BLDC 모터 고정자의 인서트 사출 성형에 관한 연구

최두순(Choi, Du-Soon),김홍석(Kim, Hong-Seok) 한국산학기술학회 2015 한국산학기술학회논문지 Vol.16 No.9

인서트 사출 성형은 용융 플라스틱을 인서트가 삽입된 금형에 주입하는 공정이다. 사출 과정 중에 인서트는 용융 플라스틱이 가하는 압력에 의해 변형될 수 있다. 인서트의 변형은 인서트 주변의 유로 폭을 변화시키고, 이것은 미성형이나 성형품의 뒤틀림 같은 심각한 결함을 야기시킬 수 있다. 인서트의 변형을 감소시키기 위해서는 게이트 시스템, 인서트 형상, 성형 조건 등을 성공적으로 설계해야 한다. 본 연구에서는 BLDC 모터 고정자의 사출 성형 시 발행하는 인서트의 변형을 수치해석을 통하여 분석하였다. 인서트 변형을 감소시키기 위하여 게이트 위치와 인서트 형상을 수정하였다. 마지막으로, 수정된 설계로 사출 성형을 수행하고, 변형이 감소되었음을 확인하였다. Insert injection molding is a process in which molten plastic is injected into a mold that contains a pre-placed insert. During the injection stage, the insert can be deformed by the pressure applied by the polymer melts. The deformation of the insert changes the width of the flow path around the insert, which can cause several defects such as short shots or warpages of the parts. In order to reduce the deformation of the insert, it is important to achieve successful design of gating system, insert geometry, and molding conditions. In the present study, the insert deformations that occured during the injection molding of the BLDC motor stator were investigated by numerical analyses. The gate location and the insert shape were modified to reduce the insert deformation. Finally, the injection molding with the modified designs was carried out, and it was confirmed that the insert deformation was reduced.

금형 냉각을 고려한 다단 열간 단조 공정의 유한요소해석

최두순(Du-Soon Choi),강형부(Hyoungboo Kang) 한국기계가공학회 2020 한국기계가공학회지 Vol.19 No.5

Multistage hot forging process enables mass production of various parts at a high speed, wherein, it is important to design the forging steps in an optimal way. Finite element methods are widely applied for optimizing the forging process design; however, they present inaccurate results due to the rapid change in the mold temperature during multistage hot forging. In this study, the temperature distributions of the mold in a steady state were calculated via heat transfer analysis during mold cooling. The flow stress and friction coefficient of the material were measured according to the temperature and were applied for numerical analysis of the multistage hot forging process. Eventually, the accuracy of the analysis results is verified by comparing these results with the experiments.

케이블 트레이 설계시스템 개발

최두순(Du-Soon Choi),최우석(WooSeok Choi) 한국기계가공학회 2017 한국기계가공학회지 Vol.16 No.4

A cable tray is a structure made of metal or a non-combustible material that supports cables in the electrical wiring of buildings. Cable trays should be developed to meet the various requirements of the construction site. In this study, a design system was developed to calculate the maximum support load and the maximum deflection according to the cross-sectional shape of the cable tray. The cross-sections of cable trays were modeled by combining linear and arc elements, and cross-sectional characteristics such as the 2nd moment of area were calculated. The distributed load and the concentrated load were applied to the cable tray using the Euler beam theory, and then the deflection profiles and maximum stress were calculated. To verify the developed system, deflection distributions and maximum stresses for two types of cable trays were calculated and compared. The maximum deflection and maximum stress errors calculated from the developed system were found to be less than 4% compared with numerical analysis results.

탄소나노튜브 박막 제조를 위한 분무공정에서의 증착 두께 분포 예측 모델 개발

최두순(Du Soon Choi),김덕종(Duckjong Kim),장동환(Dong Hwan Jang) 대한기계학회 2011 大韓機械學會論文集B Vol.35 No.9

탄소나노튜브(CNT)는 원통형의 탄소나노 구조물로서, 뛰어난 전도특성과 열전도율을 갖는다. 이러한 특성을 이용한 다양한 응용 분야의 하나로 CNT 를 박막형태의 그물망으로 제작하여 전도성 필름으로 응용하는 방안이 연구되고 있다. 이러한 CNT 의 박막 제조 방법 중, 분무 코팅 방식은 대면적 박막 제조에 널리 사용되나, 박막 두께를 균일하게 제작하는 점에 어려움이 있다. 이러한 문제점을 해결하려면 분무시의 공정조건이 증착 두께 분포에 미치는 효과를 잘 분석해야 한다. 본 연구에서는 분무 공정에서의 증착두께분포를 예측하기 위한 수치해석 모델을 개발하였다. 또한, 개발된 모델을 이용하여 여러가지 노즐 경로에 따른 증착 두께 분포를 분석하였다. A carbon nanotube (CNT) is a cylindrical carbon nanostructure with good transport properties along the tube’s axis. As an approach for realizing the practical use of CNTs, CNT networks are fabricated and their applications in many fields are investigated. To fabricate thin CNT-based films, several methods have been proposed and used. Among these methods, the spray coating method is a robust method for fabricating a large area. However, it is difficult to achieve uniformity in the CNT network. To solve this problem, it is necessary to understand the effect of the sprayprocess parameters on the deposition thickness distribution. In this study, a numerical model for predicting the deposition thickness distribution during the spray process was developed. The spatial deposition thickness distributions obtained according to various nozzle paths were analyzed using the developed numerical model.

모바일 기기용 초소형 나사의 냉간 단조 공정 설계

최두순(Choi, Du-Soon) 한국산학기술학회 2015 한국산학기술학회논문지 Vol.16 No.6

나사는 나선형의 홈으로 구성된 체결용 기계요소이다. 최근의 모바일 기기의 소형화 추세로 인하여 나사의 소형화 및 경량화 요구도 크게 증가하고 있는 실정이다. 우수한 기계적 성질과 높은 정밀도의 나사를 생산하기 위해서는 금형 및 공정설계가 성공적으로 수행되어야 한다. 본 연구에서는 유한요소해석을 통하여 초소형 나사의 머리부 냉간 단조 성형에 대한 공정설계를 수행하였다. 특히, 금형의 형상과 마찰력이 성형에 미치는 영향을 분석하기 위하여 실험계획법을 적용하였 고, 그 결과 마찰력이 성형 시 발생하는 접힘 결함의 지배적인 요인임을 밝혀내었다. 이러한 결과로부터 금형 형상을 개선하 였고, 개선된 금형으로 단조 실험을 수행하였고, 실험 결과로부터 접힘 결함 불량이 해소된 것을 확인하였다. A screw is a type of fastener characterized by a helical ridge known as thread. The demands for screws with the miniaturization and weight reduction are increasing for the trend of small size of mobile devices. The successful designs of mold and process are very important to obtain screws with good mechanical properties and high precision. In this study, the design of cold forging process of micro screw was carried out by using finite element method. In particular, in order to investigate the effects of die geometries and friction, design of experiment method was adopted and it was revealed that the friction was the dominant factor of folding defects. From these results, the design of die was modified and experiments were carried out with the modified die. From the experimental results, it was found that the folding defects disappeared.

비정형 물체의 안정적인 파지를 위한 유연한 로봇 그리퍼 설계

최두순(Du Soon Choi),이주은(Ju Eun Lee),황면중(Myun Joong Hwang) 제어로봇시스템학회 2020 제어·로봇·시스템학회 논문지 Vol.26 No.3

Many studies on agricultural robots are actively underway; hence, the design and the manufacture of robot grippers for manipulating a variety of fruits are attracting attention. A flexible gripper is required for harvesting without damage because the fruit size and shape are not uniform. This study executes optimal design and analysis to determine the design parameters of a spatial flexible gripper for grasping unstructured objects. The actual gripper was manufactured through 3-D printing. The grasping motion was realized by adapting the cam structure to convert rotation by a servo motor into translation to stretch or fold the finger. The experiment result shows that each part of the finger holds the object stably without excessive bending.

Investigation of Spray Process for Carbon Nanotube Thin Films

Duckjong Kim(김덕종),Du Soon Choi(최두순) 대한기계학회 2011 대한기계학회 춘추학술대회 Vol.2011 No.10

Industrial use of carbon nanotube (CNT) films is in the spotlight due to their good physical properties and high economic feasibility. Spray coating process is one of feasible approaches for large area CNT films. Uniform spray coating is an important issue in applications requiring large area conductive films. In this work, we present a numerical model for the prediction of CNT deposition thickness distribution in the spray process and experimental data validating the numerical work. From the results, we can find that the pitch of the nozzle path is a key parameter affecting the deposition thickness uniformity and that there is optimal pitch value for unfirom and productive coating. We also discuss future research direction for improved numerical simulation tool.

협소 공간 작업을 위한 6축 다관절 로봇의 기구학 및 구조해석

정성엽(Seong Youb Chung),최두순(Du-Soon Choi) 한국산학기술학회 2017 한국산학기술학회논문지 Vol.18 No.3

본 연구팀은 프레스 성형 공정에서 버텀 섀시 (bottom chassis)에 팸너트 (pem nut)를 고정하는 것과 같은 협소 공간작업을 위한 6축 다관절 로봇을 개발하고 있다. 본 논문에서는 6축 다관절 로봇의 위치 제어를 위한 기구학 해석과 가반하중에 따른 위치 정밀도 파악을 위한 구조해석을 수행하였다. 먼저, 로봇의 Denavit-Hatenberg 파라미터를 정의하고, 정기구학과 역기구학 모델을 제시하였다. 기구학 모델은 Coppelia Robotics 사의 virtual robot experimentation platform (V-REP)을 이용하여 시각적인 시뮬레이션을 통해 검증하였다. 위치 정밀도 분석은 완전 펼침 상태와 완전 접힘 상태에서 자중에 의한 처짐량과 가반하중에 의한 처짐량에 대한 구조해석을 통해 수행하였다. 해석 결과, 최대 변형량은 완전 펼침 상태에서 자체 하중만 있는 경우 0.339 mm로 나타났으며, 5kgf의 하중이 장착된 경우에는 0.667 mm로 나타났고, 설계 조건 1 mm 내에 있음을 확인하였다. 또한, 최대 발생 응력은 축 2와 3을 연결하는 링크에서 22.05 MPa로 나타났고, 부품 재질을 고려할 때 이 값은 구조적으로 안전함을 확인하였다. Our research team is developing a 6-DOF manipulator for narrow workspaces in press forming processes, such as placing PEM nuts on the bottom of a chassis. In this paper, kinematic analysis was performed for the position control of the manipulator, along with structural analyses for position accuracy with different payloads. First, the Denavit-Hatenberg (DH) parameters are defined, and then the forward and backward kinematic equations are presented using the DH parameters. The kinematic model was verified by visual simulation using Coppelia Robotics" virtual robot experimentation platform (V-REP). Position accuracy analysis was performed through structural analyses of deflection due to self-weight and deflection under full payload (5 kgf) in fully opened and fully folded states. The maximum generated stress was 22.05 MPa in the link connecting axes 2 and 3, which was confirmed to be structurally safe when considering the materials of the parts.