Young-Soo Yang

Sensitivity analysis for process parameters in GMA welding processes using a factorial design method

Generally, the quality of a weld joint is strongly influenced by process parameters during the welding process. In order to achieve high quality welds, mathematical models that can predict the bead geometry and shape to accomplish the desired mechanical properties of the weldment should be developed. This paper focuses on the development of mathematical models for the selection of process parameters and the prediction of bead geometry (bead width, bead height and penetration) in robotic GMA (Gas Metal Arc) welding. Factorial design can be employed as a guide for optimization of process parameters. Three factors were incorporated into the factorial model: arc current, welding voltage and welding speed. A sensitivity analysis has been conducted and compared the relative impact of three process parameters on bead geometry in order to verify the measurement errors on the values of the uncertainty in estimated parameters. The results obtained show that developed mathematical models can be applied to estimate the effectiveness of process parameters for a given bead geometry, and a change of process parameters affects the bead width and bead height more strongly than penetration relatively.

Adaptive neuro-fuzzy control of ionic polymer metal composite actuators

An adaptive neuro-fuzzy controller was newly designed to overcome the degradation of the actuation performance of ionic polymer metal composite actuators that show highly nonlinear responses such as a straightening-back problem under a step excitation. An adaptive control algorithm with the merits of fuzzy logic and neural networks was applied for controlling the tip displacement of the ionic polymer metal composite actuators. The reference and actual displacements and the change of the error with the electrical inputs were recorded to generate the training data. These data were used for training the adaptive neuro-fuzzy controller to find the membership functions in the fuzzy control algorithm. Software simulation and real-time experiments were conducted by using the Simulink and dSPACE environments. Present results show that the current adaptive neuro-fuzzy controller can be successfully applied to the reliable control of the ionic polymer metal composite actuator for which the performance degrades under long-time actuation.

Spreading and solidification of a molten microdrop in the solder jet bumping process

This work develops a model to predict the spreading and solidification of solder droplets deposited on a solid pad in the solder jet bumping process. The variational principle is employed to solve the fluid flow and the semi-solid phase is modeled as a non-Newtonian slurry. This modeling greatly saves the computational expenses of conventional numerical procedures. The simulations reveal that the substrate temperature is the single dominant controlling parameter that determines the final bump diameter (or height) when the substrate possesses a high effusivity. When the effusivity of a substrate is relatively low, both the substrate temperature and the droplet temperature at impact play important roles in determining the final bump diameter. Our model can be used in designing the experimental conditions to find the optimal process conditions for a desired bump geometry.

Analysis of Bending Deformation in Triangle Heating of Steel Plates with Induction Heating Process Using Laminated Plate Theory

Abstract The steel-forming process in shipyards is considered an important stage with respect to productivity and precision of curved plates. The induction heating process has been of interest to steel formation because the power and its distribution are easier to control and reproduce. Besides, induction heating equipment can be easily integrated with a robotic system for automation. The heating process usually utilizes line heating or triangle heating methods to form hull plates. Even though a number of studies on the line heating method have been performed, there have been few studies on the triangle heating method. In this study, using a simplified elasto-plastic model and laminated plate theory, an analytic means of predicting the bending deformation in triangle heating of steel plates is derived. For the purpose of this, the induction heating process is modeled in advance, with numerical heat flux and heat flow analyses to determine the plastic region. The plastic region is considered as an inclusion that has eigenstrains in the laminated plate. The analytic solution is applied to predict deformations to verify its exactness. The results of the analytic solution are quite good compared with those of the triangle heating experiment, revealing the effectiveness of the analytic solution.

Derivation of Simplified Formulas to Predict Deformations of Plate in Steel Forming Process with Induction Heating

Recently, the electro-magnetic induction process has been utilizing to substitute the flame heating process in shipyard. However, few studies have been performed to exactly analyze the deformation mechanism of the heating process with mathematical model. This is mainly due to the difficulty of modeling the inductor travelling on plate during the process. In this study, heat flux distribution of the process is firstly numerically analysed with the assumption that the process has a quasi-stationary state and also with the consideration that the heat source itself highly depends on the temperature of base plate. With the heat flux, the thermal and deformation analyses are then performed with a commercial program for 34 combinations of heating parameters. The deformations obtained and heating parameters are synthesized with a statistical method to produce simplified formulas, which easily give the relation between the heating parameters and deformations. The formulas are well compared with results of experiment.

Fatigue Strength Evaluation on Resistance Spot Welds of the Vehicle Body

Abstract This article evaluates the fatigue stress–fatigue life relationship of spot-welded structures in the vehicle body, considering the residual stress effect. When a vehicle travels on an actual road, the resistance spot welds of the vehicle structure are exposed to complex loadings. Because fatigue strength in the resistance spot weld of a vehicle body can be determined by residual stresses, joint geometry, and loading state during driving, actual loading state must be estimated with consideration of residual stresses. In this study, fatigue stress–fatigue life relationship derived from residual stress was obtained by thermoelastic, plastic, finite-element analysis. Applied loading in resistance spot weld of the vehicle body was calculated by dynamic analysis. Assumptions regarding fatigue life were based on proposed methods.

Effects of Inductor Shape in Steel Forming Process with High Frequency Induction Heating

Because of high intensity and easy controllability of the heat source, high frequency induction heating has been concerned and studied for the steel forming process in the ship building industry. However, the heating and forming characteristics have to be further properly modelled and analyzed for the process to be utilized with its optimal working parameters. In this study, a modelling with thermo-elasto-plastic analysis is performed using the FEM to study heat flow and deformation of the steel plate during the forming process with the electro-magnetic induction heating. The numerical model is then used to study the effect of the inductor shape on the magnitude of angular deformation of the plate during the forming process. It is revealed that the square shape of inductor induces the largest deformation among the rectangular inductors.

Development of Simplified Formulas to Predict Deformations in Plate Bending Process with Oxy-Propane Gas Flame

Simplified mathematical formulas are presented to predict deformations during the plate forming process when the heating parameters are given. To obtain the formulas, firstly, the thermal analysis for steel plate is performed, and the thermo-mechanical analysis is followed with actual heating conditions. The analyses have been carried out by the commercial software MARC, which is programmed based on the FEM. Secondary, the results of the mechanical analysis are synthesized with their variables for a statistical approach, which results in simplified formulas. The results of the analysis are well compared with those of experimental measurements.

Thermal deformation compensation in the molding of aspheric glass lenses

Abstract. Generally, aspheric glass lenses are manufactured using a glass molding press (GMP) method and a tungsten carbide mold core. This study analyzes the thermal deformation that occurs during the GMP process, and the results were applied to compensate an aspheric glass lens. After the compensation process, the form accuracy of aspheric glass lenses improved from ∼3.7 to ∼0.35  μm. The compensated lens complied with the actual specifications.

Analysis for the angular deformation of steel plates in a high-frequency induction forming process with a triangle heating technique

A triangle heating technique with the use of a heat source of high-frequency induction heating to make a steel plate deformed into a curved shape was modeled and analyzed using the numerical analysis of the finite element method in order to predict the angular deformation of the steel plate formed by the technique. For the analysis of the deformation, heat generation by an electromagnetic field was first analyzed with consideration of the preheat effect, and heat flow using the heat generated from the plate as the heat source was then analyzed. Thermal history of the plate predicted by numerical analysis was compared with that measured in an experiment of triangle heating on a steel plate. Deformations of the plates were then analyzed with changes of heating parameters including heating dimensions and plate thickness. The analyses were also verified with a series of experiments. In order to derive a simplified equation to readily predict deformation from the triangle heating technique, deformations predicted by numerical analyses and measured by the experiments were synthesized in association with the heating parameters using a statistical method of recursion analysis. The equation was verified to be able to predict the deformations conversely and expected to be practically used in the industry to select the heating parameters for the desired shapes of curved plates.