SFT, which has a high glass fiber content, is one of the effective methods to replace metal and secure weight reduction and price competitiveness. Also, paintless injection molding in which a functional pattern is applied to the mold surface can eliminate the cost of painting. In this study, three types of SFTs were manufactured by adding round glass fibers measuring Φ7 and Φ10 μm and flat glass fiber measuring 27 × 10 μm for the experiment. DOE (Design of Experiment) was conducted to confirm the change in the warpage of the product and the gloss of the micro pattern due to the cross-sectional shape of glass fibers and the major injection conditions. Based on the results, it was identified that the flat SFT had a very small warpage compared to the round SFTs, and the holding pressure was the main factor in the warpage of all three SFTs. The Φ7 μm SFT had the largest gloss value, and the Φ10 μm SFT and the flat SFT had similar average values. All SFTs demonstrated an enormous change in gloss according to the change in mold temperature. The flat SFT had the smallest standard deviation in both warpage and gloss.
In the heating and drying system using microwaves, an optimal design method was presented to effectively shield microwaves leakage between the door and the cylindrical applicator. In order to protect the human body from leaking microwaves, it is necessary to keep the intensity of microwaves below 5 mW/cm². The door part adopts a choke structure and includes a number of design factors, such as, fin shape, slit shape, and a gap between the applicator and the door. The geometry was optimized by design of experiments, applying full factorial design and response surface method in a 4-factor, 2-level design. The results obtained by ANSYS HFSS analysis were applied to the intensity of microwave leakage according to the change of the design factors. The shape of the choke structure was optimized using Minitab, a statistical program. The microwave heating and drying system was manufactured based on optimal design value and the leakage of microwaves between the door and the applicator was measured. We confirmed that the experimental values were consistent with the simulation values.
SFT, which has a high glass fiber content, is one of the effective methods to replace metal and secure weight reduction and price competitiveness. This study evaluated the effect of glass fiber shape on mechanical properties in injection molding by fabricating SFT with a glass fiber content of 60%. Three types of SFTs were manufactured by adding round glass fibers of Φ7 μm and Φ10 μm and flat glass fibers of 27 × 10 μm. DOE (Design of Experiment) conducts to confirm the change in tensile strength due to changes in significant injection conditions. As a result of the experiment, Φ7 μm SFT and flat SFT have similar tensile strength and Φ10 μm SFT showed the lowest tensile strength value. As for the standard deviation of strength value, the Φ7 μm SFT had the largest standard deviation, and the Φ10 μm SFT showed the slightest change in the injection conditions. In flat SFT, it confirms that the tensile strength increased as the molding temperature increased. The fracture surface observes using SEM. It founds that the tensile strength lowers due to the small glass fiber density and many pullouts at the fracture surface of Φ10 μm with weak strength.
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An optimal design was developed for housing of a 50-ton hydraulic breaker. A four-factor, two-level design was created using the full factorial design, and it was confirmed that the safety factor, the response value, exhibited a curvature. As the curvature was confirmed, a higher-order experiment, a response surface analysis was performed. Based on the Minitab"s optimized prediction of the safety factor and weight, the actual analysis was performed using ANSYS Workbench, the finite element analysis program. As a result, the safety factor was 2.03 and the weight was 3222.2 kg, which was almost consistent with the Minitab’s prediction. The safety factor decreased from 2.33 to 2.03 compared to that in the initial model, but the optimization model can also be judged as being safe because the safety factor was set to 2.00. The weight was reduced by 119.1 kg, from 3341.3 to 3222.2 kg.
As global warming is rapidly emerging as one of the inherently global issues, one of the renewable energies, i.e. thermo-electric generation, has received attention. In order to increase the efficiency of thermo-electric generation, a maximum temperature difference in plain fins in a heat exchanger is needed, and an appropriate pressure drop is required to ensure stable flow of high temperature fluid. In the present study, the characteristics of the temperature difference and pressure difference for the 2 kW-class thermo-electric generator installed in exhaust pipes of a cogeneration plant were investigated numerically via thermal fluid analysis using ANSYS CFX. Then, size optimization for plain fins of a heat exchanger was carried out using SAS JMP, in which the temperature difference was maximized while meeting the requirement of a given pressure drop condition. A meta-model was generated by using the response surface model, and individual desirability functions were defined to derive the optimal solution that provided the maximal overall desirability function. The result obtained by size optimization showed that the temperature difference of the optimized plain fins of a heat exchanger increased by approximately 27% in comparison with the original model under the given pressure drop condition.
In this paper, the boom structure of a telescopic boom-type forklift truck was analyzed using ANSYS, a finite element analysis program. As a result, 494.22 MPa exceeded 456.08 MPa, allowable stress of the material, in the second boom. Thus, structural analysis was performed by reinforcing the thickness of the boom and stress was reduced. The experiment was conducted by selecting four factors of the thickness of the boom T1, T2, T3, and T4. Through response surface analysis, the curvature of the factors for stress was confirmed, and T1 was the most influential factor. Through regression equations from the variance analysis of each response, response maximization was performed to optimize mass and stress. As a result, 467.65 MPa was predicted. This exceeded allowable stress of 456.08 MPa. To obtain the result that does not exceed allowable stress, the mass was fixed at 118 kg, the initial value, and multiple response optimization was performed to limit target value and minimize stress. As a result, 432.96 MPa was expected to occur, and structural analysis resulted in 428.87 MPa stress demonstrating 13.22% reduction of stress compared to the existing model, and it is safe because allowable stress was less than 456.08 MPa.
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