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인정제 ( Jeong-je Yin ) 한국고등직업교육학회 2006 한국고등직업교육학회논문집 Vol.7 No.1
Surface deflection is defined as a wrinkle with height lower than 0.2mm, and generally occurs where shape change is large. Surface deflection around the door handle is generally as small as tens of microns in height, but it results in shadows due to light deflection, which deteriorates car quality in terms of appearance. In this study, simulation of surface deflection has been conducted using PAM-STAMP, and applied to a front door of a pre-production model. In order to obtain higher accuracy of the simulation, meshes have been carefully aligned along the feature line of the door handle. Importance of the mesh alignment has been shown clearly with a U-bending test. The simulation result has shown clear pattern of surface deflection, which was in good accordance with the pattern experimentally obtained. Simulations of three different forming processes have been conducted using a simplified model to find how to reduce surface deflection.
4-스포크 스켈리튼 스틸 휠 디스크의 드로우 금형 개발
인정제 ( Jeong-je Yin ),정태은 ( Tae-eun Chung ) 한국고등직업교육학회 2006 한국고등직업교육학회논문집 Vol.7 No.2
It is difficult to draw skeleton steel wheel disk which is made of high strength steel because of various bends. But the skeleton steel wheel has many merits such as light weight, fuel economy and product price. So 4-spoke typed skeleton steel wheel disk was developed considering effective structure, profit forming process and other factors. Finite element simulation and draw test were done to examine the draw processes. The desirable model for drawing process was proposed from the detailed simulation. This result will be used for developing 5-spoke typed skeleton steel wheel disk.
콤플렉스법을 이용한 U-채널 성형의 스프링백 강건 설계
인정제(Jeong-Je Yin),김경모(Kyung-Mo Kim),박종천(Jong-Cheon Park) 한국기계가공학회 2013 한국기계가공학회지 Vol.12 No.1
Variations of springback in stamped parts are induced by the uncontrollable noises including the variation of incoming material properties, lubrication and other forming process parameters. Reduction of springback variation is very important during springback compensation processes on stamping dies and assembly processes. To reduce the variation of springback, a robust optimization methodology which uses complex method combined with orthogonal array is proposed. The proposed method is applied to the robust design of U-channel die for the reduction of side wall curl. It is shown that the drawbead and die radius of U-channel draw die can be effectively optimized by the proposed method.
측면 충돌 성능을 고려한 테일러드 블랭크 사이드 패널 설계
인정제 ( Jeong-je Yin ) 한국고등직업교육학회 2002 한국고등직업교육학회논문집 Vol.3 No.2
Tailored blanks are increasingly used in car body design. Among these, the tailored blank side panels have merits in both weight reduction and the improvement of structural performances. This paper presents the optimal design of tailored blank side panels considering side crash performances. 12 different designs of tailored blank side panels for a mid-class vehicle were proposed to examine the crash performances. Side crash analyses using PAMCRASH were performed for the vehicles adopting tailored blanks and reference vehicle. From the analysis results, the optimum parting patterns and materials combinations of tailored blank side panels could be found.
인정제(Yin, Jeong-Je) 한국산학기술학회 2010 한국산학기술학회논문지 Vol.11 No.11
본 연구에서는 대형 차체 판넬과 같은 유연성이 큰 판넬의 3차원 형상을 스캐닝 하기 위한 고정구를 개발하 였다. 유연 판넬에 대한 N-2-1 설계원리에 따라 자중의 영향이 최소화되는 지지점들을 유한요소 해석을 통하여 선정 함으로써 hood outer 판넬의 고정구를 설계하고, Alufix 시스템을 이용하여 스캐닝 고정구를 제작하였다. 제작된 고정 구를 이용하여 레이저 스캐닝을 수행하여 성공적으로 스프링 백을 측정함으로써, 본 연구에서 제안된 고정구 제작 방 안의 유용성을 확인하였다. In this study, a scanning fixture for flexible parts such as large automotive panels is developed. For the minimization of the weight deflection of a hood outer panel, the N-2-1 fixture principle for flexible parts is adopted in the fixture design. The designed fixture for a hood outer panel is fabricated using the Alufix system. The springback of the entire hood outer panel can be measured successfully by the laser scanning with the developed fixture, which verifies the usefulness of the proposed design method for the flexible panels.
Application of Operatig Window to Robust Process Optimization of Sheet Metal Forming
Kyungmo Kim(김경모),Jeong Je Yin(인정제),Yong S. Suh 한국기계가공학회 2009 한국기계가공학회지 Vol.8 No.4
It is essential to embed product quality in the design process to win the global competition. Many components found in many products including automobiles and electronic devices are fabricated using sheet metal forming processes. Wrinkle and fracture are two types of defects frequently found in the sheet metal forming process. Reducing such defects is a hard problem as they are affected by many uncontrollable factors. Attempts to solve the problem based on traditional deterministic optimization theories are often led to failures. Furthermore, the wrinkle and fracture are conflicting defects in such a way that reducing one defect leads to increasing the other. Hence, it is a difficult task to reduce both of them at the same time. In this research, a new design method for reducing the rates of conflicting defects under uncontrollable factors is presented by using operating window and a sequential search procedure. A new SN ratio is proposed to overcome the problems of a traditional SN ratio used in the operating window technique. The method is applied to optimizing the robust design of a sheet metal forming process. To show the effectiveness of the proposed method, a comparison is made between the traditional and the proposed methods using simulation software, applied to a design of particular sheet metal forming process problem. The results show that the proposed method always gives a more robust design that is less sensitive to noises than the traditional method.
김경모(Kyung-Mo Kim),인정제(Jeong-Je Yin),박종천(Jong-Cheon Park) 한국기계가공학회 2014 한국기계가공학회지 Vol.13 No.2
Fractures and wrinkles are two major defects frequently found in the sheet metal forming process. The process has several noise factors that cannot be ignored when determining the optimal process conditions. Therefore, without any countermeasures against noise, attempts to reduce defects through optimal design methods have often led to failure. In this study, a new and robust design methodology that can reduce the possibility of formation of fractures and wrinkles is presented using decision-making theory. A two-attribute value function is presented to form the design metric for the sheet metal forming process. A modified complex method is adopted to isolate the optimal robust design variables. One of the major limitations of the traditional robust design methodology, which is based on an orthogonal array experiment, is that the values of the optimal design variables have to coincide with one of the experimental levels. As this restriction is eliminated in the complex method, a better solution can be expected. The procedure of the proposed method is illustrated through a robust design of the sheet metal forming process of a side member of an automobile body.
김경모(Kyung-Mo Kim),인정제(Jeong-Je Yin) 한국기계가공학회 2013 한국기계가공학회지 Vol.12 No.2
Springback is a very typical dimensional discrepancy phenomenon, which occurs usually on the final stamping parts after the tool loading is removed. Variation of springback leads to amplified variations and problems during assembly of the stamped components, in turn, resulting in quality issues. The variations in the properties of the incoming material and process parameters are the main causes of springback variation. In this research, a robust design methodology which combines orthogonal array based experimental design and design space reduction skim to reduce the springback variation for advanced high strength steel parts in sheet metal forming is suggested. The concept of design space reduction is adapted in the experimental design setup to improve the quality of the obtained solution. The effectiveness of the proposed procedures is illustrated through a robust design of springback in metal forming process of a cross member of auto body.