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Design of Rotor Disc Replacing Riveting
정종윤,김준섭 한국산업경영시스템학회 2017 한국산업경영시스템학회 학술대회 Vol.2017 No.추계초록
대형 선박의 Cargo Oil Pump Driving Steam Turbine 내에 설치되는 COPT (Cargo Oil Pump Turbine)는 유조선에 탑재되어 탱크에 저장되어 있는 유류를 다른 저장소로 하역하는데 사용되는 필수 장치이다. 펌프 터빈의 로터를 고속으로 회전시켜 유류를 고속으로 이송하는 역할을 하는데, COPT의 Rotor Disc는 터빈의 로터를 고속으로 회전 시키는 주요 핵심부품이다. 로터 디스크는 inner ring에 터빈 블레이드를 조립하고 원주방향의 끝 부분에 shroud 커버를 조립하여 블레이드의 테논을 리벳팅으로 마무리하고 체결하여 고속회전 시 안전성을 담보한다. 리벳팅은 오랜 수작업의 전통 체결방식으로서, 가해지는 힘의 정도에 따라 리벳 헤드부분이 깨지거나 변형되어 크랙이 발생할 수 있으며 또한 블레이드의 중량이 불균형되어 Balancing에 문제가 생길 수도 있다. 또한 오랜 수작업으로 인해 작업자의 근골격계 질환이나 직업병 유발 및 산재사고의 위험에 처할 수 도 있다. 본 연구에서는 shroud 커버가 없는 블레이드 형상을 설계하여 리벳팅 작업을 제거한 로터 디스크를 개발한다. 블레이드의 설계 시 구조안전성을 평가하고 설계 안전율을 점검한다. 설계형상을 대상으로 피로수명을 분석하고 수명을 예측하여 새로운 로터 디스크가 장착되어도 사용상의 안전성이나 내구성을 보장할 수 있도록 한다.
정종윤,박희성,김준섭 한국산업경영시스템학회 2018 한국산업경영시스템학회지 Vol.41 No.3
Modern manufacturing industries is to produce both precise and robust mechanical parts without failure while they are in service. In order to prevent a part failure for its lifetime, a mechanical design for a part should be examined on a basis of mechanical simulation. A nozzle plate, being a key part in steam engines, changes flow directions of steam in a turbine used in power plant. This paper is to the design and test for part safety and durability. Currently, nozzle plates are fabricated by welding nozzles to their plates. Welding causes some defects on the used materials while they are being manufactured. Another major defect is un-even pitches between welded nozzles. Welding causes phase changes because of high melting temperature of metal. This leads to decay on the welding spots, which weakens their structural strength and then, may lead to early damages on mechanical structures. This research proposes assembly-typed nozzle plate without welding. From the beginning, nozzle and plate are designed for insertion-typed assembly. Nozzle head and foot are designed in accordance with the grooves on outer ring and inner ring of a plate to make mating surfaces. Then the nozzle plate should be proved for structural and fatigue safety before they are put in manufacturing. This research adopts commercial softwares for modeling and mechanical simulation. The test result shows that the design with smaller mating area and deeper insertion produces higher safety in terms of structure and durability. From the conclusion, this paper proposes the assembly-typed nozzle plate to replace the welding typed.
FEM 시뮬레이션을 이용한 유니버설 조인트의 구조안전성
정종윤 한국산업경영시스템학회 2018 한국산업경영시스템학회지 Vol.41 No.4
Mechanical components are to be produced with accurate dimensions in order to function properly in assemblies of a machine. Once designs of mechanical components are created, designers examine the designs by adopting many known experimental methods. A primary test method includes stress and strain evaluation of structural parts. In addition, fatigue test and vibration analysis are an important test method for mechanical components. Real experiments at a laboratory are established when products are manufactured. Since design changes should be done before producing the designs in factories, rapid modifications for new designs are required in production industries. FEM simulation is a proper choice for a design evaluation with speed at a detail stage in design process. This research focuses modeling and mechanical simulation of a mechanical component in order to ensure structural safety. In this paper, a universal joint, being used in driving axels of vehicles, is studied as a target component. A design model is created and tested in some ways by using commercial software of FEM. The designed component is being twisted to transmit heavy power and thus, torsional stress should be under strengths of the component’s material. The next is fatigue analysis to convince fatigue cycles to be within the endurance limit of the material. Another test is a vibration analysis for rotational components. This research draws final conclusions from these test analyses and recommends whether the designed model is under safety condition in terms of mechanical structure.