Inconel 718, a typical ultraheat-resistant alloy, is recognized as a useful component in aircraft parts owing to its high-temperature strength and good chemical stability. Although many studies have been conducted to determine the proper drill shape to overcome the poor machinability when drilling into Inconel 718, most have involved a cutting process program known as AdvantEdge, as an experimental approach requires much time and money. In this study, our purpose is to optimize the drill shape for efficient drilling by conducting a trust force and temperature analysis using AdvantEdge. In order to achieve this purpose, the reliability of the results of the analysis was verified and by applying design of experiment an analysis of the geometric parameters of the drill shape considering the thrust force and temperature was conducted.
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Analysis of Cutting Force and Plastic Deformation Occurring During Machining of Ti-6Al-4V Alloy Aircraft Parts Hwi Jun Son, Seok Kim, Ki-Beom Park, Hyoun Chul Jung, Young Tae Cho Journal of the Korean Society of Manufacturing Process Engineers.2022; 21(8): 25. CrossRef
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This study proposes a method for identifying correlations between tension and drop height for sessile droplets in a roll-toroll processing system. The effect of tension and drop height on the contact angle of a sessile droplet is presented. Design of experiment (DOE) methodology and statistical analysis are used to define a correlation between the process parameters. The contact angle is decreased while increasing tension and drop height. The influence of the tension is less significant on the contact angle compared with the effect of the drop height. However, tension should be considered as a major parameter because it is not easy to fix with roll eccentricity and compensating speed of the driven roll. The results of this study show that the effect of tension on the contact angle of a sessile droplet is more important than drop height because the drop height is fixed when the process systems are determined.
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Recently, a high-precision ball screw is an essential part of high-speed machines. However, producing high-precision ball screws has been costly and time-consuming. Nowadays, a whirling machine is used to produce high-precision ball screws efficiently. Rotating multi-tips are used to turn the ball screw in the whirling machine. In this study, a structural analysis was performed by a finite-element method to develop a whirling machine. An improved model of the whirling machine was proposed by the analysis. In addition, a thermal analysis was performed to confirm the thermal stability. The results of the analysis can be applied in order to further develop the whirling machine.
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Recently, traffic accidents and damage on the highway have increased because of overloaded vehicles. The existing overload-detecting system has a low accuracy rate. An overload-detecting system using a weigh-in-motion (WIM) system has been developed to solve this problem. The WIM system can be used to detect overloaded vehicles by measuring the weight of the vehicles. The WIM system is divided into high-speed and low-speed types. The inaccuracy rate in the lowspeed WIM system results mainly from the low response rate of the sensor when the velocity is moving at more than 20 ㎞/h. In this study, a low-speed overload-detecting pad with a hydraulic structure using a WIM system was developed to make the system more accurate. The structural and formal analysis was carried out by using a finite element method (FEM) in order to analyze the structural stability and the extrusion velocity of the system. In addition, a static load test was performed to confirm the linearity and accuracy of the pad.
Recently, titanium alloys have been widely used in aerospace, biomedical engineering, and military industries due to their high strength to weight ratio and corrosion resistance. However, it is well known that titanium alloys are difficult-to-cut materials because of a poor machinability characteristic caused by low thermal conductivity, chemical reactivity with all tool materials at high temperature, and high hardness. To improve the machinability of titanium alloys, cryogenic cooling with LN2 (Liquid Nitrogen) and nanofluid MQL (Minimum Quantity Lubrication) technologies have been studied while turning a Ti-6Al-4V alloy. For the analysis of turning process characteristics, the cutting force, the coefficient of friction, and the surface roughness are measured and analyzed according to varying lubrication and cooling conditions. The experimental results show that combined cryogenic cooling and nanofluid MQL significantly reduces the cutting forces, coefficients of friction and surface roughness when compared to wet condition during the turning process of Ti-6Al-4V.
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Light detection and ranging (LiDAR) is one of the most efficient technologies to obtain the topographic and bathymetric map of coastal zones, superior to other technologies, such as sound navigation and ranging (SONAR) and synthetic aperture radar (SAR). However, the measurement results using LiDAR are vulnerable to environmental factors. To achieve a correspondence between the acquired LiDAR data and reality, error sources must be considered, such as the water surface slope, water turbidity, and seafloor slope. Based on the knowledge of those factors’ effects, error corrections can be applied. We concentrated on the effect of the seafloor slope on LiDAR waveforms while restricting other error sources. A simulation regarding in-water beam scattering was conducted, followed by an investigation of the correlation between the seafloor slope and peak timing of return waveforms. As a result, an equation was derived to correct the depth error caused by the seafloor slope.
Hot embossing techniques are used to engrave patterns on plastic substrates. Roll based hot embossing uses a heated roll for a continuous process. A heated roll with relief patterns is impressed on a preheated plastic substrate. Then, the substrate is cooled down quickly to prevent thermal shrinkage. The roll speed is normally very slow to ensure substrate temperature increase up to the glass transition temperature. In this paper, we propose a noncontact preheating technique using focused infrared light. The infrared light is focused as a line beam on a plastic substrate using an elliptical mirror just before entering the hot embossing roll. The mid range infrared light efficiently raises the substrate temperature. For preliminary tests, substrate deformation and temperature changes were monitored according to substrate speed. The experiments show that the proposed technique is a good possibility for high speed hot embossing.
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Critical speed analysis was conducted for a active steering bogie prototype, developed to improve the curving performance of railway vehicles. The critical speed for the design concept was about 169.2 ㎞/h. To validate the analysis result, we performed a critical speed test for the prototype bogie using a roller-rig tester. The test results showed that the critical speed for the prototype bogie was about 165 ㎞/h. From the analysis and test results, The critical speed for the prototype bogie was determined to be 165 ㎞/h. Considering the maximum operating speed of the test vehicle is 100 ㎞/h, the prototype bogie is considered stable.
This research analyzes bucket elevator roller chain pins by finite element (FE) analysis and static structural analysis for a lightweight pin design. The stress distribution of light weight roller chain pins under static load is analyzed for safety factors and damping effect. The results show that the stress distribution is higher on the plate than on the bush pin. In order to compare experimental and FE analysis results, a light weight design approach was used to produce a prototype base pin. Because the inner diameter of the pin was different, the impact damping effect was most appropriate when the inner diameter was 34.05 ㎜, and it is used as basic research data on the impact of the roller chain and sprocket.
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Structural pipe frames are usually manufactured by complex processes, in which a straight pipe with an arbitrary crosssection is prepared via a roll-forming process and then fabricated into three-dimensional shapes by a secondary process. These conventional processes have low productivity. Recently, the inefficiency of the conventional processes has created the need to develop new forming technologies. In this study, a new incremental roll-forming process is proposed. The study is aimed at verifying the feasibility of the proposed process and investigating the fundamental process parameters using finite-element simulations. The result of the simulation demonstrates that the proposed process can be used effectively for cold fabrication of various shapes of structural pipes. In addition, the result of the investigation of parameters shows that the forming amount, number of roll sets, and distance between roll sets are significant factors to be considered in resolving dimensional errors of the product and improving its quality.
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