Material extrusion (ME) type 3D printing has been widely utilized through various types of systems depending on the fabrication methods, materials, and precision to fabricate complex workpieces that cannot be made with conventional methods. This study provides basic considerations in response to the current demands on performance evaluation of ME type 3D printing related to dimensions as well as the realization of the guidelines to be established in the near future. As a simple specimen for these purposes, 2D and 3D hole-plates were designed and fabricated by using a ME type entry-level 3D printer. For evaluation of dimensions on the specimen, both specimens were measured by a calibrated tool-maker’s microscope which is to length standard. The measurement parameters were the center position of the holes, the diameter of the holes, and the circularity error of the holes.
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The goal of this research is to develop intelligence data analytics system for quality enhancement of die-casting process. Targeting a die-casting factory in Korea, we first constructed an edge device-based infrastructure with wireless communication environment for data collection and a processing infrastructure to support the intelligence data analytics system. Using the real quality regarding data of the target factory, we developed two data analytics models for defect prediction and defect cause diagnosis using AdaBoostC2 algorithm. Accuracy of the developed data analytics model for defect prediction was verified as 86%. To use the developed data analytics model efficiently and produce a sequential process of data analytics model generation, execution, and update were conducted automatically. The edge device and integrated server-based dualized analysis system was proposed. The developed intelligence data analytics system was applied to the target factory, and the effectiveness was demonstrated.
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Development of AI-based Bearing Machining Process Defect Monitoring System Dae-Youn Kim, Dongwoo Go, Seunghoon Lee Journal of Society of Korea Industrial and Systems Engineering.2025; 48(3): 112. CrossRef
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The large gas turbine rotor used for power generation has a structural characteristic comprising a shaft, disk, and blade assembled to the disk. Because the start/stop is repeated, the tightening force may be reduced in the process of repeating the tightening force between the tie rod and the disk. When the tightening force falls below the threshold, changing the critical speed, increasing the vibration, or in extreme cases, the rotor may loosen and cause a major accident. Also, it is imperative to continuously maintain the proper tightening force because the thread of the tie rod is damaged when the tightening force exceeds the yield stress condition of the tie rod. In this paper, the gas turbine rotor system is modeled and simplified to identify the control variable of the tightening force of the tie rod bolts of the rotor. For verification, a simplified model of the gas turbine rotor was designed, manufactured, and verification tests were conducted to confirm the adequacy of the calculation method. As a result, the tightening force decreased as the stiffness of the pressing disk decreased, so the stiffness of the pressing disk should have a stiffness range similar to that of the tie rod.
The sanding device support bracket is part of the axle box and is one of the railway vehicles parts that must withstand extremely harsh environments. Conventional welded structure type brackets were cracked at welds during operation, requiring design changes. To minimize harsh environments and manufacturing errors, this review was conducted from the design stage, and design changes were made through several trial and error. In this paper, the optimal design was derived by performing topology optimization on the model designed and manufactured through trial and error and applied to the actual vehicle. The comparison of the existing model with the empirically designed model confirmed the improvement of the optimal design using the topology optimization. The optimized design was verified by the analysis and the vibration test of IEC 61373 was satisfied. The test parts based on the optimal design were applied to the actual vehicle and the performance was verified. In the optimum design process, the shape and material as well as the weight analysis were performed and finally the brackets were designed to be light in weight and improved in strength.
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This study is to investigate the cooling performance of the secondary battery in electric vehicles according to three different gaps between battery cells. To accomplish the convective cooling performance of the battery surface with three different gaps, selected local positions (X, Y, Z) for various temperature distributions were marked on the gap surface contacting the cell surface. The cooling performance of the gap of 0.5 mm was compared with the gaps of 5 mm, and 1 mm. Normalized local Nusselt number of the cooling area at the normalized width position indicated that the gap of 0.5 mm was on average 26.99% lower than that of 5 mm and 0.49% lower than that of 1 mm. At the normalized height, the gap of 0.5 mm was on average 12.12% higher than that of 1 mm. Because of the vortex at the outlet area, cooling performance at the gap of 0.5 mm was on average 13.19% higher than that of 5 mm and 0.79% higher than that of 1 mm at normalized thickness. Ultimately, the best cooling performance existed at the gap of 5 mm, but the gap of 0.5 mm was best for improving space efficiency, energy storage capacity, and vehicle-driving durability.
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Sound waves propagate in a manner in which energy is transmitted by adjacent molecules in the medium. These adjacent molecules exhibit inherent sound wave characteristics, such as height and wavelength, depending on the sound frequency. The Helmholtz resonator, one of the well-known acoustic elements, comprises a neck and a cavity, and features a resonance at a specific frequency related to structural dimensions. The acoustic characteristics of the Helmholtz resonator can be explained by a lumped spring-mass system in mechanical engineering; the resonant frequency can be calculated with the same analysis. The Helmholtz resonator is widely used as an acoustic filter as it can re-radiate sound waves with the opposite phase and significantly attenuate the original sound wave in the resonance frequency range. In this study, we fabricated a Helmholtz resonator-inspired film-type acoustic absorber (FAA), comprising a microscale resonator array made with polydimethylsiloxane (PDMS). Through acoustic attenuation experiments, the FAA revealed that the novel attenuation values reached up to 36.3 dB mm-1. Additionally, a continuous fabrication of the FAA was achieved via a custom-built roll-type equipment.
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In this study, experiments were performed to determine if the pattern fabricated by the UV nano imprint process could be modified using additional processes such as surface treatment. We wanted to confirm the fabrication possibility of a special pattern such as the reverse trapezoidal shape difficult to produce because of the releasing problem. The UV ozone treatment (Hydrophilic Treatment) and OTS coating (Water Repellent Treatment) were used and shape modification occurred under controlled treatment time. As a result of performing the UV ozone treatment for 30 minutes or more on a micro pattern manufactured by UV curing resin of PUA series, the contraction phenomenon of the micro structure occurred and the shrinkage was dependent on treatment time. When the OTS treatment was performed, the surface of the microscale pattern could be roughened. When the nanoscale pattern was treated, the pattern change could be induced. It was possible to partially cure the resin by adjusting the UV absorption using dye material, and the deformation of the pattern was made by an additional pressing process. As a result of the experiment of the various methods causing the shape change of the cured pattern, the possibility of the methods was verified.
In this study, aluminum, used throughout the industry and actively studied for surface modification, is selected as the test subject. Micro-structured through acid etching, nano-structured through alkali treatment to maximize surface roughness, and the superhydrophilic surfaces were fabricated by forming the surface chemicals into aluminum hydroxide (Al(OH)₃). The superhydrophobic surfaces were fabricated through the self-assembled monolayer coating on the surface, and the surface structure and components were analyzed. The superhydrophilicity and superhydrophobicity were applied on the aluminum surface at the bottom of the low speed water vehicle. For the superhydrophilic and superhydrophobic surfaces, the reasons for the drag reduction performance on the bare surface and the difference in the amount of reduction were analyzed. A coating material that strong bonds with the surface are selected for anti-corrosive performance under NaCl solution. To verify that, the contact angle was measured by exposing each prepared aluminum surface to a 3.5% NaCl solution for 14 days. Additionally, we analyzed why the superhydrophobic surfaces were robust against the NaCl solution.
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The manufacturing technologies have undergone significant innovation at the beginning of this century from the development of science and technology. One of the most important inventions in manufacturing technologies is the creation of additive manufacturing technology. Additive manufacturing technologies allow building of a 3D object by adding ultra-thin layers of 2D cross-sectional slices of materials upon these previous layers. The most crucial effectiveness of additive manufacturing technologies is to fabricate the complex geometry of products. As a result, the lattice structure is used extensively in industrial product design to minimize usage of materials and reduce the weight of products. However, the simulation to investigate the mechanical properties of the lattice structure in the design space of a product has many issues such as calculation time, memory-consuming, etc. Thus, the paper presents a new method to automatically generate a geometric model of the lattice structure in a computer-aided design environment. This model will be used to make a simulation using the finite element method analysis to investigate the mechanical properties of each configuration of the lattice structure.
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