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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (20 November 2022) | Viewed by 31628

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Prof. Dr. Min Soo Park

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Department of Mechanical System Design Engineering, Seoul National University of Science and Technology, Seoul, Korea
Interests: ceramic 3D printing; polymer PBF; food printing; laser machining; EDM
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Special Issue Information

Dear Colleagues,

The development of manufacturing technologies has made it possible to produce precise parts and to realize complex shapes. These new attemps made possible a high-functional structure by overcoming the limitations of design based on traditional manufacturing methods. In addition, as the diversity of available engineering materials increases, functional design attempts are being made, not only due to structural complexity but also material complexity. In particular, these innovative manufacturing and design processes based on complexing between various materials can be used in various ways in aviation, automobiles, sports, and national defense, where precision and function are important. While it took a lot of time and cost to fabricate complex and precise shapes in traditional manufacturing processes, newly developed processes can help overcome these limitations. Therefore, in this Special Issue, we deal with various researches related to innovative design and manufacturing processes for engineering materials.

Prof. Dr. Min Soo Park
Guest Editor

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Keywords

innovative design
innovative manufacturing processes
engineering materials
functional design
manufacturing technologies

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Published Papers (11 papers)

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11 pages, 3736 KiB

Open AccessArticle

Deep Electrochemical Etching of Stainless Steel Using a Deposited Copper Layer

by Hong-Shik Shin

Appl. Sci. 2022, 12(23), 12473; https://doi.org/10.3390/app122312473 - 6 Dec 2022

Cited by 2 | Viewed by 2908

Abstract

Deep electrochemical etching (DEE) is proposed in this paper. DEE is a process that repeats steps consisting of electrodeposition, laser patterning, and electrochemical etching. In the electrodeposition step, a deposited layer is formed on the surface of the workpiece. This deposited layer serves as a protective layer to protect the surface of the workpiece until it is completely dissolved in the electrochemical etching step. Laser patterning is the step of patterning a deposited layer by irradiating a laser beam while minimizing surface damage to the workpiece. The etching of the workpiece proceeds through the electrochemical etching step. If these three steps are performed sequentially, one cycle of the DEE process is completed. By repeating this cycle, an improved etch factor can be obtained in the DEE process. The processing characteristics according to DEE process conditions were analyzed through an SEM and 3D surface profiler. Through the DEE process, a microstructure with a deep etching depth was fabricated, and the micropatterns successfully penetrated a one-hundred-um-thick stainless steel specimen. Through the DEE process, it was confirmed that it is possible to fabricate a micro with a high aspect ratio structure pattern by improving the etch factor. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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14 pages, 6553 KiB

Open AccessArticle

Prediction of Ply Angles of Air Springs According to Airbag Positions and Their Effects on Lateral and Torsional Stiffness

by Hyoungwook Lee and Chul-Su Kim

Appl. Sci. 2022, 12(22), 11815; https://doi.org/10.3390/app122211815 - 21 Nov 2022

Cited by 4 | Viewed by 1728

Abstract

The stiffness in various directions of air springs have a great influence on the stability of high-speed trains. Due to the change in the bogie structure, the required functions of the air springs have also diversified, and the damping of various loading modes such as vertical, lateral, and torsional movements is emerging as important. The stiffnesses are affected by the shape of the air bag, the material, and the ply angles. In this paper, the relationship between the ply angle and the radial position is proposed by equations from deformation modes. The variable angles in the plies were compared and demonstrated in air-spring analysis using the rebar elements. The vertical, lateral, and torsional stiffness of air springs without auxiliary springs were compared between constant ply angles and variable ply angles with respect to the positions. When mainly dealing with the vertical stiffness, the effect of the angle variation was small; however, it was found that it had a large effect of more than 24% and 30% on the stiffness in the lateral direction and torsional direction, respectively. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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13 pages, 3114 KiB

Open AccessArticle

A Study of Microdrilling of Fused Silica Using EDMed PCD Tools

by Pyeong An Lee and Bo Hyun Kim

Appl. Sci. 2022, 12(21), 11166; https://doi.org/10.3390/app122111166 - 3 Nov 2022

Cited by 8 | Viewed by 1586

Abstract

In microbiochips and microfluidic devices, microholes are a basic and important feature. The microdrilling of glass materials without cracks is still challenging in the fabrication of glass-based microdevices. This paper investigates the characteristics of microdrilling fused silica using polycrystalline diamond (PCD) tools fabricated by electrical discharge machining (EDM). In particular, peak forces, which are observed at the beginning of drilling, are discussed because crack formations are related to peak forces. To reduce peak forces and to minimize cracks, the effects of drilling conditions, such as tool shape, the surface roughness of a tool, and axial feedrate, were therefore investigated. It was observed that D-shape tools with high surface roughness was useful to reduce the peak force. In through-hole drilling, a sacrificial layer was used to prevent exit cracks, and a variable feedrate was applied to increase drilling speeds. Finally, a dressing process using EDM was conducted to recondition the worn tool’s surface. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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16 pages, 14795 KiB

Open AccessArticle

Fabrication of a Conductive Pattern on a Photo-Polymerized Structure Using Direct Laser Sintering

by Jung-Hoe Jo and Min-Soo Park

Appl. Sci. 2022, 12(21), 11003; https://doi.org/10.3390/app122111003 - 30 Oct 2022

Cited by 2 | Viewed by 1608

Abstract

Three-dimensional (3D)-printed electronic technology is considered to have great potential as it can be utilized to make electronic products with complex 3D shapes. In this study, based on a 3D printer with single UV laser equipment, we continuously performed photo-polymerization (PP) and selective metal powder sintering to fabricate a conductive pattern. For this, 3D structures were printed at a low energy using a 355 nm DPSS laser with a galvanometer scanner, which are widely used in PP-type 3D printing, and then the selective sintering of metal powders was performed with a high energy. In order to obtain a high-conductivity pattern by laser sintering, a circuit pattern that could actually be operated was fabricated by experimenting with various condition changes from mixing the metal composite resin to the laser process. As a result, it was found that the optimal result was to irradiate a 0.8 W UV laser with a beam spot size of 50 µm to 50 vol% aluminum composite resin. At this time, an optimal conductive pattern with a resistance of 0.33 Ω∙cm⁻¹ was obtained by setting the pulse repetition rate, scan path interval, and scanning speed to 90 kHz, 10 μm, and 50 mm/s, respectively. This suggested process may be of great help in the manufacturing of practical 3D sensors or functional products in the future. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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14 pages, 5117 KiB

Open AccessArticle

Elasto-Inertial Particle Focusing in Microchannel with T-Shaped Cross-Section

by Jaekyeong Jang, Uihwan Kim, Taehoon Kim and Younghak Cho

Appl. Sci. 2022, 12(20), 10552; https://doi.org/10.3390/app122010552 - 19 Oct 2022

Cited by 4 | Viewed by 1677

Abstract

Recently, particle manipulation in non-Newtonian fluids has attracted increasing attention because of a good particle focusing toward the mid-plane of a channel. In this research, we proposed a simple and robust fabrication method to make a microchannel with various T-shaped cross-sections for particle focusing and separation in a viscoelastic solution. SU-8-based soft lithography was used to form three different types of microchannels with T-shaped cross-sections, which enabled self-alignment and plasma bonding between two PDMS molds. The effects of the flow rate and geometric shape of the cross-sections on particle focusing were evaluated in straight microchannels with T-shaped cross-sections. Moreover, by taking images from the top and side part of the channels, it was possible to confirm the position of the particles three-dimensionally. The effects of the corner angle of the channel and the aspect ratio of the height to width of the T shape on the elasto-inertial focusing phenomenon were evaluated and compared with each other using numerical simulation. Simulation results for the particle focusing agreed well with the experimental results both in qualitatively and quantitatively. Furthermore, the numerical study showed a potential implication for particle separation depending on its size when the aspect ratio of the T-shaped microchannel and the flow rate were appropriately leveraged. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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13 pages, 726 KiB

Open AccessArticle

Research on Adhesive Coefficient of Rubber Wheel Crawler on Wet Tilted Photovoltaic Panel

by Minh Tri Nguyen, Cong Toai Truong, Vu Thinh Nguyen, Van Tu Duong, Huy Hung Nguyen and Tan Tien Nguyen

Appl. Sci. 2022, 12(13), 6605; https://doi.org/10.3390/app12136605 - 29 Jun 2022

Cited by 5 | Viewed by 2745

Abstract

The demand for renewable energy sources is growing fast because of the negative impact of the utilization of fossil energy, nuclear energy, and hydroelectricity. One of the renewable energy sources, known as solar energy, which uses the photovoltaic panel (PV) to generate electricity from the sun, is a promising alternative that has great potential to deal with the power crisis. However, the power productivity and efficiency conversion are affected significantly by dust accumulation on PVs. Many researchers investigated PV panel dust cleaning methods to improve performance, yield, and profitability. Various dust cleaning and mitigation methods such as rainfall, labor-based, and mechanized cleaning are explored, and we demonstrated that dust removal could be automated with cleaning robots effectively. Due to the specified geographical site of PV panel installation, cleaning robots might work on the misalignment and uneven PV arrays, presenting huge challenges for an autonomous cleaning robot. Thus, a rubber wheel crawler robot with semi-autonomous handling provides a flexible motion that is a well-suited solution to clean rooftop PV arrays. Nevertheless, the rubber wheel crawler robot might suffer slippage on the wet glass of tilted PV arrays. This paper studies the anti-slip effect of the rubber wheel crawler equipped with a cleaning robot under the wet surface of tilted PV panels. First, a theoretical model consisting of several parameters is established to validate the slippage of the rubber wheel crawler on the wet tilted PV. Then, some parameters of the theoretical model are approximated through experimental tests. Finally, simulation results of the theoretical model are conducted to evaluate the accuracy of the proposed theoretical model in comparison to the experimental results under the same working conditions. The merits provide the efficient design of rubber wheel crawlers, enabling the anti-slip ability of robots. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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12 pages, 5832 KiB

Open AccessArticle

Processing and Evaluation of a Carbon Fiber Reinforced Composite Bar Using a Closed Impregnation Pultrusion System with Improved Production Speed

by Byungsoo Kang, Changki Lee, Seung-Mo Kim and Hyeong-Min Yoo

Appl. Sci. 2022, 12(10), 4906; https://doi.org/10.3390/app12104906 - 12 May 2022

Cited by 3 | Viewed by 2542

Abstract

In this paper, an epoxy resin-based carbon fiber reinforced composite (CFRP) bar pultrusion system using a closed impregnation device which has various advantages in process compared to traditional open bath type pultrusion system was developed, and the fiber impregnation system was improved through the analysis of resin properties for the high-speed production of CFRP bars used to support the mother glass in the display transfer cassettes. To improve the fiber feeder system, fiber guides were switched from perforated plates to roller guides for spreading fibers, which allowed the input fibers to be widened and flattened while reducing the fiber thickness. Additionally, the correlation between resin viscosity and impregnation speed were analyzed to evaluate the resulting mechanical properties at different pultrusion speeds and temperatures. A CFRP bar was produced with resin injection at room temperature and a pultrusion rate of 400 mm/min and compared to a CFRP bar produced with fiber spreading, a resin injection temperature of 40 °C, and a pultrusion rate of 600 mm/min; the latter with a 50% improved production rate showed improvements in mechanical properties, including the cross-sectional void by 98.7%, surface roughness by 75.5%, deflection by 34.9%, and bending strength by 70%. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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11 pages, 2755 KiB

Open AccessArticle

A Numerical Investigation of Delamination Response of CNT/Epoxy Film Interleaved Composite

by Yongchul Shin and Seungmo Kim

Appl. Sci. 2022, 12(9), 4194; https://doi.org/10.3390/app12094194 - 21 Apr 2022

Viewed by 1495

Abstract

In this study, numerical modeling through the cohesive zone theory was performed to simulate the end notch flexure (ENF) test with same conditions of the experimental results of previous study that investigated the effect of a carbon nanotube (CNT)/epoxy film in carbon fiber reinforced polymer (CFRP) composite through the mode II interlaminar fracture toughness of a non-interleaved, epoxy film interleaved, CNT/epoxy film interleaved CFRP laminate specimen. The effect of the presence of CNT/epoxy film interleave on a composite laminate was modeled. The influence of the interleave cohesive parameters was studied to link the parameters to the material strength and energy release rate. Cohesive parameter identification was performed by matching the initial loading and the damage evolution phase by dividing the cohesive zones into cohesive front and remaining cohesive zones. This is because, when modeling with a single cohesive zone, the critical load point that causes delamination or the curve after load drop do not match the experimental values. Results showed that the divided cohesive zone model is in good agreement with the experimental results and that there is a clear relationship between the cohesive energy of the interface and CNT/epoxy film parameters. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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14 pages, 3834 KiB

Open AccessArticle

Texture Modification of 3D-Printed Maltitol Candy by Changing Internal Design

by Ga-In Kim, Seong-Jae Boo, Jang-Wook Lim, Jin-Kyo Chung and Min-Soo Park

Appl. Sci. 2022, 12(9), 4189; https://doi.org/10.3390/app12094189 - 21 Apr 2022

Cited by 5 | Viewed by 2363

Abstract

The purpose of this study is to show more diverse texture modifications by changing the material of a food 3D-printed structure conducted only with soft materials (in this case, potatoes and chocolate) to a hard material (in this case, maltitol here). However, unlike previous 3D-printed food materials, sweetener materials such as sucrose and maltitol are sensitively caramelized at a high melting temperature. As such, there is no commercialized printing equipment. Therefore, a printing process experiment was conducted first in this case. To do this, a high-temperature syringe pump-based extrusion device was designed, and process tests according to the temperature and environment were conducted. An assessment of the internal structural changes according to the infill patterns and infill percentages was conducted based on the acquired process conditions. The texture strength increased as the infill percentage increased. Depending on the infill patterns, the texture strength increased in the order of the Hilbert curve, honeycomb, and rectilinear samples here. As a result, a change in the texture strength was determined through a change in the internal structure of a hard food material using 3D printing, which showed a wider range of change than in conventional soft food materials. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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15 pages, 6824 KiB

Open AccessArticle

Research on Identification Method for Interface Flange in Automatic Docking System of Fluid Loading and Unloading Arm for Bottom Loading

by Mingqin Liu, Zongzhou Li, Jie Liu, Zhongguo Mao, Minglong Xu and Sungki Lyu

Appl. Sci. 2022, 12(6), 3037; https://doi.org/10.3390/app12063037 - 16 Mar 2022

Cited by 1 | Viewed by 2155

Abstract

The automatic docking system of the loading and offloading arm of a tank car is the key link to realizing the unmanned operation of tank car loading and unloading. The spatial position detection of the flange port of a tank car can guide the automatic docking of the fluid loading and offloading arm and flange port of the tank car. In this paper, a flange position detection method based on image recognition was proposed. Firstly, the end state of the loading arm was analyzed to determine the expression mode of the loading arm’s spatial pose so as to form a unified expression with the flange position and docked pose on the tank car. Then, for the image processing of the flange port of the tank car, this paper binarized the edge of the flange end face based on the Otsu algorithm, used the Canny algorithm for edge detection, used the least squares method to fit the image edge coordinates into a spatial circle, calculated the center coordinates and normal vector of the flange end face, and used these parameters to guide the end of the loading arm to adjust the position and attitude so that it was consistent with the position and pose of the flange port to realize docking. Then, a circular object center detection and calibration experiment, a flange end face image experiment, and an automobile tank car flange port physical detection experiment were carried out. The test results show that the spatial coordinate accuracy of the flange port diameter and center detected by this method meets the requirements of the loading arm automatic docking system, providing a research idea for the design of an automatic docking system for the loading and unloading arm of a tank car. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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Review

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21 pages, 3149 KiB

Open AccessReview

A Review of Cell Operation Algorithm for 3D NAND Flash Memory

by Jong Kyung Park and Sarah Eunkyung Kim

Appl. Sci. 2022, 12(21), 10697; https://doi.org/10.3390/app122110697 - 22 Oct 2022

Cited by 6 | Viewed by 9655

Abstract

The size of the memory market is expected to continue to expand due to the digital transformation triggered by the fourth industrial revolution. Among various types of memory, NAND flash memory has established itself as a major data storage medium based on excellent cell characteristics and manufacturability; as such, the demand for increasing the bit density and the performance has been rapidly increasing. In this paper, we will review the device operation algorithm and techniques to improve the cell characteristics and reliability in terms of optimization of individual program, read and erase operation, and system level performance. Full article

(This article belongs to the Special Issue Innovative Design and Manufacturing Processes for Engineering Materials)

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