDX analyses of the machined components (before and after processing) showed that the material composition was not changed. Additionally, the magnetic abrasive tool composition was not found on the surface of the finished samples. In conclusion, the possibility of using vegetable oil as the grinding oil for high-precision machining of Ti-6Al-4V (Eli) bars via a magnetic abrasive finishing process at room temperature conditions was verified.
A magnetic abrasive finishing process was proposed for improving the surface accuracy of microscale -diameter STS 304 bar used in many applications such as, medical, aerospace, and nuclear industries. Most of the previous research has already explored the conventional finishing technique to improve the accuracy of material in terms of the surface roughness. However, their results are still not good enough for the requirement in the today’s engineering industry. Especially, when the workpiece is a material of microscale-diameter, use of such conventional processes becomes impossible because they entail the application of high pressures that may damage the surface to be finished. Moreover, less control is available over these conventional finishing processes. In this study, an ultra-high-precision magnetic abrasive finishing process was applied to the precision machining of microscale-diameter STS 304 bar and the experimental work are performed with many critical parameters such as, different workpiece revolution speeds, abrasive grain sizes, different finishing temperatures, and pole vibrations. The results showed that in The initial surface roughness of 0.20 μm (Ra) was decreased to 0.025 μm with 0.5 μm of abrasive grain size and pole vibration 12Hz at 40,000 rpm.