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![Page 1: The Korean Society of Manufacturing Process Engineersmsjoun.gnu.ac.kr › pub › 2012-papers › conference › local... · 2013-01-03 · 국부요소망재구성기법을 이용한](https://reader034.vdocuments.site/reader034/viewer/2022042401/5f101d317e708231d44783ef/html5/thumbnails/1.jpg)
국부요소망재구성기법을 이용한 절삭공정의 유한요소해석
1) 경상대학교 기계공학부
#) 경상대학교 기계공학부
E-mail:[email protected]
The Korean Society of Manufacturing Process Engineers
심규하1), 김수진1), 전만수#)
www.afdex.com
AFDEX
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목차
▣ 서 론
▣ 결론
⊙ 문헌조사
⊙ 연구배경 및 목적
⊙ 연구대상
▣ 본 론
⊙ 해석조건
⊙ 해석결과
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⊙ 요소망재구성과 수치적 순화
○ 선형등매개변수 요소의 경우 요소 경계에서
응력, 변형률, 변형률속도 등의 상태변수가
불연속.
○ 변형률, 손상도 등과 같은 이력변수는 요소망
재구성으로 수치적 순화가 불가피
○ 이 순화는 곧 정확도를 떨어뜨리는 직접적인
원인이 됨.
⊙ 국부요소망재구성 및 전체요소망재구성
○ 요소망재구성을 줄이는 것이 대책이지만, 이
경우 소재의 경계가 금형을 충분히 표현하지
못하는 문제를 유발하며, 요소의 심한 뒤틀림
은 수치적분 시의 오차를 증가시키는 요인
○ 이러한 문제를 해결하기 위한 목적으로 국부
요소망재구성과 전체요소망재구성의 조화가
필수적 이다.
연구배경 및 목적
0.43
0.37
손상도의 순화 예
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1) 황준, 황덕철, 우창기, 양계준, 한국정밀공학회 춘계학술대회, pp1000~1003, 2001
2) 김기환, 문상돈, 신형곤, 김태영, 한국정밀공학회 춘계학술대회, pp988~991, 2001
3) 심규하, 엄재근, 전만수, 한국소성가공학회 춘계학술대회, pp235~238, 2012
4) Kai Liu, Shreyes N. Melkote, Int. J. Mach. Sci 49, pp650-660, 2007
5) Kbdullah Duran, Muammer Nalbant, Mater. Des 26, pp549-554, 2005
6) Pradip Majumdar, R. Jayaramachandran, S. Ganesan, Appl. Therm. Eng. 25, pp2152-2168, 2005
7) Martin Baker, J. Mater. Process. Technol 176, pp117-126, 2006
8) Jun Yan, John S. Strenkowski, J. Mater. Process. Technol 174, pp102-108, 2006
9) Guoqin Shi, Xiaomin Deng, Chandrakanth Shet, Finite Elem. Anal. Des 38, pp863-883, 2002
10) A.G. Mamalis, A.S. Branis, D.E. Manolakos, J. Mater. Process. Technol 123, pp464-475, 2002
11) Z.C. Lin, Y.Y. Lin, Theor. Appl. Fract. Mech 35, pp137-153, 2001
문헌조사
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AFDEX3D
Shephard(RPI)
DEFORM3D
M.S. Shephard
DEFORM3D
AFDEX3D vs Shephard(RPI) vs DEFORM3D
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0 1.0 2.0
1.0
1
4 3
2 5
6
21
( )
0
2.0
2.01.0
1.0
1
2
3
2
=
=
1 1.0
0
2.0
)(
1.0 2.0
by insight
by least-square method
( )
0
2.0
2.01.0
1.0
1
2
3
2
=
=
1 1.0
0
2.0
)(
1.0 2.0
by insight
by least-square method
상태변수의 순화 이유
1 2 3
1 22 2
2 1 1 3 2 2 30 1
2 2 2
1 2 3 1 2 2 3 1 2 3
( , , )
(( ) 1) (( ) 2 2)
1( 2 3 9 6 15)
3
E
x dx x dx
1 2 3( , , )E
0, 1,2,3i
Ei
1 2
1 2 3
2 3
2 3 0
4 9 0
2 6 0
1 0.75, 2 1.50, 3 2.25
1.125, ① 1.875 ②
요소치를 절점치의 대수평균값
오차함수 가 최소값을 가진 조건
수치적 순화 현상
2 =1.875
1 =1.125
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국부요소망재구성 기법
⊙ Case 1
Local remeshing
(r-method)
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국부요소망재구성 기법
1.0R 2.0R 3.0R
= weighting factor of boundary nodes ⊙ Case 2 ( 100)W W
R
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국부요소망재구성 기법
100W 150W 200W
⊙ Case 2 ( 2.0)R = weighting factor of boundary nodes W
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소재 단면크기 및 금형형상
공정도 모델링 (FM Model) 바이트 공작물(평면변형)
홀더
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절삭공정 해석 적용
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절삭공정 시뮬레이션 - 전체요소망재구성 기법
⊙ Effective strain distribution
2.000
1.795
1.590
1.385
1.180
0.975
0.770
0.565
0.360
0.155
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절삭공정 시뮬레이션 - 국부요소망재구성 기법
⊙ Effective strain distribution
2.000
1.795
1.590
1.385
1.180
0.975
0.770
0.565
0.360
0.155
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절삭공정 시뮬레이션 - 전체요소망재구성 기법
⊙ Damage distribution
0.4900
0.4390
0.3880
0.3370
0.2860
0.2350
0.1840
0.1330
0.0820
0.0310
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절삭공정 시뮬레이션 - 국부요소망재구성 기법
⊙ Damage distribution
0.4900
0.4390
0.3880
0.3370
0.2860
0.2350
0.1840
0.1330
0.0820
0.0310
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절삭공정 시뮬레이션 - 전체요소망재구성 기법
⊙ Metal Flow line
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절삭공정 시뮬레이션 - 국부요소망재구성 기법
⊙ Metal Flow line
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절삭공정 시뮬레이션 – 결과 비교
⊙ Effective strain distribution ⊙ Damage distribution
2.000
1.795
1.590
1.385
1.180
0.975
0.770
0.565
0.360
0.155
전체요소망재구성 기법 전체요소망재구성 기법
국부요소망재구성 기법 국부요소망재구성 기법
0.4900
0.4390
0.3880
0.3370
0.2860
0.2350
0.1840
0.1330
0.0820
0.0310
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절삭공정 시뮬레이션 – 결과 비교
⊙ Metal Flow line
전체요소망재구성 기법
국부요소망재구성 기법
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절삭공정 해석 적용 – Burr formation
Normalized
Cockroft, Latham
Element deletion
scheme
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절삭공정 시뮬레이션 – Burr formation
⊙ Effective strain distribution
⊙ Damage distribution
⊙ Metal Flow line
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절삭공정 시뮬레이션 – 비등온공정
⊙ 해석 유형: 비등온해석, 열간
⊙ 공작물조건 - 물성치: AISI_1020 (T=600-1100 ℃) - 초기온도: 700℃ ⊙ 바이트와 홀더의 조건 - 마찰계수: μ=0.1 - 속 도: -10.0 mm/s (x방향 성분) - 초기온도: 200℃(바이트), 20℃(홀더)
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절삭공정 시뮬레이션 – 비등온공정
⊙ Temperature distribution
709.4
658.7
608.0
557.3
506.6
455.9
405.2
354.5
303.8
253.0
202.3
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해석결과
⊙ Load vs Stroke [xx]
▪ 국부요소망재구성
▪ 전체요소망재구성
0 0
10 20 30 40
0.005
0.01
0.015
0.02
Time[s]
Load[t
on]
0 10 20 30 40
0.005
0.01
0.015
0.02
Time[s]
Load[t
on]
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해석결과- 애니메이션_strain
⊙ Global remeshing ⊙ Local remeshing
⊙ Burr formation ⊙ Non-isothermal global remeshing
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결론
⊙ 국부요소망재구성기법에 근거한 자동 절삭시뮬레이션 기법을 제시하였음.
⊙ 절삭공정의 해석에 적용하여 기존의 전체요소망재구성기법과 비교함으로써 유용성
을 강조함.
⊙ 국부요소망재구성기법을 통하여 상태변수의 순화를 최소화함으로써 보다 정확한 공정
시뮬레이션이 가능하게 됨.