The objective of this study is to solve a problem that is occurred during the spline machining of tubular shaft yoke in both side IMS module. In order to simulate the problem, the movement direction of upper die was set as standard case and error case. The material of tubular shaft yoke was set to S20C as refer to the analysis library. The movement directions of upper die were separated with standard case and error case. The error case was set to simulate the problem in the spline machining of tubular shaft yoke. In order to solve the problem, the outer radius of upper die were modelled from 9.40mm to 9.44mm. The simulation results were analyzed and compared in terms of effective stress, metal flow line and folding phenomena characteristics. In case of the outer radius of upper die was 9.42mm, it was observed a relatively uniform effective stress distribution and had a straight metal flow line.

The objective of this study is to find the optimal size of splined shaft in IMS module. Two methods were used in this study. One is for the investigation of effect of indentation process on the tubular shaft yoke, and another is for the investigation of effect of indentation process on splined shaft. The spline outer size of splined shaft was increased from 0.00mm to 0.20mm. The simulation results were analyzed and compared in terms of under-fill, metal flow, effective strain, Von-mises stress and load characteristics. The indentation load was increased with increasing of spline size. However, in case of 0.15mm outer diameter increasing, the separation load was decreased. The case of 0.10mm diameter increasing was the best spline size based on the low indentation load and high separation load.

The objective of this study is to solve the problem that was occurred during the spline processing in A-IMS tubular shaft. The upper dies were modelled conventional case and modified case. The tubular shafts were modelled as standard case and error case. The error case assumed production error of raw material. The material of tubular shaft was set to SCM 420H as refer to the analysis library. The simulation results were analyzed and compared in terms of metal flow, effective stress, and effective strain characteristics. The crushed and buckling problems were observed at the upper side of tubular shaft body when conventional upper die was applied. However, the crushed and buckling problems were solved when modified upper die was applied.

This study has been performed to investigate on the spur gear with the spline key of heat treatment process analysis. The heat treatment process for gear has been widely used at the production of moving parts in order to improve its manufacture productivity. A driving spur gear is modeled with three dimensions for the heat treatment process. The variable conditions for the heat treatment analysis are the shape of gear tooth, the environmental heating temperature, heating time, cooling temperature and cooling. The analytical results of mechanical properties as micro structure and hardness are analyzed using the software. As the analysis result, the hardness value(HRC) becomes 20.2 of the inner part at gear body and of the surface part of gear tooth has shown the max. valve of HRC 47.5. The beinite structure forms up to 70%. This is because the cooling becomes slow at the center part than the end part. Therefore, it is estimated that the gear tooth have the high anti-wear property and the inner center part maintains the sufficient stiffness. These results can be utilized for the production of the driving gear by the heat treatment process as the fundamental information

막 구조물은 일반적인 설계와는 달리 형상해석, 응력변형해석 및 재단도 과정을 수행하여야만 설계가 가능하다. 처음 두 과정과는 달리 재단은 3차원 곡면을 최소 오차를 가진 평면 스트립을 형성하는 과정이다. 경제적인 이유로 재단 선은 주로 측지선을 이용하여 작성된다. 그러나 일반적으로 측지선은 초기 형상탐색에서 구성된 삼각형 요소의 정보에서 추출됨으로 부드러운 곡선이 아니며, 불규칙한 직선이다. 그러므로 어떻게 불규칙한 직선을 곡선으로 표현할 것인가가 중요하다. 따라서 본 연구에서는 스플라인 함수를 이용한 보간 방법을 재단도 생성에 적용하였다. 이를 위해서 삼차 스플라인 함수, B-스플라인 함수 및 최소자승 스플라인 함수의 세 가지 경우에 대해서 고찰하고, 단순 모델 및 카테나리 모델을 대상으로 재단도 작성 결과를 검토하였다. 단순모델의 해석요소수와 추출된 불연속 절점 수에 따른 보간 곡선 비교결과는 요소수가 큰 경우 추출된 절점의 수가 적은 것이 효과적이며, 최소자승 보간이 다른 방법보다 더 부드러운 재단 경계선을 제공한다.

확장 B-스플라인 기저함수(extended B-spline basis functions)을 이용한 레벨셋 기반의 위상 형상 최적설계 기법을 정상 상태의 열전도 문제에 대하여 개발하였다. 본 해석법은 레벨셋으로 결정된 영역 안쪽만 고려하여 해석을 수행하게 되므로 열전달 문제에서 생길 수 있는 영역 바깥부분 영향을 제거할 수 있다. 설계민감도 해석으로부터 결정되는 법선속도를 활용하여 헤밀턴-자코비 방정식의 해를 구하게 되며, 주어진 체적조건 하에서 열 컴플라이언스(thermal compliance)가 최소가 되는 방향으로 최적의 형상을 결정할 수 있다. 형상 설계민감도를 정확하게 얻기 위해서는 레벨셋 함수와 B-스플라인 함수를 이용하여 수직 단위 벡터와 형상의 곡률을 정확히 결정하며, 위상 설계민감도를 통해 최적화과정 동안 필요한 위치와 시점에서 위상의 변화를 주는 홀을 쉽게 생성할 수 있다.