한국정밀공학회:학술대회논문집 (Proceedings of the Korean Society of Precision Engineering Conference) (Proceedings of the Korean Society of Precision Engineering Conference)
한국정밀공학회 (Korean Society for Precision Engineering)
- 반년간
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- 2005-8446(pISSN)
과학기술표준분류
- 기계 > 정밀생산기계
한국정밀공학회 2002년도 춘계학술대회 논문집
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최근 자동차가 편리성과 안전성을 추구함에 따라서 자동차 부품도 과거의 기계식 동작 방법에서 전자 제어 장치가 부착된 전자식 동작 방법으로 발전되어 가고 있는 추세입니다. 또한 연비 향상을 위하여 부품의 소형화가 급속히 추진되고 있습니다. 이러한 전자화, 소형화를 실현시키기 위해 자동차 부품에서의 정밀성이 요구되어 지고 있고, 부품 제조 측면에서는 고속화, 정확성이 요구되고 있는 실정입니다. 당사의 경우 CBS (Conventional Brake System)를 생산하다가 전자 제어 장치가 부착된 ABS (Anti-lock Brake System)의 생산을 시작할 때, 부품의 정밀도를 좌우하는 각 치수의 공차 영역이 전체적으로 CBS 대비 약 1/5 수준밖에 되지 않고, 가공 속도는 약 2 배가 빨라야 하기 때문에 생산 준비 단계에서 많은 시행 착오를 겪어야만 했습니다. 여기서 당사가 ABS를 양산하면서 겪은 경험을 토대로 기술토록 하겠습니다. 가공 기술의 경우 고속, 정밀 가공을 실현시키기 위해서 크게 4 가지 측면을 고려해야만 하며, 그 4가지는 설비, Tool Holder, Tool, Chip 측면입니다. 먼저 설비가 고정도가 되기 위해 고강성을 필요로 하는 것은 물론 가동중에 필연적으로 발생하는 열변형에 대한 대책을 수립하지 않으면 안됩니다. 이러한 열변형은 설비 설계 단계에서 대책을 수립할 수 있는 것도 있지만 주위 온도 변화에 의한 열변형처럼 사용 중에 발생되는 것은 설비 사용자가 장시간에 걸친 Data 를 확보하여 대책을 수립하지 않으면 안됩니다. 또한 Tool Holder의 정도도 일반적으로 사용하는 것보다는 고정도의 것이 요구되어지므로 Tool Holder Maker 에 반드시 요구 정도를 명기하여 주문하여야 합니다. Tool도 고속화를 실현시키기 위해 고정도의 다이아몬드 공구가 필요하였고 이를 국내에서 개발하기 위해 많은 시행 착오를 겪어야만 했습니다. 또한 Chip 배출이 고정도의 필수 고려 항목으로서 당사에서는 경우에 따라 여러 가지의 방법을 사용하고 있습니다. 조립 기술의 경우 스테인레스 박판을 열변형을 최소로 하면서 용접을 하기 위해서 레이저 용접을 도입하였고, 부품을 압입하면서 정확하고 정밀한 치수 셋팅을 위하여 서버 모타를 이용한 압입 방법을 사용하였습니다.
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An intelligent polishing robot automation system is developed. Automatic Tool Change System(A.T.C.), Tool Posture Angle Control, and Robot Program for Polishing Application are developed and integrated into a robotic system that consists of a robot, pneumatic finding tool, and finding abrasives (papers and special films). A.T.C. is specifically designed to exchange whole grinding tool set for complete unmanned operation. Tool Posture Angle Control is developed to give a certain skew angle rather than right angle to tools on the surface for best finishing results. A.T.C. and Tool Posture Angle Control is controlled by a PC and the robot controller. Also, there have been some considerations on enhancing the performance of the system. Some elastic material is inserted between the grinding pad and the holder for better grinding contact. The robot path data is generated automatically from the NC data of previous machining process.
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Ferrule is widely used as fiber optic connecters. In fiber-optic communications, the shape accuracy such as coaxiality and cylindricity of ferrule affects insertion loss. When coaxial grinding of ferrule supported by two pin, pin alignment and chucking accuracy are very important. In this research, the kinematic behavior of the ferrule center is investigated in the case where cone-shaped center pins and round circle hales which make contact with each other near the edge of the holes, using homeogenous coordinate transformation and numerical analysis. The obtained results are as follows: The alignment errors between center pins alone do not affect the rotation accuracy of ferrule. The alignment errors between center holes cause a sinusoidal displacement of ferrule. And the maximum displacement of ferrule centers increase in proportion to the center pin angle in the case of a fixed alignment errors
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With the rapid development of industrial technologies, the demand for high precision products has been increasing drastically. For this reason, the need for developing of high performance machine tool, which can ensure high precision, is desired in the industrial fields. Technologies on the spindle system manufacture, guideway manufacture, error compensation, design of bed structure, protection against vibrations, and system integration are core technology for developing of high precision machine tools. Especially, among these, design of spindle system, which is leading precision and manufacturing technique. is one of the most important technologies. A high speed and high precision spindle system, which will be used for final machining of ferrule, is designed considering the effect caused by thermal, cutting torque, cutting farce, and work-piece materials. The detail process of analysis is presented.
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In silicon wafer manufacturing process, the grinding process has been adopted to improve the quality of wafer such as flatness, roughness and so on. This paper describes the effect of grinding process on the surface quality of wafer. The experiments are carried out by high precision in fred grinder with air bearing spindle. The relationship between the inclination of chuck table and the flatness of wafer is investigated, and the effect of grinding conditions including wheel speed, table speed, and feed rate on damage depth and roughness of wafer is also investigated. The experimental results show that there is close relationship between the inclination of the chuck table and the flatness of wafer, and the grinding conditions within this paper little affect the flatness of wafer and relatively high affect the damage depth of wafer.
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The environmental problems by using coolant demanded the new cooling methods. As one of them, the studies on the finding with compressed cold air and oil mist have been done. The cooling method using compressed cold air was effective through going down the temperature of compressed air supplied below
$-25^{\circ}$ and increasing the amount of compressed cold air, but had not enough cooling effect due to the low performance of lubrication. Therefore, the cooling methods using oil mist newly were suggested. This method can satisfy both cooling effect and lubrication with only small amount of coolant, also have the benefit in the point of decreasing the environmental pollution. This paper focused on analyzing the grinding characteristics of the cooling method using oil mist. The grinding test according to compressed cold air, oil mist spray pressure and oil mist supply direction were done. -
This paper compared the surface roughness with variables before development of centerless grinding using far ferrule machining. In this paper, theoretical surface roughness is obtained from variables such as mesh number, rate of concentration of grinding wheel, wheel rotation of work-piece etc., and optimum condition of machining is selected. For satisfaction the technical side and economical side, centerless grinding using fur ferrule machining should be designed more than #600, 18.8% rate of concentration of grinding wheel, 1440rpm wheel rotation outwork-piece.
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This paper presents the structural characteristic analysis of a centerless grinding machine with concrete bed. The centerless grinding machine is composed of grinding wheel head, regulating wheel head, concrete bed, wheel dresser and so on. Especially, the concrete bed is introduced to improve the static, dynamic and thermal characteristics of the centerless grinding machine. The structural analysis model of centerless grinding machine is constructed by the finite element method, and the structural characteristics in the design stage are estimated based on the structural deformation and harmonic response under the various testing conditions related to gravity force and directional farces
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Thermal characteristics of hydrostatic guideway is largely depended on the temperature of supplied oil. For improving the positioning accuracy of hydrostatic guideway, relationship between setting temperature of oil cooler and thermal characteristics is analyzed, and influence of thermal characteristics on positioning accuracy is also analyzed experimental1y in this paper. Laser scale which has 0.01
$\mu\textrm{m}$ of resolution is used as feed-back unit. From the experimental results, it is confirmed that positioning error and repeatability is minimize upto 0.21$\mu\textrm{m}$ and 0.18$\mu\textrm{m}$ when the temperature of supplied oil is setting equal to temperature of atmosphere, and also confirmed that thermal deformation, which occurs by the temperature deviation between table and rail or scale supporter, works as limit of repeatability in long time operation. -
General wheel mark in mono-crystalline silicon wafer finding is able to be expected because it depends on radius ratio and angular velocity ratio of wafer and wheel. The pattern is predominantly determined by the contour of abrasive grits resulting from a relative motion. Although such a wheel mark is made uniform pattern if the process parameters are fixed, sub-surface defect is expected to be distributed non-uniformly because of characteristic of mono-crystalline silicon wafer that has diamond cubic crystal. Consequently it is considered that this phenomenon affects the following process. This paper focused on kinematic analysis of wafer grinding process and simulation program was developed to verify the effect of process variables on wheel mark. And finally, we were able to predict sub-surface defect distribution that considered characteristic of mono-crystalline silicon wafer
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A grinding technology is very essential to finish the surface of IT and BT industrial application parts such as wafer, optical connection part and lenses etc. However the finding machine has bead depended on imports. Especially, it is completely imported for machining high precision part relevant to domestic electric and communicational industries. The amount to import grinding machine is about $110milions. It takes about 35% of total import amount of all the machine tools. A domestic finder manufacturer is a very small-scaled bussinessman and research facilities is poor. Recently, it is increasing to demand high speed and precision grinding technology because it brings cost down and value added up. Its further study will be something related to inteligent grinding system fur value added and high precision part. It will make domestic grinding technology to its advanced country level.
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In this research, the modification method of spherical aberration, and aspherical lens shape design method were investigated. Spherical aberration affects lens's performance directly. Many studies have attempted to remove spherical aberration with a lot of methods in order to reduce the bad effect of spherical aberration. The approach to lens shape design was base on the ray tracing method. From the result, it was confirmed that ray reverse-tracing method was convenient to remove spherical aberration, and could be used very effectively and usefully for aberration-free aspherical lens design.
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Recently the applications of high speed machining are increasing due to the need for high performance and high accuracy machining and machining for difficult-to-cut material. However, the high speed machining also accompanies some problems: the product quality can be degraded due to the tool wear and the product cast can go up due to frequent tool replacements. Therefore, it is necessary to develop a technique of quantitative tool wear measurement to determine the precise timing for tool replacement. In this respect, this study suggests a reliable technique far the reduction of error components by developing a system using a CCD camera and an exclusive jig to be able to precisely measure the size of tool wear in flat end mill for high speed machining.
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In a high speed spindle system, it is very important to monitor the state of rotating rotor. Particularly in active control spindle system, the position sensor must provide feedback to the control system on the exact position of the rotor. In order to monitor the state of a high speed spindle exactly, High accuracy and wide frequency bandwidth of sensors are important. This paper describes the factors which has an effect on performances of inductive position sensor. We also report the experimental results that characterize the performances of the inductive position sensor.
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The geometry parameter of tool such as rake angle and clearance angle is defined clearly to solve the difference in communication between design and measurement stage. Using the developed simulation program, wheel is properly determined and end mill can be manufactured accurately. The performance test with well defined end mill provides sufficient information to decide optimal geometry. For machining hardened steel, end mills are designed and manufactured. Optimal rake angle and clearance angle is obtained from performance test. A specific software for automatic end mill production is developed far simulation and fur generation of NC code as Cad/CAM system.
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The requirements for higher productivity call for high speed of the machine tool axes. Iron core type linear DC motor is growly accepted far a viable candidate of the high speed machine tool feed unit. LDM, however, has inherent disturbance force components: cogging and force ripple. These disturbance force directly affects tracking accuracy of the carrage and must be eliminated or reduced. Reducing motor ripple, this paper adapted the feed forward compensation method and neural network control. Experiments carried 7ut on the linear motor test setup show that this control methods is usable in order to reduce the motor ripple.
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To achieve high precision machine totals with high speed, it is needed to develop excellent rigidity statically, dynamically and thermally as well. In this view the chief things that thermal deformation of machine tool structure is directly related to high precision. And thermal behavior for transmission procedure have an effect on high precision. It is needed to exact temperature distribution of each members and all contact elements included for machine tool structure. This paper deals with thermal behavior caused by temperature variation in a high speed feeding process. At this procedure of temperature distribution is estimated using a Predictor-Corrector Method.
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Due to various advantages over the conventional linear motion device such as ball-screw, linear motors have been used in wide variety of industrial applications for years. Driven by increased demand for precision machine tools, the importance of high positioning accuracy, high stiffness and high thrust are greatly increasing. In this paper, thrust ripple, detent force and thermal behavior are considered for the development of high performance linear motor whose thrust is up to 4, 000N. This paper presents a comprehensive study for an iron core type linear motor characteristics that include the influence of PM position on thrust thrust ripple by detent farce and motor dynamics as well.
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In NC machining, the ability to automatically generate an optimal process plan is an essential step toward achieving automation, higher productivity, and better accuracy. For this ability, a system that is capable of simulating the actual machining process has to be designed. In this paper, a milling process simulation system for the general NC machining was presented. The system needs first to accurately compute the cutting configuration. ME Z-map(Moving Edge node Z-map) was developed to reduce the entry/exit angle calculation error in cutting force prediction. It was shorn to drastically improve the conventional Z-map model. Experimental results applied to the pocket machining show the accuracy of the milling process simulation system.
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In view of reliability assessment, the failure mode analysis by performance tests for machine totals is researched in this study. First, the error analysis with circular movement test data is studied. The various errors and their origins are analyzed by error equations and related parts are investigated. Second, This paper deals with analysis of vibration testing fur machine tools spindle. The various frequency components are classified by FFT and order analysis. The simple measuring devices and error evaluation programs for tests are also developed.
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KS and ISO have proposed several evaluation methods of conventional machine tools. Even though the accuracy of the tools can be evaluated with these methods, there are still no proper evaluation methods of high speed machining. Because it is hard to evaluate characteristics of high speed machining such as decrease of cutting temperature, cutting force, and reduced machining time. Therefore, new evaluation method for high speed machine should be developed. In this paper, several shapes of model have been proposed to evaluate cutting accuracy of high speed machine.
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The recent machine tools are requested so high-quality processing and productivity increasing. Therefore it is so necessary to develop technology far high-speed and high-precision. This thesis touches on the development of high speed and intellectual line center. At first, the line center is necessary that strong structure, compact structure and light weight design far high-speed processing and transfer. So. It is necessary that examination of new materials and structures for light-weight and control devices for precision processing. So. It is going to make mention of the process of 1st model production for the above-mentioned base on test model production and evaluation.
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Direct Metal Manufacturing (DMM) is a new additive process that aims to take die making and metalworking in an entirely new direction. It is the blending of five common technologies : lasers, computer-aided design (CAD), computer-aided manufacturing (CAM), sensors and powder metallurgy. The resulting process creates parts by focusing an industrial laser beam onto a tool-steel work piece or platform to create a molten pool of metal. A small stream of powdered tool-steel metal is then injected into the melt pool to increase the size of the molten pool. By moving the laser beam back and forth, under CNC control, and tracing out a pattern determined by a computerized CAD design, the solid metal part is built line-by-line, one layer at a time. DMM produces improved material properties in less time and at a lower cast than is possible with traditional fabrication.
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This paper presents a multi-step structural design optimization method fur machine tool structures using a genetic algorithm with dynamic penalty. The first step is a sectional topology optimization, which is to determine the best sectional construction that minimize the structural weight and the compliance responses subjected to some constraints. The second step is a static design optimization, in which the weight and the static compliance response are minimized under some dimensional and safety constraints. The third step is a dynamic design optimization, where the weight static compliance, and dynamic compliance of the structure are minimized under the same constraints. The proposed design method was examined on the 10-bar truss problem of topology and sizing optimization. And the results showed that our solution is better than or just about the same as the best one of the previous researches. Furthermore, we applied this method to the topology and sizing optimization of a crossbeam slider for a high-speed machining center. The topology optimization result gives the best desirable cross-section shape whose weight was reduced by 38.8% than the original configuration. The subsequent static and dynamic design optimization reduced the weight, static and dynamic compliances by 5.7 %, 2.1% and 19.1% respectively from the topology-optimized model. The examples demonstrated the feasibility of the suggested design optimization method.
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In this study the occlusion of dural-sac, the outer membrane of spinal cord in the lumbar region, was quantitatively analyzed using one motion segment finite element model. Occlusion was quantified by calculating cross sectional area change of dural-sac far different compressive impact duration(loading rate) due to bony fragment at the posterior wall of the cortical shell in vertebral body. Dural-sac was occluded most highly in the range of 8∼12 msec impact duration by the bony fragment intruding into the spinal canal. t=400 msec case 4% cross sectional area change was calculated, which is the same as the cross sectional area change under 6 kN of static compressive loading.
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Hong, Jung-Hwa;Kim, Gyoo-Suk;Kim, Jong-Kwon;Mun, Mu-Seong;Ryu, Jei-Cheong;Lee, In-Huk;Lee, Jong-Keun 121
The design of an air seat cushion for preventing decubitus ulcer includes many design factors such as the even distribution of interface pressure, the minimization of mean and peak interface pressure values, and the reduction of interface shear force and pressure gradient. It involves the anatomic condition of plegia's buttock as well as air pressure in air cells of cushion. As a result, a suitable design of the cushion satisfying the all requirements is a difficult problem. Therefore, an appropriate and effective numerical tool to develop an air cushion orthosis is required. The purpose of the present study was to develop an air seat cushion orthosis having optimized air cells for evenly distributed interface pressure between the buttock and cushion surface. For the purpose, an advanced finite element (FE) model for the design of air cushion was developed. Since the interface pressure and shear force behavior, as well as stress analyses were primary concern, a FE air cell model was developed and verified by the experiments. Then, the interactions of two cells were checked. Also, the human part of the developed numerical model includes every material property and geometry related to buttock and femoral parts. For construction of dimension data of buttock and femoral parts, CT scans were performed. A commercial FE program was employed for the simulation representing the seating process on the orthosis. Then, sensitive analyses were performed with varying design parameters. A set of optimal design parameters was found satisfying the design criteria of the orthosis. The results were utilized to produce a prototype of the orthosis. Experimentally, the buttock interface pressure distributions from the optimized and previous ones were compared. The new seat orthosis showed a significantly improved interface pressure characteristics compared to the most popular one in the market. The new orthosis will be used for the development of the AI(artificial intelligent) controlled seat orthosis fur prevention of decubitus ulcer fur various plegic patients and the elderly. -
Ceil embolisation technique has been used to treat the intracranial aneurysms. Microcoils inserted into the aneurysm sac induce the blood flow stagnation inside the aneurysm sac, which causes the thrombus formation and embolisation of aneurysm. Since the intraaneurysmal flow patterns affect the embolisation process, we want to measure the flow field for different locations of coil inside the aneurysm sac . Lateral aneurysm models are manufactured using rapid prototyping, and the velocity fields are measured using particle image velocitimeter. Distally blocked models showed less flow into the aneurysm sac comparing to proximally blocked models. Also blocking the neck of aneurysm showed better inflow blocking comparing to blocking the dome of aneurysm. These results suggest that distal neck should be the preferred locations of coil for aneurysm embolisation.
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Several FE models were developed based on micro-CT images of a mandibular specimen. A new dental implant model was suggested from parameter study for the relation between shape and interfacial stress of dental implants. It is found that the proposed model is highly beneficial.
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In the present study, an electro-mechanical KAFO (knee-ankle-foot orthosis) which satisfies both the stability in stance and the knee flexion in swing was developed and evacuated in eight polio patients. A knee joint control algorithm suitable for polio patients who are lack of the stability in pre-swing was also developed and various control systems and circuits were also designed. In addition, knee flexion angles and knee moments were measured and analyzed for polio patients who used the developed KAFO with the three-dimensional motion analysis system. Energy consumption was also evaluated for the developed KAFO by measuring the movement of the COG (center of gravity) during gait. From the present study, the designed foot switch system successfully determined the gait cycle of polio patients and controlled knee joint of the KAFO, resulting in the passive knee flexion or foot clearance during swing phase. From the three-dimensional gait analysis for polio patients, it was found that the controlled-knee gait with the developed electro-mechanical KAFO showed the knee flexion of 40
$^{\circ}$ ∼45$^{\circ}$ at an appropriate time during swing. Vertical movements of COG in controlled-knee gait (gait with the developed electro-mechanical KAFO) were significantly smaller than those in looked knee gait(gait with the locked knee Joint). and correspondingly controlled-knee gait reduced approximately 40% less energy consumption during horizontal walking gait. More efficient gait patterns could be obtained when various rehabilitation training and therapeutic programs as well as the developed electro-mechanical KAFO were applied for polio patients. -
This paper presents a design and a control of a biped walking RGO-robot and dynamic walking simulation for this system. The biped walking RGO-robot is distinguished from other one by which has a very light-weight and a new AGO type with servo motors. The gait of a biped walking RGO-robot depends on the constrains of mechanical kinematics and initial posture. The stability of dynamic walking is investigated by ZMP(Zero Moment Point) of the biped walking RGO-robot. It is designed according to a human wear type and is able to accomodate itself to human environments. The joints of each leg are adopted with a good kinematic characteristics. To test of the analysis of joint kinematic properties, we did the strain stress analysis of dynamic PLS and the study of FEM with a dynamic PLS. It will be expect that the spinal cord injury patients are able to train effectively with a biped walking AGO-robot.
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In order to develop a self-propelled microendoscope, the frictional resistance of the capsule-type endoscope inside the intestine should be understood. In this work the frictional resistance behaviors of capsules with different designs were experimentally investigated using a pig intestine. It was found that cylindrical capsule design had the least frictional resistance. Also, the resistance increased as the speed of the capsule motion was decreased. It is expected that the results of this work will be used to design the optimum propulsion system for the microendoscope.
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It is reported that the mechanical properties of vertebral trabecular bone depend on the density and the mass of bones. Osteoporosis is a systemic skeletal disease caused by low bone mass and microstructure deterioration of trabecular bone. Silva and Gibson (1997) studied the treatment of age-related bone loss using drug therapy. Vertebroplasty is a minimally invasive surgery for the treatment of osteoporosis vertebrae. This procedure includes puncturing vertebrae and filling with Polymethylmethacrylate (PMMA). However, the relative effect of drug therapy and bone cement for osteoporosis treatment is not reported yet. In this study, several 2D models of human vertebral trabecular bone are analyzed by finite element method. The mechanical behaviors of the vertebral trabecular bone treated by the drug therapy and the bone cement are compared. This study shows that bone cement treatment is more effective strategy than drug therapy to prevent the degradation of bone strength.
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The use of the finite element method for biomechanical analysis is increasing rapidly in recent years. Since biomechanical models are usually in very complex shapes, it takes a lot of time and efforts to build reasonable finite element models. In this paper, a new tetrahedral meshing algorithm from the series of 2-D computed tomography(CT) images has been proposed. In this scheme, the planar sections of three-dimensional objects and the side surfaces between two planar sections are triangulated first, and then an advancing front algorithm is employed to construct tetrahedral elements by using basic operators. A sample finite element model for thoracic vertebra is presented.
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A cyto-indentation technique was used to obtain the biomechanical compressive compliance property of an chondrocyte cell attached to glass surface, which was tried to generate joint cartilage by tissue engineering. Piezo-transducer system and dual photo-diode system were used to conduct mechanical indentation through displacement-controlled testing and the measurement of corresponding cell reaction force. The Poisson's ratio of 0.37 was quoted from other report. The compressive compliance of chondrocyte, that was determined by elastic contact theory, was 1.38
${\pm}$ 0.057 kPa. This value is 30% higher than that of MG63 osteoblast-like cell. The cyto-indentation technique employed in this study is so precise that it can quantify the biomechanical property of single cell. -
We investigated whether controlled dynamization enhanced regenerative bone healing of the tibia in 12 adult mongrel dogs. An average of 2 cm (∼ 10% of bone length) lengthening was obtained. The left hindlimb was allowed dynamization of 1 mm, 2 mm, and 3 mm in magnitude when 1 cm (∼ 5%) of lengthening was achieved, whereas the right hindlimb was not dynamized and served as a control. Bone mineral density (BMD) of the regenerative bone was measured periodically until nine weeks after the end of distraction. After sacrifice, uniaxial compression testing was performed. Relative BMD ratio and
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In most shipyards, the measurement of 3-dimensional relative position of pipes should be connected in the block depends on the manual operation. It results a very tedious and inefficient procedure, thus the proper measurement system is needed to improve productivity and accuracy. This paper describes the development results of pipe measurement system including system concepts, measuring procedures, system calibration, and its accuracy and productivity. And also, the possibility and things to be improved for application in shipyard are discussed in this paper.
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A vision sensor measure range data using laser light source. This sensor generally use patterned laser which shaped single line. But this vision sensor cannot satisfy new trend which feeds foster and more precise processing. The sensor's sampling rate increases as reduced image processing time. However, the sampling rate can not over 30fps, because a camera has mechanical sampling limit. If we use multi line laser pattern, we will measure multi range data in one image. In the case of using same sampling rate camera, number of 2D range data profile in one second is directly proportional to laser line's number. For example, the vision sensor using 5 laser lines can sample 150 profiles per second in best condition.
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In this paper, we present the combined 2-D and 3-D algorithms for automatic solder paste inspection. For automatic inspection, optical system for the combined inspection and driving unit is made. One-pass run length algorithm that has fast and efficient memory space is applied to the input image fur extracting solder paste patterns. The path of probe movement is then calculated for an automatic inspection. For a fast 3-D inspection, the phase shift algorithm based on Moire interferometry is also used. In addition, algorithms used in this paper are coded by
$MMX^{TM}$ . A probe system is manufactured to simultaneously inspect 2-D and 3-D for 10mm$\times$ 10mm field of view, with resolutions of 10$\mu\textrm{m}$ for both x, y axis and 17$\mu\textrm{m}$ for z axis, and then, experiments on several PCBs are conducted. The processing times of 2-D and 3-D, excluding an image capturing, is 0.039 sec and 0.047 sec, respectively. The credible result with$\pm$ 1$\mu\textrm{m}$ uncertainty can be also achieved. -
Generally, it is very difficult to inspect geometric shape of large 2D objects after machining. To maintain the accuracy for inspection, a robot vision is used to divide overall shape into several enlarged images, and image processing technique is applied to acquire one minute geometric contour. The inspection is to compare the NC data with the measured contour data by the vision system, and the algorithm is to rotate to minimize the maximum deviation coinciding two geometric centers. This paper experimentally shows that the proposed inspection algorithm is very useful fur a large machined object.
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Lately, as going on increasing in the demand of high power density(power/weight), it is necessary for hydraulic axial piston pump/motor to operate more high pressure and speed. But in these condition, there are some trouble like as friction loss. To reduce this friction loss, hydrostatic bearing is used far axial piston pump/motor frequently. In general, it is difficult to measure accurate friction torque of spherical hydrostatic bearing in the use of the existing devices. So, we have developed the measurement device using the reaction torque sensor to obtain the pure friction torque, fitted in the casing. In this report, we intend to make an introduction about this measurement device for friction torque of the spherical wear part and clarify the effect of friction characteristics on supply pressure and rotational speed with three types of pocket size by using this measurement device.
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Confocal microscopy is very popular technology in bio-medical inspection due to its ability to reject background signals and to measure very thin slide of thick specimens, which is called optical sectioning. But intensity of detected signal in fluorescence type confocal microscopy is so small that only 0.2% of emitted fluorescence light can be detected in the best case. In this paper, we proposed the reflecting optical system to improve the detection intensity and designed the optical system by optimal design method. At the end of the paper, we analyzed the characteristics of the proposed reflecting optical system.
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In optical pick-up, optical components such as objective lens, collimator, mirror, laser diode and photo diode are mounted on the pick-up base. These components must keep their original position during operation for proper transmittance of information from laser diode to optical disk and back to photo diode. However, micro thermal deformation of pick-up base which is induced by thermal environment during operation can deteriorate the performance of optical pick-up. Therefore, it is important to measure and analyze the thermal deformation behavior of pick-up base under thermal environment. In the present study, a measurement system using holographic interferometry was designed to measure micro thermal deformation of pick up base. The measurement system was verified by using the deformation of cantilever with prescribed motion actuated by PZT with 1 nm resolution. Interferometric measurement was compared quantitatively with that induced by PZT actuator. Finally, micro thermal deformation of pick-up base under actual thermal environment was measured using the present holographic interferometry and the results were analysed.
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Demand for high precision measurement of large area is increasing in many industrial fields. White-light Scanning Interferometer(WSI) is a well-known method for 3D profile measurement. However WSI has some limitations in a measurement range because of the sensing mechanism. Therefore, in this paper we use a heterodyne laser interferometer to get over the limitations of a short measurement range in WSI, We suggest a new WSI system combined with heterodyne laser interferometer. This system is aimed at eliminating Abbe error with measuring the focus point directly. With the use of triggering functionality of WSI, we can use this system as a probe of a precision stage such as a probe of CMM. The suggested system gives a repeatability of 87 nm in the absolute distance measurement test under the laboratory environment.
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Moire topography method is a well-known non-contacting 3-D measurement method. Recently, the automatic 3-D measurement by moire topography has been required since the method was frequently applied to the engineering and medical fields. 3-D measurement using digital projection moire topography is very attractive because of its high measuring speed and high sensitivity. In this paper, using different N-bucket algorithm method of digital projection moire topography is tested to measuring object with the 2
$\pi$ -ambiguity problem. Experimental results prove that the proposed scheme is capable of finding measurement errors that decreased more by using the flour-three step algorithm method than the same step in the phase shifting of different pitchs. -
One of the ever-increasing demands on the performances of heterodyne interferometers is to improve the measurement resolution, of which current state-of-the-art reaches the region of sub-nanometers. We propose a new scheme of phase-measuring electronics that reduces the measurement resolution without further increase in clock speed. Our scheme adopts a super-heterodyne technique that lowers the original beat frequency to a level of 1 MHz by mixing it with electrically generated reference signal. The technique enables us to measure the phase of Doppler shift with a resolution of 1.58 nanometer at a sampling rate of 1 MHz. To avoid the undesirable decrease in the maximum measurable speed caused by the lowered beat frequency, a special from of frequency up-down counting technique is combined with the super-heterodyning. This alloys performing required phase unwrapping simply by using programmable digital gates without 2
$\pi$ ambiguities up to the maximum velocity of 2.35 m/s. -
This paper is concerned with the experiments on the active vibration control of a plate with piezoceramic sensors and actuators. The natural frequencies of the composite plate featured by a piezo-film sensor and piezo-ceramic actuator are calculated by using the modal analysis method. Modal coordinates are introduced to obtain the state equations of the structural system. Six natural frequencies were considered in the modelling, because robust control theory which has inherent robustness to structured uncertainty is adopted to suppress the transients vibrations of a glass fiber reinforced(GFR) composite beam. A robust controller satisfying the nominal performance and robust performance is designed using robust theory based on the structured singular value. Simulations were carried out with the designed controller and effectiveness of the robust control strategy was verified by results.
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The detection of tool wear is very important in an automated manufacturing system. This paper presents a tool condition monitoring system based on the wavelet transform analysis of the AC servo motor current in a milling process. The current measurement is relatively simple and does not affect machining operations. The discrete wavelet transform was used to decompose the current of a spindle AC servo motor in the time and frequency domain. The feature vectors were extracted from the decomposed signals and compared to clarity normal and wear conditions. The results show the feasibility of the wavelet transform analysis for the tool condition monitoring.
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A control strategy for a dynamic system under irregular disturbance by using stochastic controller is developed. In order to design stochastic controller, system dynamic model in real domain i transformed dynamic moment equation in stochastic domain by F-P-K approach. A study of real time control technique four stochastic controller is performed in this paper.
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There are two important variables in machining process control, which are feed and cutting speed. In this work, a two degree-of-freedom controller is designed and implemented to achieve on-line cutting force control based on the modelling of cutting process dynamics which are established through step response test. Two schemes are proposed and implemented. The first is feed control under the constant spindle speed and spindle speed control under the constant fled speed. The second is a simultaneous control of feed and spindle speed. Those are confirmed to work properly. Especially the latter shows a faster response and we'll be evaluated to pare away workpiece by simultaneous control of position and cutting farce sooner or later.
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When the fuzzy logic controller (FLC), which is designed based on the plant model, is applied to the real control system, satisfactory control performance may not be attained due to modeling errors from the plant model. In such cases, the control parameters of the controller must be adjusted to enhance control performance. Until now, the trial and error method has been used, consuming much time and effort. To resolve such problem, response surface methodology (RSM), a new method of adjusting the control parameters of the controller, is suggested. This method is more systematic than the previous trial and error method, and thus optimal solutions can be provided with less tuning. First, the initial values of the control parameters were determined through the plant model and the optimization algorithm. Then, designed experiments were performed in the region around the initial values, determining the optimal values of the control parameters which satisfy both the rise time and overshoot simultaneously.
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This paper describes the development of robot's finger 3-axis force sensor that detects the Fx, Fy, and Fz simultaneously fur stably grasping an unknown object. In order to safely grasp an unknown object using the robot's fingers, they should detect the force of gripping direction and the force of gravity direction, and perform the force control using the detected farces. The 3-axis force sensor that detects the Fx, Fy, and Fz simultaneously should be used for accurately detecting the weight of an unknown object of gravity direction. Thus, in this paper, robot's finger for stably grasping an unknown object is developed. And, the 3-axis farce sensor that detects the Fx, Fy, and Fz simultaneously fur constructing a robot's finger is newly modeled using several parallel-plate beams, and is fabricated. Also, it is calibrated, and evaluated.
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Vehicle Dynamics Control(VDC) has been a breakthrough and become a new terminology for the safety of a driver and improvement of vehicle handling. This paper examines the usefulness of a brake steer system (BSS), which uses differential brake forces for steering intervention in the context of VDC. In order to help the car to turn, a yaw moment can be achieved by altering the left/light and front/rear brake distribution. The steering function achieved through BSS can then be used to control lateral position in an unintended road departure system. A 8-DOF non-linear vehicle model including STI tire model will be validated using the equations of motion of the vehicle, and the non-linear vehicle dynamics. Since Fuzzy logic can consider the nonlinear effect of vehicle modeling, Fuzzy controller is designed to explore BSS feasibility, by modifying the brake distribution through the control of the yaw rate of the vehicle. The control strategies developed will be tested by simulation of a variety of situation; the possibility of VDC using BSS is verified in this paper.
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This paper presents a design and a control of a biped walking AGO-robot and dynamic walking simulation for this system. The biped walking RGO-robot is distinguished from other one by which has a very light-weight and a new RGO type with servo motors. The gait of a biped walking AGO-robot depends on the constrains of mechanical kinematics and initial posture. The stability of dynamic walking is investigated by ZMP(Zero Moment Point) of the biped walking AGO-robot. It is designed according to a human wear type and is able to accomodate itself to human environments. The joints of each leg are adopted with a good kinematic characteristics. To test of the analysis of joint kinematic properties, we did the strain stress analysis of dynamic PLS and the study of FEM with a dynamic PLS. It will be expect that the spinal cord injury patients are able to train effectively with a biped walking RGO-robot.
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The performance of the precision micro-positioning 4-dof stage is presented. The compact design utilizes the monolithic mechanism to achieve the translation in the Z axis and rotation in the
$\theta$ z,$\theta$ x and$\theta$ y axes with high stiffness and high damping. Hysteresis, nonlinearity, and drift of the piezoelectric effects are improved by incorporating the sensors in a feedback control. Experiments demonstrate that the micro-positioning stage is capable of 2nm resolution over the travel range of 25$\mu\textrm$ m in the Z axis, 0.0l7$\mu\textrm$ rad resolution over the 170$\mu\textrm$ rad in the$\theta$ z and 0.011$\mu\textrm$ rad resolution over the$\mu\textrm$ rad in the$\theta$ x and$\theta$ y axes. The cross-axis interferences among the axes are at a noise range. This stage is available for positioning error compensation of the XY stage with large stroke. -
In this study, a synchronous controller which can be applied to two-axes position synchronization has been developed. The synchronous control system based on coupling structure has been composed of speed and synchronous controller. The speed controller has been designed to fellow speed reference. And the synchronous controller has been designed in the view point of accurate synchronization and robust stability by
$H_{\infty}$ approach. The effectiveness of the designed synchronous controller has been demonstrated by experiment. -
This work is concerned with the estimation of output derivatives and their use for the design of robust controller for linear systems with systems uncertainties due to modeling errors and disturbance. It is assumed that a nominal transfer function model and quantitative bounds for system uncertainties are known The developed control schemes are shown to achieve regulation of the system output and ensures boundedness of the system states without imposing any structural conditions on system uncertainties and disturbances. Output derivative estimation is first conducted trough restructuring of the plant in a specific parameterization. They are utilized for constructing robust nonlinear high-gain feedback controller of a SMC(Sliding Mode Controller)Type. The performances of the developed controller are evaluated and shown to be effective and useful through simulation study.
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This paper provides the experimental verification of a non-destructive time domain approach to examine structural damage. Time histories of the vibration response of structure were used to identify the presence of damage. Damage in a structure cause changes in the physical coefficients of mass density, elastic modulus and damping coefficient. This paper examines the use of beam like structures with PVDF sensor and PZT actuator to perform identification of those physical parameters, and hence to detect the damage. Experimental results are presented from tests on cantilevered composite beams damaged at different location and with damage of different dimensions. It is demonstrated that the method can sense the presence of damage, and characterize the damage to a satisfactory precision.
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An optical method for surface roughness estimation based on statistical analysis of the light intensity of a scattered laser beam pattern. The method is very simple but has a disadvantage that no more information than the averaged roughness is estimated. In this study a new try was conducted to derive more advanced surface information from the details of the light intensity distribution. Some periodic ripples among the light intensity distribution being assumed to relate with scratch left on the machined surface, a corresponding surface profile is estimated from the ripples using FFT and IFFT algorithm. IFFT technique is used to extract some dominant signal components among the intensity distribution. Compared to the measured profiles by a stylus type surf-tester, the profiles obtained through the proposed method are probably acceptable in a sense of the profile shape. Calibration of the amplitude needs more works in the future.
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The accuracy and the dynamic bandwidth are the two most important indices that an inductive position sensor is evaluated with. Eddy currents and magnetic hysteresis affect both of these performance indices. As the modulation frequency of the sensor increases to improve the dynamic bandwidth, the effects of eddy currents and hysteresis also increases, which results in the loss of accuracy. In this paper, a magnetic circuit model of the differential inductive sensor is developed. This model includes the effects of hysteresis and eddy currents. Experimental results confirm the validity of the model. The model predicts that the eddy current effects are not significant below the modulation frequency of 50kHz, as long as the lamination thickness is adequate.
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The 3-D measurement using interference pattern projection is very attractive because of its high measuring speed and high sensitivity. When a sinusoidal amplitude grating was projected on an object, the surface-height distribution of the object is translated into a phase distribution of the deformed grating image. The patters was generated by a interferometer, and a PZT was used to shift the fringes on the target surface. The phase-acquisition algorithms are so sufficiently simple that high-resolution phase maps using a CCD camera can be generated in a short time. A working system requires a interferometer, a PZT, and a detector array interfaced to a microcomputer. Results of measurements on the diffused test objects are described.
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The performance of Terfenol-D, the commercially available magnetostrictive material, is highly dependent on the prestress, magnetic field intensity and temperature. This paper presents an experimental investigation of the temperature effect on the magnetostriction in Terfenol-D. The effects of both prestress and magnetic field on the magnetostriction are also presented. Experimental results show that both the prestress and magnetic field on the magnetostriction are significant. It is also observed that the displacement decreases slightly to around 40
$^{\circ}C$ , then increases to 80$^{\circ}C$ . It indicates that the displacement decreases due to the reduced magnetization, and increases due to the thermal expansion, as the temperature increases. It means that the reduced magnetization affects more in the displacement change up to 40$^{\circ}C$ , and the thermal expansion affects more in the displacement change beyond 40$^{\circ}C$ . -
In this paper, we present a new method for monitoring of ECU's self diagnostic signals of vehicle without wire. In order to measure the ECU's self diagnostic signals, the interfaced circuit is designed to communicate ECU and a designed display terminal according to the ISO, SAE regulation of communication protocol standard. A 80C196KC processor is used for communicating ECU's self diagnostic signals and the results are sent to PDA monitoring system. Software on PDA is developed to monitor the ECU's self diagnostic signals using the Embedded Visual C++ compiler in which RS232 port is programmed by half duplex method. The algorithms for measuring the ECU's self diagnostic signals are verified to monitor ECU's state. At the same time, the information to fix the vehicle's problem can be shown on the developed PDA software. The possibility for remote measurement of ECU self diagnostic signal using PDA is also verified through the developed systems and algorithms.
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In fiber optic sensor, the error of the measurement is influenced by the surface roughness of the target and surroundings, especially the outside light. To reduce or modify this error, the sensitivity of the fiber optic sensor and the noise change by the surface roughness of the target should be known. The purpose of this paper is to observe the sensitivity of the fiber optic sensor and the noise according to the surface roughness of the target.
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This paper presents a reverse engineering method for compound surfaces using vision system. A CNC machining center is used as a measuring station, which is equipped with slit beam generator and vision probe. Since obtained data using slit beam or laser scanner may have much data loss along the edge of compound surfaces, an algorithm is presented in this study to recover missing geometric data at such region. First, b-spline interpolation is applied to extract edge information of the surface, and as a next step, b-spline approximation is applied to recover the missing geometric data. Finally, b-spline skinning method is applied to regenerate the surface information. Appropriate simulation and experimental works are preformed to very the effectiveness of the proposed methods.
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This work presents the reconstruction of impact force produced by the collision between two elastic structures. The 2-DOF impactor was designed. The shape control of impact farce using correlations of the dynamic characteristics and impact force history between two elastic structures is accomplished. The effects of the relative motion between impactor and elastic structure on the impact force shape are studied. Reconstruction characteristics of impact force in cantilever beam are reviewed.
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In this study, the deformation of the free surface motion of a magnetic fluid for the change in electromagnetic force is discussed and carried out theoretically and experimentally on the basis of Rosensweig Ferrohydrodynamic Bernoulli Equation. While applied magnetic fields are induced by 4
$\times$ 4 electromagnet located under the magnetic fluid, the surface of the magnetic fluid is formed the balance of surface force, gravity, pressure difference, magnetic normal pressure and magnetic body farce. In case, magnetic fluid in characteristics of fluid adjusted to the opposite direction of the gravity direction. thus, the device of a magnetic fluid proposed the surface actuator. The device of surface deformation as well comparison between numerical simulation and experiments as will be presented. -
Powertrain simulation is important fur the analysis of a vehicle performance. Automotive powertrain has been considered as the unified system and should be remodeled, whenever a powertrain system is changed. In this study, a new method is proposed for the synthetic modeling for the automotive powertrain. Components are separated from the powertrain system and constructed the matrix through dynamic relationships. The dynamic equation of the total powertrain system can be driven from the combination of each component. In order to combine each component, the superposition method is modified for the powertrain composition.
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The mechanics, electronics and manufacturing technology have been developed rapidly. Nowadays vehicle stability becomes more and more important then ABS (Anti-lo7k Brake System), ASR (Anti-Slip Regulator), TCS, (Traction Control System), ESP (Electronic Stability Program), and VDC (Vehicle Dynamic Control) which actively control the vehicle stability actively has been improved. In this study, instead of automatic transmission, CVT (Continuously Variable Transmission) is used because of the continuously gear ratio changes. It can effectively transfer the torque from engine to tire more than other gear transmission. The modeling is simplified assuming that there are no resistance parameters.
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This paper presents an artificial intelligent model for a soccer robot. We classified soccer robot as artificial intelligent model into three elemental groups including instinct intuition and reason. Instinct is responsible for keeping the ball, walking or rushing toward the ball. This is very simple fundamental action without regard to associates and enemies. Intuition contributes to the faster/slower moving and simple basic turning to get near to the ball and to make a goal noticing associates and enemies. Reason is the most intelligent part, the law of reason is not simple relatively with instinct and intuition. We shall expect to design the best law of reason for a soccer robot some time. We also compared nerve system and muscles of human being model with controller and motors of a physical soccer robot model individually. We had designed several algorithms and made programs to investigate effects and control soccer robot.
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The sloshing phenomenon sometimes happens to be occurred in the liquid storage tank due to the unexpected and/or inevitable vibrating conditions and may result in severe effects on the structural stability. This study deals with the development of experimental techniques for the evaluation of sloshing behavior in the liquid storage tank and for the identification of natural frequencies and mode shapes by varying with various vibrating conditions. In addition, suitable method is suggested to minimize the sloshing effect on the liquid storage tank and its validity is experimentally investigate d.
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The LQG/LTR controller is a robust and stable control which is systematic method with a view of engineering. And the H
$^{\infty}$ scheme is adopted for the design of the controller to reduce the effects of the disturbances. In this paper, LQG/LTR and H$^{\infty}$ Controller Design of Lateral Control System for an Automobile is developed with 3 DOF (degree-of-freedom) model. The performance has been compared for the employed two types of controllers via computed simulations. The results show that the H$^{\infty}$ controller provides more robustness property for the disturbances and lower control input. -
We describe the looper controller design for a hot strip mill. The looper is to control the strip tension which influences on the width of the strip. It is very important to control the looper control of the hot strip mill, but difficult to control the looper, because there exists on mutual interaction among strip gauge, looper angle, and strip tension. In this paper, we present the modeling for the hot strip finishing mill to control the tension of the strip and suggest a cross control method. The cross control is a very simple method that allows non-interacting control.
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Engine noise is one of the major causes of the interior noise, and so has been studied in various ways in recent days. Recently Intake noise has been extensively studied to reduce the engine noise. Conventional method to reduce the noise is adding several resonators to the induction system. However this causes a reduction of engine output power and an increase of fuel consumption. In this study, the prototype of Active Intake Noise Control System is developed by using the Filtered-x LMS algorithm to reduce the Intake noise during acceleration. Intake noise is more excessively increased when the engine is rapidly accelerated. So, Normalized LMS algorithm is applied to improve the control performance under the rapid acceleration.
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This study Presents improvement of Precision in the non-contacted laser application measuring techniques. The phase map of deformation obtained by phase shifting method in Electronic Speckle Pattern Interferometry displays the wrapped image by the arctangent function, which is a characteristic of 4-step phase shifting method. To obtain deformation distribution from the results, the wrapped phase map is processed by an unwrapping method. But a previous method cannot apply discontinuous object as like plate with a circular hole to obtain precious deformation distribution To solve this problem, new algorithm is developed and the result is compared with previous method.
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The paper presents noise and vibration characteristics of three kinds of pipe materials (PVC pipe, cast-iron pipe and newly developed pp pipe). In order to measure structure bone noise, impact force using small balls was applied to earth pipe. It was confirmed that structure bone noise can be reduced by more large damping materials. Also, transmission loss of pipes depending on the frequency ranges was investigated by using sound source through speakers.
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A human-friendly interactive system, based on the harmonious symbiotic coexistence of humans and robots, is explored. Based on this interactive technology paradigm, a robotic cane is designed to help blind or visually impaired travelers to navigate safely and quickly among obstacles and other hazards faced by blind pedestrians. We outline a set of the hardware solutions and working methodologies that can be used for successfully implementing and extending the interactive technology to complex environments, robots, and humans. The issues discussed include the interaction of human and robot, design issue of robotic cane, hardware requirements for efficient human-robot interaction.
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After the industrial revolution in 20 century, the world are preparing for new revolution that is society with knowledge for a basis such as IT(Information Technology), NT(Nano Technology) and BT(Bio Technology). Recently, NT is applied to various fields that are composed of science, industry, media and semiconductor-micro technology. It has need of IT that is ultra-precision positioning technology with strokes of many hundreds mm and maintenance of nm precision in fields of ultra micro process, ultra precision measurement, photo communication part and photo magnetic memory. Performance test of servo control system that is used ultra-precision positioning system with single plane X-Y stage is performed by simulation with Matlab. Analyzed for previous control algorithm and adapted for modern control theory, dual servo algorithm is developed by minimum order observer, and stability and priority on controller are secured. Through the simulation and experiments on ultra precision positioning, stability and priority on ultra-precision positioning system with single plane X-Y stage and control algorithm are secured by using Matlab with Simulink and ControlDesk made in dSPACE
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a basis such as IT(Information Technology), NT(Nano Technology) and BT(Bio Technology). Recently, NT is applied to various fields that are composed of science, industry, media and semiconductor-micro technology. It has need of IT that is ultra-precision positioning technology with strokes of many hundreds mm and maintenance of nm precision in fields of ultra micro process, ultra precision measurement, photo communication part and photo magnetic memory. This thesis represents optimal design on ultra-precision positioning with single plane X-Y stage and development of artificial control system for adequacy of industrial demand. Also, dynamic simulation on global stage is performed by using ADAMS (Automated Dynamic Analysis of Mechanical System) for the purpose of grasping dynamic characteristic on user designed X-Y global stage. The error between displacements from micro stage and from FEM(Finite Element Method) is 3.53% by verifications of stability on micro stage and control performance. As maximum Von-mises stress on hinge of micro stage is 5.981kg/mm
$^2$ that is 1.5% of yield stress, stability on hinge is secured. Preparing previous results, optimal design of micro stage can be possible, and reliance of results with FEM can be secured. -
In vehicle accidents, the rolling, pitching, and yawing which are produced by collisions affect the motions of vehicle. Therefore, vehicle behavior under impact situation should be analyzed in three-dimension. In this study, three-dimensional vehicle dynamic equations based on impulse-momentum conservation principles under vehicle impact are introduced for simulation. This analysis has been performed by the real vehicle impact data from JARI and RICSAC. This study suggested each system modeling such as suspension, steering, brake and tire as well as the appropriate vehicle behavior simulation model with respect to pre and post impact.
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Nowadays, the improvement and development of Multi-media, information and communication technology are rapidly processed. And many products, for example, digital camera, digital camcorder, and PDA, are used for them. They need large data storage capacity and small size, light storage system. Due to that, many studies and researches in data storage system have been carried out. Especially, micro drive system was presented by IBM.(1) However, its system is expensive and uneasy to be portable. In ODD technologies, 1 inch drive system is not yet or in processing status.(2) If to be possible and to be come up, it is cheap than HDD system and easy to transfer information. In this paper, a miniaturized actuator(about linch) is designed and tested for ODD system. Specially, it is adapted for NFR(Near-field Recoding) system using SIL(Solid Immersion Lens). It is the dual-servo actuator which consists of a coarse actuator and fine actuator. Its actuating force generation method is VCM(Voice Ceil Motor). The fine actuator has 4-wire suspensions and bobbin wrapped by coil and includes focusing motion as well as tracking motion. The coarse actuator has an actuating coil and V-grooved guide mechanism. Also, the characteristics of the designed actuator is estimated by sine-swept mode and LDV(Laser Doppler Vibro-meter).
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This research is presented for optimizing the coefficients of spring and damper by impulse which is applied to AGV when the two containers are loaded on AGV. The suspension is estimated to the condition that two containers, initial velocity of container, initial height of container and maximum of suspension stroke. The coefficients of spring and damper are calculated numerically through Newmark method uses finite difference expansions. The procedure of calculation is applied by one DOFs of mass-spring-damper system. The coefficients of spring and damper have large value as increase of height or decrease of stroke. The result of calculation is shown in graph and the investigation is used AGV design.
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In this research, a vision system for detecting tool breakage which is hardly detected by such indirect in-process measurement method as acoustic emission, cutting torque and motor current was developed and embedded into a PC-NC system. The vision system consists of CMOS image sensors, a slit beam laser generator and an image grabber board. Slit beam laser was emitted on the tool surface to separate the tool geometry well from the various obstacles surrounding the tool. An image of tool is captured through two steps of signal processing, that is, median filtering and thresholding and then the tool is estimated normal or broken by use of change of the centroid of the captured image. An air curtain made by the jetting high-pressure air in front of the lens was devised to prevent the vision system from being contaminated by scattered coolant, cutting chips in cutting process. To embed the vision system to a Siemens PC-NC controller 840D NC, an HMI(Human Machine Interface) program was developed under the Windows 95 operating system of MMC103. The developed HMI is placed in a sub window of the main window of 840D and this program can be activated or deactivated either by a soft key on the operating panel or M codes in the NC part program. As the tool breakage is detected, the HMI program emit a command for automatic tool change or send alarm to the NC kernel. Evaluation test in a high speed tapping center showed the developed system was successful in detection of the small-radius tool breakage.
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In the end milling operation the deflection of the cutter is an important factor affecting the accuracy of machining with implications on the selection of cutting parameters and economics of the operation. The deflection of the end mill was studied both experimentally with strain gauge, tool dynamometer, laser measuring apparatus and on a finite element model of the cutting using ANSYS software. The deflection of machining tool with various helix angles was studied with FEM simulation and experiment. ANSYS analysis performed on the finite element model of the end mill provides deflection results which agree within 15.0% with the experimental ones.
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A 250mm stroke aerostatic stage, which detects position with laser scale and is driven by linear motor, is made and analyzed positioning error in 20
$\pm$ 0.5$^{\circ}C$ controlled atmosphere, aiming at investigating positioning characteristic of ultra-precision stage. We prove this aerostatic stage has a 10nm micro step resolution by experiment. By means of analyzing laser interferometer system, the scale of measuring error is about 0.2-0.4$\mu\textrm{m}$ according to refractive index error from missing the temperature change. To improve laser interferometer system, compensate refractive index error using measuring data from thermocouple. And, confirm 0.10$\mu\textrm{m}$ repeatability and 0.13$\mu\textrm{m}$ positioning accuracy using the compensating refractive index. Also, we confirm 0.07${\mu}{\textrm}{m}$ repeatability of the stage using capacitive displacement sensor. -
The tapping is machining process that makes a female screw on the parts to be assembly together. It is used for the high-speed tapping machine with synchronizing function for the high productivity. This paper describes the development of the ultra high-speed tapping machine with 10,000rpm. The key factors in the tapping speed are the acceleration/deceleration velocity and the synchronizing errors between the spindle motor and feeding motor. To minimizing acceleration/deceleration time, the low inertia spindle with synchronous built-in servo motor is developed. To minimizing synchronizing errors, the tapping cycle algorithm under open architecture CNC environment is optimized. The developed tapping machine has 0.13sec/10,000rpm in acceleration/deceleration time and the synchronizing error below 4.0%. It has 0.55sec for cycle time of one female screw, M3 tap, 2 times depth of tap diameter.
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In machine tools, the stiffness of feed drive system is very important for high speed and accurate operation. The ball screw driven feed system has small friction, so the longitudinal and twist stiffness are connected directly and affected by each other. As the longitudinal and twist stiffness are participated in total stiffness of feeding system by about ratio of 4:1, the combined stiffness is necessary to compute when stiffness of feed system is estimated. In this paper, calculation of this combined stiffness is derived and applied for an actual ballscrew fled drive system. The static stiffness and 1 st natural frequency of the feed system is measured, and it is proved the difference between estimation and experiment result is less than 6%.
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This paper introduces that the lathe optimize for main and sub spindle's synchronous in Opening-CNC. In view of optimal design, the mathematical modelling and the frequency domain analysis of spindle's system are performed. For the compensation of synchronous error in compounded manufacture process, the optimization method of motor drive's control parameter and the related parameter is proposed. By the experiment in prototype machines using the server/client program, the validity of the proposed method is verified.
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This study is to examine the safety by analizing the hardness of bed and the characteristic of vibration to improve basic efficiency of machine-tool of drill-cell which is a high line center. The mistake of existing design was shown through the analysis of 3-D and structure. The purpose of this paper is to draw up a plan to improve performance and to propose the design method through finding out the optimum by analyzing dynamic property of structure in a quantity-way by CAE for a quantity-analogy of dynamic property in design steps.
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Improvement of measuring accuracy is an essential part of quality control manufacturing process. The OMM is less than the CMM in measure accuracy but the OMM system is more efficient, easier to use than other measurement system. About 40~70% of the machine tool errors are induced by the thermal errors. Therefore, a key requirement for improving the measuring accuracy is to reduce the geometric and thermal errors. Thermal errors are measured by a ball bar system and predicted by the thermal error modeling. Furthermore, using the pre-defined thermal error map approach compensates the geometric accuracy of the OMM. Appropriate experiments are performed using ball-bar system, temperature measuring devices and touch-type probe. Compensated results are compared with those obtained using CMM to verify the proposed methods.
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A high speed feeding type laser cutting UC is developed for the precise cutting of sheet metal. The M/C is a flying optics type one with specified functions of movability and strength in order to increase workability. The gantry frame should be moved with a certain velocity within a relatively short time for the proper cutting of object materials. The gantry is actuated by rack and pinion. In this paper, modal and structural analysis for a laser culling M/C, is carried out in development of the machine The machine is modeled by placing proper shell and solid finite elements and fictitious mass properties to represent the real one.
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This paper presents a measurement method to compromise surface error in surface machining processes. In order to compromise the surface error in machining process, on-machine measurement is essential. There are two kinds of on-machine measurement methods available to measure the surface errors in flat workpieces: i.e., surface scanning method and sensor scanning method. However, motion errors are inevitably engaged in both methods. This paper proposes a new idea to measure the surface error for error compensation. The measurement system consists of a laser, a CCD camera and processing system, a carrier system with a stylus, and some optical units. The experimental results show that the proposed method is useful to compensate the surface errors of machined workpieces.
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In this study, we suggest a environmentally-conscious and dry cleaning process mechanism for the recycling of end-of-life CRT, and also develope a protype cleaning system to verify the faulty of the designed mechanism. This system accommodates the specifications of 14 ~ 32" end-of-life CRT. In experimental result, it is expected that the developed system improve the productivity up to 10% and decrease the loss rate of cleaning glass 3~4 times rather than the existing methods.hods.
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In this paper a clutch using ER Fluids is called ER Clutch. An experiment of ER Clutch using PID control is performed. In this way the validity of ER Clutch was verified.
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Pneumatic control systems have the potential to provide high output power to weight and size ratios at a relatively low cost. However, they are mainly employed in open-loop control applications where positioning repeatability is not of great importance. This paper presents precision positioning control of pneumatic servo cylinder with on-off valve, Pneumatic low-friction cylinder with servo valve and DC servo motor under parameter variations. Basically positioning control uses PID controller, where needs a linearized model. A neural network is added to a PID controller to compensator nonlinearity of the system and an influence of friction force is consider as disturbance. The performances of the proposed algorithms were compared by experiments with them of PID controller. From those experiments is was shown that the proposed algorithms are more efficient about settling time, steady 7tate error and overshoot than PID control algorithm.
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Yard cranes are very useful equipments for handling of heavy containers. But rope-driven yard cranes must have a little of sway and skew motion because ropes are passive mechanical device. So many researches have been concentrated on anti-sway algorithm controlling trolley speed. But control algorithm of trolley speed is not practical in windy weather. In this paper, we are going to propose a new structure for anti-sway. This structure uses aux. ropes. The control strategy with auxiliary rope is very useful to sway control of yard crane because rope length is shorter than quay-side container cranes. In this paper, we derive equations of motion of trolley system which have anti-sway controller to use auxiliary rope. And main schemes are introduced and explained briefly.
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DSPA311(Analog Subscriber Line Board Assembly) is offer the interface of between analog subscriber and TDX-100 exchange system. DSPA311 is belong ASI block, accommodate dial and MFC telephone subscriber of 32 channel, and voice signal designed for interface with TSW, and 2 and 4 wire loop impedance is 600 (ohm). DSPA311 is consist 4 channel daughter beard QSLM-10(Quad Subscriber Line Module-10) and perform BORSCHT and be possible A/U-law select and GAIN value control by data control of DSPA171(Device controller I). In this Paper, We described the function test program for the DSPA311 Board by using the HP3070CT combinational test system, and an unmanned automatic test system.
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Today, it is concentrating on automation and these appearance of industrial robot has been dealing flexibly with this field. If it is drilling through these industrial robot, it will be a high efficiency of the productivity. Therefore, electric drill is setting on articulated robot with six degree of freedom and the 5 face is drilling as the type of articulated robot by a machine object setting. This study was carried out to get the possibility about drilling as analyzing with experimental frequency, original vibration of robot and appearance of vibration when it is practical drilling.
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The casing oscillator used for the foundation work in the construction place. Construction machinery which makes the casing rotate and roll can insert the casing in the ground. It is very important to make the casing perpendicular to sea level regardless of slope of ground. So in this paper, we present the new type casing oscillator that need not to level the ground for the work of casing insertion. The inverse kinematics analysis for the real-time control of casing oscillator is presented.
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Quadruped walking robot requires dynamic control to keep its stability in high speed walking. To keep its walking stability by control of only legs' Joint angle lowers energy efficiency. It is known that an animal or a human use the moving of the mass center of one's upper body to keep the stability. We have developed a quadruped walking robot with weight balancing oscillator that have high energy efficiency. In this study, walking tests are performed for the robot to verify the validity of the weight balancing oscillator.
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This paper is concerned with smooth walking robot using genetic algorithm. The new walking algorithm is proposed and we simulated and experimented the algorithm. We suggested the leg trajectory algorithm and balancing trajectory algorithm by applying genetic algorithm. First the leg trajectory algorithm generated the smooth trajectory. Also the balancing trajectory generated the optimal trajectory. We compared results with the previous walking algorithm. It showed that the new proposed algorithm generated the better walking trajectory.
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This paper presents a new motion control for singularity avoidance in 6 DOF articulated robot manipulators, based on a speed limiting algorithm for joint positions and velocities. For a given task, the robot is controlled so that the joints move with acceptable velocities and positions within the reachable range of each joint by considering the velocity limit. The proposed method was verified using MATLAB-based simulations.
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This study presents development of a machine for shrink wrapping of cans or drink bottles with thermoplastic films. The accurate position-control, the safety factor of chains, the reduction-ratio of the chain and gear, the appropriate heating temperature for banding vinyl are discussed for the optimum shrink wrapping M/C design.
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This paper deals with the problem of synthesis of stable and optimal grasps with unknown objects by 3-finger hand. Previous robot grasp research has analyzed mainly with either unknown objects 2D by vision sensor or unknown objects, cylindrical or hexahedral objects, 3D. Extending the previous work, in this paper we propose an algorithm to analyze grasp of unknown objects 3D by vision sensor. This is archived by two steps. The first step is to make a 3D geometrical model of unknown objects by stereo matching which is a kind of 3D computer vision technique. The second step is to find the optimal grasping points. In this step, we choose the 3-finger hand because it has the characteristic of multi-finger hand and is easy to modeling. To find the optimal grasping points, genetic algorithm is used and objective function minimizing admissible farce of finger tip applied to the object is formulated. The algorithm is verified by computer simulation by which an optimal grasping points of known objects with different angles are checked.
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Burr is a projected part of finished workpiece. It is unavoidable and undesirable by-product of most metal cutting or shearing process. Also, it must be removed to improve the fit of machined parts, safety of workers, and the effectiveness of finishing operation. But deburring process is one of manufacturing processes that have net been successfully automated, so deburring automation is strongly needed. This paper focused on developing a basic algorithm to find edge of workpiece and match two different image data for deburring automation which includes automatic recognition of parts, generation of deburring tool paths and edge/corner finding ability by analyzing the DXF drawing file which contains information of part geometry. As an algorithm for corner finding, SUSAN method was chosen. It makes good performance in finding edge and corner in suitable time. And this paper suggested a simple algorithm to find matching point between CCD image and drawing file.
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Most networks for automation are tuned to an expected traffic at their design stage. During their actual operations, however, the networks experience considerable changes in traffic from time to time. These traffic changes caused by common events like machine failure and production schedule change may adversely affect the network performance and, in turn, the performance of the connected devices. This paper presents communication delay model for Profibus token passing protocol, and introduces TTR selection methods to maintain a uniform level of network performance at all stations under changing network traffic.
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Safety is very important to operate nuclear power plant. To guarantee the safety, nuclear power plant should be run without trouble. This paper presents the application of a failure diagnosis approach based on discrete event system theory to the pressurizer pressure control system for Pressurized Water Reactor. Also, this paper shows a scheme of failure diagnosis by distributed diagnoser.
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Recently, the demand for the optical cable is rapidly glowing because the number of internet user increases and high speed internet data transmission is required. To meet this demand, it is necessary to have a sufficient manufacturing capability for mass and high-quality production. But the present optical cable winding system has some serious problems such that the optical cable of radius (6 mm -40 mm) is often piled up and collapsed usually at the edge of the bobbin in the process of the cable winding. It is often necessary to have an additional operator in order to adjust the cable, which causes the productivity decrease. In order to improve a performance of cable winding system which deals with relatively thick cable( radius : 6 mm -40 mm ), we developed a new guiding system for a high-speed self-align cable winding. First of all, the winding mechanism was analyzed. Synchronization logics for the motions of winding, traversing, and the guiding were created and implemented by using the PLC and guiding system controller in a prototype cable winding system manufactured in the CILS( Computer Integrated Large scale System ) lab. An experimental verification was carried out to validate the logic. Results showed that the winding system with the developed guiding system outperformed in reducing pile-up and collapse in the high-speed winding(up to 300 mm/s) compared with the system without the guiding system.
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Toggle bolt is mechanical device constructed with toggle spring wing toggle and machine screw, and defined as an expansive bolt consisting of a nut with flanged wings which are pressed to the bolt and, after insertion in a thin or hollow wall, spread open through spring pressure, thus anchoring it to the wall. And spring wing toggle is aligned with two wings, spring and nut manually in domestic manufacturing line. Then it is regarded as major problem for exports increasement to make cost down in the view of total manufacturing process. Accordingly in this study, high speed type automatic alignment mechanism is guided for spring wing bolt, and exclusive alignment dies and some special additional units are designed and manufactured.
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AGV is very useful equipment to transfer containers in automated container terminal. AGV must have Obstacle Detection System (ODS) fur port automation. ODS needs the function to classify some specified object from background in acquired data. And it must be able to track classified moving objects. Finally, ODS could determine its next action for safe deriving whether it should do emergency stop or speed down, or it should change its deriving lane. For these functions, ODS can have many different kinds of algorithm. In this paper, we present one of them under developing.
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The real-time industrial network often referred to as fieldbus, is an important element for building automated manufacturing systems. Thus, in order to satisfy the real-time requirements of field devices such as sensors, actuators, and controllers. numerous standard organizations and vendors have developed various fieldbus protocols such as Profibus, WorldFIP and Foundation Fieldbus. However, the application of fieldbus has been limited due to the high cost of hardware and the difficulty in interfacing with multi-vendor products. In order to solve these problems, the computer network technology, especially Ethernet (IEEE 802.3), is being adopted lo the industrial environment. The crucial technical obstacle for Ethernet is that its non-deterministic behavior makes it inadequate for industrial applications where real-time data such as control command and alarm signal hale to be delivered within a certain time limit. Recently, the development of switched Ethernet shows a very promising prospect for industrial application due to the elimination of uncertainties in the network operation resulting in much improved performance. This paper focuses on the application of the switched Ethernet for industrial comm unications.
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This paper describes a design methodology of a tri-axial silicon-based farce sensor with square membrane by using micromachining technology (MEMS). The sensor has a maximum farce range of 5 N and a minimum force range of 0.1N in the three-axis directions. A simple beam theory was adopted to design the shape of the micro-force sensor. Also the optimal positions of piezoresistors were determined by the strain distribution obtained from the commercial finite element analysis program, ANSYS. The Wheatstone bridge circuits were designed to consider the sensitivity of the force sensor and its temperature compensation. Finally the process for microfabrication was designed using micromachining technology.
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Mask manufacturing is a high COC and COO process in developing of semiconductor devices, because of the mass production tool with high resolution. Direct writing has been thought to be one of the patterning method to cope with development or small-lot production of the device. This study focused on the development of the direct, mastless patterning process using stereolithography tool for the easy and convenient application to micro and miso scale products. Experiments are utilized by three dimensional CAD/CAM as a mask and photo-curable resin as a photo-resist in a conventional stereo-lithography apparatus. Results show that the resolution of the pattern was achieved about 300 micron because of complexity of SLA apparatus settings, inspite of 100 micro of inherent resolution. This paper concludes that photo resist and laser spot diameter should be adjusted to get finer patterns and the proposed method is significantly feasible to mastless and low cost patterning with micro and miso scale.
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With increasing the needs for micro and precision parts, micro machining technology using micro tools has been studied to fabricate a small part with high density such as electronics, optics, communications, and medicine industry more than before. Though these micro tools have developed rapidly, it is difficult to apply them to micro fabrication technologies, because of the inherent manufacturing. In this study, micro tools(wc) to produce micro structures and parts were manufactured by cylindrical grinding machine employing ELID(Electrolytic In-process Dressing) technique and good dimensional accuracy was achieved. Furthermore we researched the characteristics of machining on the micro drilling using micro drills and manufactured micro tools. Finally it is confirmed that manufactured micro tools can be used for micro machining.
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The lubrication characteristics of SAM(self-assembled monolayer) have been investigated according to the change of surface group and surface temperature treatment with FDTS(1H, 1H, 2H, 2H-Perflurodecyltrichlorosilane) SAM and OTS(octadecyltrichlorosilane) SAM in micro scale. From the experimental results, it was found that OTS SAM gets destroyed at
$200^{\circ}C$ and stiction and fiction coefficient increased, but FDTS SAM was stable up to$400^{\circ}C$ . Also, it was found that the friction coefficient of normal OTS SAM is lower than that of FDTS SAM, but stiction is vice versa. This work shows the importance of surface group of self-assembled monolayer to control the lubrication characteristics and thermal stability. -
In this paper, a new type of inchworm motion actuator is introduced. This is consisted of two piezoelectric ceramics; one is for moving the slider, and the other is for clamping the slider in the guide way of the body. The linearity and positional accuracy of the system is good enough for the high precision motion. Since the system is more compact than the conventional system using three piezoelectric ceramics, it is applicable fur the micro-machine or MEMS. However, the effort for reducing the vibration, velocity discrepancy in the motion direction, and compensating the hysteresis behavior is additionally needed.
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The o]d technique of sandblasting which has been used for paint or scale removing, deburring, and glass decorating has recently been developed into a powder blasting technique for brittle materials, capable of producing micro structures larger than
$100\mu\textrm{m}$ . In this study, we investigated the effect of the size of abrasive and the stand-off distance on the machinability of SUS 304. The varying parameters were the impact angle$90^{\circ}$ , scanning times of nozzle 10 and the different nozzle height between 70mm and 140mm. The diameter of dot pattern were 0.2mm. The powder were alumina sharp particles, WA #600, #800 and #2000. The blasting pressure of powder at 0.3 Mpa. -
This paper is on the development of an educational 6-axis articulated manipulator using 4-bar linkage system. Especially, the 2
$^{nd}$ and the 3$^{rd}$ axes need large torque to control the movement of an end-effect. However, small motors (RC-servo, DC-gear, stepping meters) are used for the 4-bar linkage. In addition the manipulator can be operated by a switch and also motion can be realized automatically, based on C-language coded users programs.. -
This paper presents a real-time collaborative system for distributed design. The aim of the system is to provide designers with a virtual workspace where they can collaborate and exchange their design knowledge in distributed environment. The system consists of two subsequent modules. One is for the visualization of design data including CAD data, documents, images, and the other is real-time collaboration module. They make it possible for distributed designers to review the design data collaboratively and to share their design knowledge. The system was implemented by using the Internet protocols such as TCP/IP and IP multicast on the peer-to-peer based network. An example is presented and discussed to validate the proposed system.
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The reverse engineering (RE) technology can quickly generate 3D point cloud data of an object by capturing the surface of a model using a 3D scanner. In the rapid prototyping (RP) technology, prototypes are rapidly produced from 3D CAD models in a layer-by-layer additive basis. In this paper, a physical human head shape is duplicated using a new RP process, the Transfer-type Variable Lamination Manufacturing process using expandable polystyrene foam sheet (VLM-ST), after the point cloud data of a human head shape measured from 3D SNX scanner are converted to STL file. From the duplicated human head shape, it has been shown that the VLM-ST process in connection with the 3D scanner is a fast and efficient process in that shapes with free surface, such as the human head shape, can be duplicated with ease. Considering the measurement time and the shape duplication time, the use of 3D SNX scanner and the VLM-ST process is expected to reduce the lead-time fur the development of new products in comparison with the other existing RE-RP connected manufacturing systems.
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The tight integration of the part design and process planning is very effective to high quality product development and cost effective manufacturing. Moreover, the integration in the early design stage, that is, the integration of the conceptual design and the conceptual process planning may take a big impact with the forecasting the alternative of the design and manufacturing. In this paper, the real field parts are studied about the relations among the Feature, Function, and Manufacturing Process taking the style of reverse engineering method, to found the base of the systematic computer system for the integrated product design and manufacturing process planning.
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This paper proposes an error compensation method that improves accuracy with geometry information of injection molding parts. Geometric information can give an improved accuracy in reverse engineering. Measuring data can not lead to get accurate geometric model, including errors of physical parts and measuring machines. Measuring data include errors which can be classified into two types. One is molding error in product, the other is measuring error. Measuring error includes optical error of laser scanner, deformation by probe forces of CMM and machine error. It is important to compensate these in reverse engineering. Least square method(LSM) provides the cloud data with a geometry compensation, improving accuracy of geometry. Also, the functional shape of a part and design concept can be reconstructed by error compensation using geometry information.
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The paper discusses new approach for machining operation simulation using enhanced Z map algorithm. To extract the required geometric information from NC code, suggested algorithm uses supersampling method to enhance the efficiency of a simulation process. By executing redundant Boolean operations in a grid cell and averaging down calculated data, presented algorithm can accurately represent material removal volume though tool swept volume is negligibly small. Supersampling method is the most common form of antialiasing and usually used with polygon mesh rendering in computer graphics. The key advantage of enhanced Z map model is that the data structure is same with conventional Z map model, though it can acquire higher accuracy and reliability with same or lower computation time. By simulating machining operation efficiently, this system can be used to improve the reliability and efficiency of NC machining process as well as the quality of the final product.
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This paper addresses the methodologies for manufacturing systems design. While a number of design methods are used in product or part design, methods for manufacturing systems design are rarely known. Two approaches, simulation and axiomatic design theory, are discussed with respective case examples. The usual purpose of using simulation is to identify the bottleneck of a manufacturing system or to evaluate its performance with the aim of configuring the manufacturing system. The simulation typically proceeds in steps such as problem definition, model building, numerical experimentation, analysis and evaluation. The axiomatic design method transforms customer attributes into functional requirements and repeats mapping processes between functional domain and physical one until a satisfactory level of refinement of the functional requirements and the design parameters is reached. Possible design alternatives are evaluated by applying the independence axiom as well as the information axiom.
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With Rapid Prototyping system, the efficient packing in a fixed work volume reduces build time when multiple parts are built in a process. In this paper, an efficient and rapid packing algorithm is developed for SLS system that has cylindrical workspace. A genetic algorithm is implemented to place as many part as possible in a vat. For fast computation, a collision detection algorithm "k-DOPs Tree" is implemented.
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Welding variables and conditions in gas metal arc welding (GMAW) effect on the weld quality and productivity, extensive research efforts have been made to analyze the welding variables and conditions. In this study dynamic behavior of GMAW system is investigated using the characteristic equations of the power supply, wire and welding arc. Characteristic equation of wire is modified to include the effect of droplets attached at the electrode tip. The dynamic characteristics of arc length, current, voltage with respect to the step, ramp inputs of CTWD was simulated, seam tracking procedure using arc sensor was simulated with variable V-Groove geometries and weaving frequencies. From results of simulation, some predictions about dynamic characteristics of GMAW and welding process are available. The proposed simulator and results appear to be utilized to determine the proper welding conditions, to be improved by considering power supply dynamic characteristics.
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As consumer's desire becomes various, agility of mold manufacturing is most important factor for competence of manufacturer. In common works to use commercial CAM system to generate tool path, some decision making process is required to produce optimal result of CAM systems, The paper proposes a methodology for computer-assisted tool selection procedures for various cutting type, such as rough, semi-rough and finish cuts. The system provides assist-tool-items for machining of design model part of injection meld die by analyzing sliced CAD model of die cavity and core. Also, the generating NC-code of the tool size is used to calculate machining time. The system is developed with commercial CAM using API. This module will be used for optimization of tool selection and planning process.
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With the paradigm shifting from the principal of manufacturing efficiency to business globalization and rapid adaptation to its environments, more and more enterprises are being virtually organized as manufacturing network of different units in web. The formation of these enterprise called as Virtual Enterprise(VE) is becoming a growing trend as enterprises concentrating on core competence and economic benefit. This paper proposes the cooperation methodology for VEs which can be organized by the selection of manufacturing partners, and managed by the information flow infrastructure.
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In acquiring the surface information of a part, two types of measuring machines have been used: contact type and non-contact type. Since each measuring device has the pres and cons, an integrated measuring system is proposed to acquire the optimal point data. In order to implement the integrated measuring system, the relationship of coordinate systems between each measuring device should be established. In this paper, a new datum fixture and a calibration method for the multiple-sensor measuring system are proposed. The datum fixture is designed to interface two machines, a CMM and a laser scanner. The position of the datum fixture is calibrated by the axis information off motorized rotation stage which is used for a part setup.
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Molding properties of etched surface pattern are presented. Specimens, whose surface patterns are made by print-type etching, are investigated. The molding properties of surface pattern are estimated with roughness deviation of surface pattern on part and mold. The etching properties are related to physical properties of plastic materials and surface roughness of etched pattern. Also, flow mark and gate location can give influence on surface pattern molding. The experimental result can contribute to good molding of surface pattern in injection molding.
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Build-to-Order (BTO) capabilities enable manufacturing firms to design, produce, and deliver a high volume of differentiated products that meet specific customer needs in timely manner as well as at close to mass-production prices. Aim of BTO is to simultaneously achieve customer responsiveness, cost efficiency, and high volume production. This paper attempts to define the BTO system and suggests the critical components for its realization. A case study is also described to show the impact of a successful BTO implementation.
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In this study, we develop automatic design program, which create 3D model of spur gear and helical gear used VisualLISP and create helical gear in the CATIA using 2D profile of gear. This model become the standard models which give not only in itself mold information but also compare processed product with measuring date. Spur gear require mathematical examination of involute curve and trocoidal fillet curve. Automatic design program, which have a mathematical development create the profile of spur gear.
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In this study, we try to develop the 3D automatic design program of screw thread limit gauge. When users, who have some mechanical information, input some date, they can do 3D-modeling easily like expert. This is one of the merit in automatic design program and the automatic design program can compare screw thread limit gauge made in this study with processed the bolt and nut model. This demonstrates the effective value of automatic design model. Screw thread limit gauge of sort divide into ring gauge of measuring bolt and pin gauge of measuring nut. The new created automatic design program follows the KS.
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In this study, Automatic design program creates 3D solid models and constructs them. The method of making assembly model is two. One assembles the element made in automatic design program with hand, the other develops the automatic design program fur creating assembly model. Automatic design program improves the convenience of user. In creating gears, involute curve and Trochoidal fillet curve are made by mathematical development.
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In this study, we will try to develop the 3D automatic design program of limit gauge. When users, who have some mechanical information, input some date, they can do 3D-modeling easily like expert. This is one of the merit in automatic design program and the automatic design program can compare the limit gauge made in this study with processed the bolt and nut model. This demonstrates the effective value of automatic design model. Limits gauge of sort divide into ring gauge of measuring bolt and pin gauge of measuring nut. The new automatic design program follows the KS.
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In GMAW(Gas Metal Arc Welding) process, bead geometry (penetration, bead width and height) is a criterion to estimate welding quality. Bead geometry is affected by welding current, arc voltage and travel speed, shielding gas, CTWB (contact- tip to workpiece distance) and so on. In this paper, welding process variables were selected as welding current, arc voltage and travel speed. And bead geometry was reasoned from the chosen welding process variables using negro-fuzzy algorithm. Neural networks was applied to design FL(fuzzy logic). The parameters of input membership functions and those of consequence functions in FL were tuned through the method of learning by backpropagation algorithm. Bead geometry could be reasoned from welding current, arc voltage, travel speed on FL using the results learned by neural networks.
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This paper begin a new approach in the water-gate control using radio communication. The dissertation is on the controllable device development of water-gate in the remote distance from water-gate trough the transceiver by radio communication. The proposed water-gate control device is simpe in structure, an suitable for implementation of water-gate control in the remote distance. The remote controller water-gate device inspected the up and down motion of water-gate through the LCD displayer, so that it was very safety driving about the surroundings imformation, over loading and position of water-gate, and so on.
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Spin casting is one of useful methods to manufacture metal parts with low mold cost and short delivery time. But the silicon rubber based conventional method has several problems such as poor dimensional accuracy, limitation in casting materials and its dependency on speciality in meld making process. To solve those problems, this paper suggests a steel based mold making method using direct CNC machining and the experimental results shows that the parts from the developed method has better dimensional accuracy and surface roughness than those from the conventional method.
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Spinning has been used widely for the manufacture of hollow parts with rotational symmetry. With developing CNC machine, CNC machine center can be applied to the spinning processes. In this paper, a study on the development of CNC spinning technology without mandrel is carried out. The deforming process of the spinning process was simulated by DEFORM 3D to give basic design data.
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A study on machining electrode for LEO(Light Emitted Diode) mold with shaped end-mill is presented. The electrode machining by shaped end-mill has been used for maximizing the productivity in manufacture of semiconductor mold. However, it has not been researched systematically for many difficulties such as the making of shaped end-mill, generation of tool path due to distinctive tool geometry, and so on. Tool path is generated on the shaped end-mill geometry and cutting force to provide accurate and efficient machining of electrode. The verification program can drive enhancement of productivity, selecting cutting conditions from experiment function of cutting force. Also, compensation of tooting and machina error can make the electrode accurate by modifying tool path. Therefore, the research on machining with shaped end-mill can contribute to enhancement of accuracy and productivity in building semiconductor mold.
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This paper has executed FE-analysis to review the feasibility for developing the process, which produces the narrow-cubic type cans, using the Backward Impact Extrusion process instead of using current process, multi-stage deep drawing. Proposes an analysis method by applying ALE(Arbitrary Lagrangian-Eulerian) description to non-axisymmetric extrusion. which is appreciated as one of good solution to mesh distortion in case of the large deformation plasticity process that has mass flux, and considers the factors which affects forming-loads related to punch velocity and fulid status of material.
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In this paper, a general procedure to determine machine tool errors from the on-machine measurement (OMM) data is described. First, a parameterized error model of a machine tool is illustrated by approximating error components as linear function of axis positions, and a modified error model is proposed which includes backlash effects. To determine the unknown model coefficient vectors of the forward and backward error model, an artifact with 8 cutes is made and calibrated on CMM. Then, lower-left and upper-right cube corners are measured with a touch-trigger probe mounted on the machine tool spindle. Measured error data are used to determine the coefficient vectors. The positioning errors in the XY plane at the fixed z position are simulated for the forward and backward error model.
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In the paper, a Visual factory model for a optical-components manufacturing process is built. The optical-components manufacturing process is composed of 3 operation processes; optical sub assembly process, package assembly process, and fiber assembly process. Each process is managed not a batch mode, which is one of most popular manufacturing styles to produce a great deal of industrial output, but though a modular cell. In the processes, a modular cell has to be processed independently of the other cells. Optimization for the composition of assembly cell in the optical-components system is made by the Visual factory model.
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This paper proposes an evolutionary computation approach for automated design of mechanical structures especially in its early stage of design phases. Due to the known characteristics of the stage, the approach basically involves a synthetic design method with the composition of building blocks representing the elements of mechanical objects. In order for the building blocks to be more suitable for representation and evolution of mechanical structures, Elementary Cell Blocks (ECBs) are introduced as new building blocks. A new Darwinian evolution process for the new building blocks is also necessarily involved in the approach. We have demonstrated the implementation of the approach with the design of multi-step gear systems.
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This study dealt with the free vibration of two identical rectangular plates coupled with fluid. In order to investigate the vibration characteristics of fluid-coupled rectangular plates, an analytical method based on the finite Fourier series expansion and Rayleigh-Ritz method was suggested. A commercial computer code, ANSYS was used to perform finite element analysis and we investigated the vibration characteristics with mode shapes and natural frequencies. As a result, the transverse vibration modes, in-phase and out-of-phase, were observed alternately in the fluid-coupled system. The effect of fluid bounding and plate boundary condition on the fluid-coupled natural frequency were investigated. It was shown that the mode numbers increased, the normalized natural frequencies monotonically increased.
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The embedded atom method based on the density functional theory is used for calculating ground state properties of realistic metal systems. In this paper, we had corrected constitutive formulae and parameters on the palladium for the purpose of doing Embedded Atom Method analysis. And then we have computed the properties of the palladium on the fundamental scale of the atomic structure. In result, simulated ground state properties, such as the lattice constant, elastics constants and the sublimation energy, show good agreement with Daw's simulation data and with experimental data.
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The fiber reinforced composite material is widely used in the multi-industrial field where the weight reduction of the infrastructure is demanded because of their high specific modulus and specific strength. Pressure vessels using this composite material in comparison with conventional metal vessels can be applied in the field where lightweight and the high pressure is demanded from the defense and aerospace industry to rocket motor case due to the merits which are energy curtailment by the weight reduction and decrease of explosive damage precede to the sudden explosion which is generated by the pressure leakage condition. In this paper, for nonlinear finite element analysis of E-glass/epoxy filament winding composite pressure vessel receiving an internal pressure, the standard interpretation model is developed by using the ANSYS 5.7.1, the general commercial program, which is verified as the accuracy and useful characteristic of the solution based on Auto LISP and ANSYS APDL. Both the preprocessor for doing exclusive analysis of filament winding composite pressure vessel and postprocessor that simplifies result of analysis have been developed to help the design engineers.
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A lot of investigations have been made in recent years on the equal channel angular pressing (ECAP) which produces ultra-fine grains. The finite element method has been used to investigate this issue. In this paper, pure-Zirconium is considered far ECAP process by three dimensional finite element analysis. The effects of fiction on the deformation behavior have been investigated and compared with two dimensional finite element analysis.
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Process design of hot forging, asymmetric to symmetric rail, which is used for the turnout of railway express has been investigated. Owing to the big difference in shape between the initial billet and the final forged product, it is impossible to hot forge the rail in a single step. Therefore, multi step forging as well as die design for each step are necessary for the production. The deformation behavior during hot forging has been analyzed by the numerical simulation through commercial FEA software, DEFORM
$^{TM}$ -2D. Modification of the design and repeated simulation have been carried out on the basis of the simulation result. For comparison with the simulation results, flow analysis experiment using plasticize has been also carried out. The results of the flow analysis experiment showed good agreement with those of the simulation. Therefore, the developed process design could be applied to the actual production. -
Automotive wheel bearings are one of the most important components to guarantee the service life of a passenger car. The endurance life of a bearing is affected by many parameters such as material properties, heat treatment, lubrication conditions, temperature, loading conditions, bearing geometry, internal clearance and so on. In this paper, we analyze the relation between loads and deformations of wheel bearing units. On the basis of it we calculate the endurance life of wheel bearing units and analyze the contribution of bearing geometric parameters on the endurance life by using Taguchi method.
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As the object of this study, a transmission system with the style of HST in combination with mechanical semi-automatic transmission for application in hydraulic wheel excavators was chosen. The dynamic characteristics of the object transmission was studied by numerical analysis of the mathematical model. The results of numerical analysis showed comparatively good agreements with experimental results, so the validity of the numerical analysis process was ascertained.
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In this paper, it has been investigated that the design and simulation of vacuum pump driven by linear motor. Vacuum pump consists of unified plunger and piston part, coils, inlet valve and outlet valve. Operating principal of vacuum pump show that air is to flow to go inside through the inlet valve when the magnetic force (16N) is exerted, whereas, air is to flow to go outside through outlet valve when spring farce (14.8N) is exerted. The results of simulation. it was turned out that reached vacuum pressure was about -0.55 bar at 150 seconds, magnetic force was loaded with 16 Newton, displacement of actuator was about 8mm.
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The authors have developed two devices which cuts the spend fuel rod to an optimal size and extracts fuel pellet from the pieces of cut fuel rods. These devices are so important to reduce radioactive wastes that some advanced countries developed their own methods and devices. The authors have benchmarked from these methods and devices. For spent fuel rod cutting, the tube cutting method has been chosen. some mechanical properties of the fuel tube and pellet has been carefully considered for an optimal cutting size. For fuel pellet extraction, a mechanically extracting method has been adopted. The existing chemical method have turned out to be inappropriate because it produced large amount of radioactive wastes, in spite of its high fuel recovery characteristics. The developed method has an advantage that it can be applied to other fuel rods that have different shapes and sizes. The two devices are set up and operated in the hot cell where people can not go in, so that the devices have been designed to be controlled remotely and modulated for easy maintenance. And the performance of the devices has been tested by using simulated fuel rod. From the experimental results, the devices are supposed to be useful for reducing radioactive wastes.
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As a tool for strain measurement to work with screw driven or hydraulic material test systems, in which mechanical vibration is inherent, SSDG(Speckle Strain/Displacement Gage), ESP(Electronic Speckle Photography) and its 3-dimension version SDSP are investigated for the theory and practical appliance. Through tension test of steel strips, their validity and shortcomings are examined. As the results, it has been shown that, although SSDG and ESP provide direct measurement of in-plane strain in one direction, they are so sensitive to the out-plane displacement. On the other hand, SDSP which is aided with DIC (Digital Image Correlation) technique to trace the movement of the speckles provides not only in-plane 2-dimensional displacement field, but also out-of-plane displacement simultaneously. However, because the DIC is time-consuming, not automated yet and it needs post-processing to evaluate strain from the displacement field, SDSP appears to be not adequate as a real time sensor.
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Induction heating process is one of the most efficient heating process in terms of temperature control accuracy and heating time saving. In the past study, fabrication process of cellular 6061 alloys by powder metallurgical route and induction heating process was studied. To supplement the framing conditions that studied in past study, effect of induction heating capacity and holding time at foaming temperature were investigated. Under the achieved framing conditions, teamed 6061 alloys were fabricated for variation of foaming temperature, and porosities(%)-foaming temperature curves were obtained by try-error experimental method. Uniaxial compression tests were performed to investigate the relationship between porosities(%) and stress-strain curves of framed 6061 alloy. Also, energy absorption capacity and efficiency were calculated from stress-strain curves to investigated. Moreover, dependence of plateau stress on strain rate was investigated in case of cellular 6061 alloy with low porosities(%)
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The pipe with a long-neck flange is widely used in power plants, chemical plants, and shipbuilding companies. New the pipe with a long-neck flange is manufactured by welding a thick flange to a pipe. But this long-neck flange pipe has some deflects in the welding region such as unfitting and local thermal fatigue, which weaken the strength around the neck of the flange. Moreover, after welding the flange, the contacting surfaces of the flange have to be machined flat. So, that is uneconomical. Therefore, to solve the above problems of the long-neck flange pipe, a new process, which has no defects around the flange neck, is required. In this study, three forming processes are suggested to get an enhanced long-neck flange. First suggested process consists of conical terming and flange forming. Second and third suggested processes consist of the bulging of a long pipe locally heated by induction coils and the flange forming. The differences between second and third suggestions are the thickness and local heating area of the pipe. That is, the thickness of the initial pipe of third suggestion is larger than that of the final product, and the local heating area is smaller than that of second suggestion. These three suggestions fur forming a long-neck flange are simulated by FE analyses with a commercial cede DEFORM 2D. Especially, the theoretical result of FE analysis on the first suggestion fur forming a long-neck flange is verified by the experiment with aluminum 6063 pipes. From the theoretical and experimental results, it is concluded that three suggested processes are very useful in order to manufacture the pipe with a long-neck flange without any deflects.
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Welding is used not only during the shipbuilding, but also during the repairing of ships. While repairing of ships, it is inevitable to weld new materials with degraded materials. In this case, it is predicted that the strength of both the sections is not identical each other. In this study, the respective welded joints in terms of mechanical properties such as microstructure, mechanical strength and fatigue crack propagation, with the component obtained from the barge used for a long-term period, were analyzed. It was found that the material degradation had a significant effect on the welded joints. The fatigue crack propagation in welded sections showed a big difference. The rate of fatigue crack growth of degraded material for both heat affected zone and parent metal was faster than that of new material. By contrast, The result within identical materials showed that the heat-affected zone was slower than that of parent metal
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Although recent research of metallic materials in high temperature fatigue have been much accomplished, many studies about brittle material as a die steel in high temperature fatigue does not have been reported. Especially, the study on the fatigue behavior over the transformation temperature is not studied sufficiently because of its difficult analysis and experiment. Therefore, reliable results of brittle material in high temperature fatigue behavior are needed. In this paper, stress-strain curves and stress-life curves in die STD61 steel at 700 and 900 are carefully examined, as the basic experimental data are used to predict from fatigue life over 700.
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This paper describes the Boolean and sectioning operations on pseudo-solid models. A pseudo-solid model is defined as a sheet body that looks like a solid model but cannot comprise a solid model due to tolerance. Most of CAD models imported from the other CAD system are pseudo-solid models and have to be repaired for further stolid modeling operations. However, healing a pseudo-solid model is a very tedious and cumbersome process. To solve this problem, we devised and implemented the Boolean and sectioning operations on pseudo-solid models. Using these operations, mold and die design can be performed more efficiently, as healing work is reduced greatly.
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Cylindrical cam mechanisms are used commonly in many automatic machinery. But the cylindrical cam is very difficult to design and manufacture the shape. The motion analysis of the cylindrical cam can check the accuracy between designed data and manufactured data of the cam shape and can reproduce without the cam design data. The motion analysis of the cylindrical cam consists of displacement analysis, velocity analysis and acceleration analysis. This paper performs the motion analysis of a cylindrical cam with translating follower by using a relative velocity method and a central difference method. The displacement is calculated by using the central difference method and the velocity is calculated by the relative velocity method. The relative velocity method is defined by the relative motion between follower and cam at a center of a follower roller. The central difference method is derived in the 3 dimensional space.
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In the recent years, as the research and the development of micro and precision machinery become active, the interest of micro actuators using SMA(Shape Memory Alloy) has been increased. The dynamic characteristic analysis of SMA is necessary for actuator application and many common researches report the material characteristics of SMA sufficiently. However, the research of dynamic characteristics is very deficient. In this paper, the helical spring is fabricated with NiTi SMA wire of high resistivity The farce, response speed, temperature, and displacement are measured by digital force gauge, infrared thermometer, and laser displacement sensor so that the dynamic characteristics of this SMA actuator is analyzed.
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Most of battery industries are growing explosively as a core strategy industry for the development of the semi-conductor, the LCD, and the mobile communication device. Dynamic characteristic analysis consists of dynamic behavior analysis and finite element analysis and is necessary for effective design of machines. In the dynamic behavior analysis, the displacement, velocity, applied force and angular velocity of each components are simulated according to each part. In the FEA, stress analysis, mode analysis, and frequency analysis are performed far each part. The results of these simulations are used for the design specification investigation and compensation for optimal design of cell manufacturing line. Virtual Engineering of the separator inserting machine on the automatic cell assembly line systems are modeled and simulated. 3D motion behavior is visualized under real-operating condition on the computer window. Virtual Prototype make it possible to save time by identifying design problems early in development, cut cost by reducing making hardware prototype, and improve quality by quickly optimizing full-system performance. As the first step of CAE which integrates design, dynamic modeling using ADAMS and FEM analysis using NASTRAN are developed.
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There have been no obvious design criteria of high efficient displacement pump using a dimensionless parameter which can represent many physical aspect of displacement pump could be very useful to estimate displacement pump performance. Many dimensionless analysis methods have been developed in fluid dynamics, machine design and so on. In this study a new dimensionless parameter is developed for estimate displacement pump performance and efficiency, until now to evaluate the performance of displacement pumps which are widely used in industry field, primarily experimental methods have been used. The dimensionless parameter contains many physical information about pump design. For example, they are the relation between flow rate and power, displacement operation displacement and size, inlet and outlet valve size. And the developed dimensionless functions are induced from numerical method.
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PTB(Power Transfer Breaker) is a device which incorporate the functions of ACB(Air Circuit Breaker) and ATS(Automatic Transfer Switch). ACB is a circuit breaker against overload and ATS is a switching device to transfer the load between two electric power sources. An existing PTB design based upon the 5 bar & cam mechanism has been regarded to be too complex and thus a simpler 4 bar mechanism with trigger lock is proposed. Experimentation and optimization of the trigger lock is presented.
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This paper describes the design and development of drills with deburring inserts. The drills can be used to drill holes and deburr the edges of the drilled holes simultaneously. The drills incorporate deburring inserts within the shank. The insert consists of a fixing base, a cantilever spring and a cutting tip. The stiffness of the cantilever spring and the details of the cutting tip play a central role for the successful deburring performance. The deburring performance is also governed by the conditions of the drilling burr best described by the burr control chart suggested by Dornfeld. With careful burr control, successful deburring is obtained by the drills with deburring inserts.
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Many malfunctions take place in container crane spreader due to impact. So we designed a 2DOF hydraulic impact absorbing system and studied the change of impulse with respect to the variation of falling height and weight. The falling height becomes higher than 1m and the falling weight goes up heavier than 100kg, the impact absorbing rate was lower. When spreader is bumped against container and impulse force concentrates on one point, impact absorbing equipment would not be operated properly and make some trouble.
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In this study, we carried out the finite element analysis about screw that is the weakest part of the centrifuge for sewage management. Structural analysis was done with respect to the change of outer radius and thickness of screw blade and screw with sewage discharge hole. If the area of circular hole is equal to that of extended holes, maximum equivalent stress was compared between hole and extended hole. Centrifugal force on account of rotation of 4000 rpm was applied the screw. The results are as follows : 1 . When the larger radius and thickness of screw blade was used, the higher maximum equivalent stress is occurred. 2. When the larger radius of sewage discharge hale was used, the higher maximum equivalent stress is occurred. 3. When the longer parallel part length of extended hole was used, the higher maximum equivalent stress is occurred. 4. If the extended hole with the same discharging area which circular hole uses, the maximum equivalent stress is lower.
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In this study, it is attempted to obtain the optimum size of holes in 15 square plate models where a hole exists on every quadrant of a plate, and to get eigenvalues by performing free vibration analysis far each model. Moreover, the specimen is produced from optimized square plate and eigenvalue of each plate is measured through the shocking load. And then the result is compared with that of finite element analysis. For free vibration analysis of the square plate, the boundary condition of finite element analysis and experiment is assumed as both ends support. From the results of this study, it is known that more stable structures can be designed by changing the natural frequency which is dependent on the location of holes and further studies are considered to be necessary for the basic design information.
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In this study, 3 kinds of holes (square, circular and elliptic holes) are attempted on a cantilever to reduce the weight by 30%. Maximum Von-Mises stresses of cantilever plate with 3 kinds of holes are investigated. For the elliptic holes, a shape optimization is attempted to fad the optimum angle of axis by rotating the axis by
$10^{\circ}\; from\; 50^{\circ}\; to\; 120^{\circ}\;$ From the results, it is known that the maximum stress is decreased to 0.868 MPa by rotation of the axis of elliptic hole and 0.26 MPa is decreased compared with the maximum stress occurred on the circular hole. -
This paper deals with the stress concentration of the rotating disc in detail. We studied maximum stress of rotating disc with respect to the various parameter of circular hole such as position, size, number of the hole, then the mollified effect of maximum stress due to pin-hole around circular hole, using FEM, the results are as follows: 1. The more the number of circular hole and the further from the center, the maximum equivalent stress reduces. 2. When the pin-hole is located 60
$^{\circ}$ from the x-axis, the maximum stress reduces significantly due to the effect of interference. -
This study focuses on designing a new gluing system for the FM-I (Freeform Master I), which is a new rapid prototyping machine using a sheet lamination technique. To design the system, we firstly verify the required parameters of the proposed gluing system. Then we analyze the electro-magnetic system by using ANSYS and the mechanical system by using numerical methods. The gluing system can contribute to reduce the cost of the machine since it can be applied to low cost materials such as a plain paper.
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The die easting process was used to manufacture a motor housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been carried out die casting process of motor housing. In this paper, we investigated about characteristics of the die casted motor housing with HPDC(High Pressure Die Casting) process. Also the MAGMAsoft was used as computer simulation code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and solidification process of a motor housing cast. The analysis results obtained about filling behavior and solidification of cast showed good agreement with test results.
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There are various methods to join mechanical structures together. They typically include welding, mechanical joints by bolts and other processes depending on specific needs. Analyses of joints in the mechanical structures are essential in understanding the dynamic characteristics of the structures. In this research an impulse technique is applies to investigate the dynamic behavior of joints produced by bolts. The length overlap in the joints was varied as the number of the bolts in the joins was changed. Also, the torque applied to the bolts were adjusted. Resonance frequencies were determined for the joints to evaluate the relationship between the increase in the applied torque and the increase in the number of bolts used in the joints. The results have demonstrated that the resonance frequencies of the joints increase with the increasing torque.
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Durability of rubber dust cover in the ball joint for automotive suspension parts were analyzed by FEM and compared with experimental data. Upper open area of ball joint is sealed by dust cover for preventing outflow of the lubricating oil and intrusion of send, dust, water, etc. This rubber cover undergoes repeated loadings such as tension and compression while the car is running. Analysis about rubber material needs to consider every kinds of nonlinearities arise in finite element analysis, which are geometric nonlinearity due to large displacement and small strain, materially nonlinearity and nonlinear boundary condition such as contact. So in the study, the deformation behavior of dust cover was analysed by using the commercial finite element program MARC. This program could solve these kinds of nonlinear analysis accurately. Finite element model of dust cover is considered as 3-dimensional half model based on 2-dimensional axisymmetric model. Material property of rubber was modeled by Ogden model and input data for calculation takes form uniaxial tension test of rubber specimen, The final object of the study is obtaining the design specification of dust covers and the result of analysis should be a useful data to design of rubber
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The goal of this research is to deduce the robust design of mold oscillator of the continuous casting machine. In the case of the system operated in the high temperature condition, the structural problems caused by the heat are dominant. Therefore, the thermal stress is considered with the connection of the thermal and structural analyses. The cooling ability of the water jacket was estimated and the robustness of mold oscillator was judged with the displacement and stress distributions obtained by the finite element method. The analytic results were compared with the real values of the iron mill.
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In this study, structural optimum design was applied to the girder of magnet over head crane. The optimization was carried out using ANSYS Code for the deadweight of girder, especially focused on the thickness of its upper, lower, side and reinforced plates. The weight could be reduced up to around 15% with constraints of its deformation, stress, natural frequency and buckling strength. The structural safety was also verified by the buckling analysis of its panel structure. It might be thought to be very useful to design the conventional structures for the weight save through the structural optimization. The objective function and restricted function were estimated by the orthogonal array, and the sensitivity analysis of design variable fur that was operated.
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On this study, the dynamic response of vibration absorber was operated by finite element analysis and this paper proposed the optimum value of spring constant and damping coefficient for three types of impact absorber. Also the reaction farce of piston which is the objective function was proposed by the optimum design and the model which has the optimum value among the reaction forces was shown.
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In this investigation, experimental attempts were made to observe and determine the variations in elastic of the PVC depending on the amounts of MBS added to the mixture, PVC/MBS, and also on the thicknesses of the specimens. An acoustic resonance technique was used for the tests in this investigation. It serves as a method to characterize properties of materials set in vibrational motions, which is initiated by low level stresses generated by externally supplied acoustic energy. Substantial variations were observed in the test results with the addition of the MBS to the PVC. It was found that the magnitudes of elastic constants decrease when MBS rubber was added in the range up to 9 phr and the shape factor effect in torsional vibration is more significant than the shape factor effect in flexural vibration.
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Continuously variable transmission(CVT) mechanisms considered here combine the functions of a K-H-V type differential gear unit and a V-belt type continuously variable unit(CVU). As combining the functions of a K-H-V type differential gear unit and a V-belt type CVU, 24 different mechanisms are presented. Some useful theoretical formula related to speed ratio, power flow and efficiency are derived and analyzed. These mechanisms have many advantages which are the decrease of CVT size, the increase of overall efficiency, the extension of speed ratio range, and the generation of geared neutral.
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This paper estimated the stability of centrifuge as its rotating speed compared with the natural frequency of cylinder and screw by finite element analysis. It shows that the one of exciting causes is the tooth passing frequency of input and output parts by the periodic characteristics of transmission error due to an planetary gear having three stages. Also, it proposed the critical speed of cylinder and screw by the Campbell diagram.
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As the requirements on precision and speed of motion in chip mounter increase, vibration forces are always exerted on operating conditions. To insure safety of the chip mounter, the vibration must be kept within an acceptable limit. The focus of this paper is on the identification of dynamic load characteristics and the estimation of static and dynamic stiffness characteristics for Frame Base by judicious selection of the number and the location of the support points. This study carried an analytical and experimental method to estimate the dynamic characteristics in structure.
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This paper deals with the buckling and vibration analysis of plate with a hole. We knew that in this paper, as aspect ratio rises in design parameter, the buckling strength and the natural frequency of laminated composite plate decrease and as diameter of hole for width of plate rises, the buckling strength decrease but the natural frequency increase. Also this paper compared the CFRP laminated composit plate with the hybrid composite plate, and proposed that the hybrid composite plate is stronger than the CFRP composite plate.
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This paper is the study on stress analysis for tooth modification of high speed gear using a finite element method. Gear drives constitute very important mechanisms in transmitting mechanical power processes compromising several cost effective and engineering advantages. The load transmission occurred by the contacting surfaces arises variable elastic deformations which are being evaluated through finite element analysis. The automatic gear design program is developed to model gear shape precisely. This gear design system developed was used by pre-processor of FEM packages. The distribution of stresses at contacting surfaces was examined when gear tooth contacts. And this paper proposes method for the tooth modification after carrying out stress analysis using a finite element method.
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MEMS structures Generally have been fabricated using surface-machining, but the interface failure between silicon substrate and evaporated thin film frequently takes place due to difference of linear coefficient of thermal expansion. Therefore this paper studied the effect of the residual stress caused by variable external loads. This study did not analyzed accurate quantity of the residual stress but trend for the effect of residual stress. Several specimens were fabricated using other material(Al, Au and Cu) and thermal load was applied. The residual stress was measured by nano-indentation using AFM. The results showed the existence of the residual stress due to thermal load. The indentation area of the thermal loaded thin film reduced about 3.5% comparing with the virgin thin film caused by residual stress. The finite element analysis results are similar to indentation test.
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Twin screw extruders are the heart of the polymer processing industry. The single most important mechanical element of a screw extruder is the screw. The proper design of the geometry of the excluder screw is of crucial importance to the proper functioning of the extruder. If material transport instabilities occur as a result of improper screw geometry, even the most sophisticated computerized control system cannot solve the problem. For this purpose, Tool shape design for the screw flights cutting in twin screw extruder.
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With the increase of storage density, high rotational speed and high access technologies in optical disk drive, mechanical issues, mainly noise and vibration, become critical. Up to now the researches of rubber mount for anti-vibration focused on how to calculate the static and the dynamic stiffness of rubber mount and leaved out of consideration of the dimensional tolerance of rubber mount for anti-vibration. This paper presents the effects of dimensional tolerance of rubber mount for anti-vibration on the dynamic characteristics of optical disk drive by finite element analysis and dynamic test. The relation between dimensional tolerance and dynamic characteristics of optical disk drive is observed and discussed.
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In this paper, we propose multi-resolutional representation of B-rep solid models using the selective Boolean operations on non-manifold geometric models. Since the union and subtraction operations of the selective Boolean operations are commutative, the integrity of the model is guaranteed for reordering design features. A multi-resolution representation is established using a non-manifold merged set model and a feature modeling tree reordered according to some criterion of level of detail (LOD). Then, a solid model for a specified LOD can be extracted from this multi-resolution model using the selective Boolean operations.
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This paper describes the selective Boolean operations on non-manifold geometric models whose union and subtraction operations are communicative. These operations guarantee the same resulting shape in spite of change of the order of Boolean operations, and the integrity of the model for omission of some features. In addition, a B-rep model for a modified modeling history is obtained in a short time, as no boundary evaluation is necessary. These features enable easy implementation of multi-resolution representation of B-rep models.
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The dry pulverizing/Mixing device is used to deal with the spent fuels for the safe disposal. The separated pellets from hulls by a slitting device are put and oxidized from UO
$_2$ solid pellet to U$_3$ O$\_$ 8/ powder in the device. The device have been developed based on a voloxidation method which is one of several dry de-cladding methods. We have benchmarked dry de-cladding methods, analyzed applicability to the advanced spent fuel management process, integrated and compared several configuration, and finally derived detailed specifications proper to requirements for the device. Also, thermal characteristics of the device such as thermal stress and strain have been analyzed by the commercial software, 1-DEAS, and the reliability of the results have been verified by the KOLAS(Korea Laboratory Accreditation Scheme). The UO$_2$ solid pellets are put in the device which has a capacity of 20 kgHM per a batch, heated up about 600$^{\circ}C$ in the air environment. Then, the UO$_2$ solid pellets are oxidized into the U$_3$ O$\_$ 8/ powder, and the powder is collected in a special vessel. The device has been designed and developed as fellows: the multi-staged fine hole meshes are used to reduce the size of the powder gradually, heat and air(oxygen) are supplied continuously to reduce the reaction time, and slight vibration effect are applied to collect powder cling to the device. -
This paper is to investigate the wear behavior of submerged-arc clad materials by the wear test with a ball-on-disk type wear testing machine in air. The specimens were clad with Stoody105 alloy wire on a carbon steel (SM45C) substrate by submerged-arc cladding process under different welding parameters. The wear behavior of the cladding through ball-en-disk test has been studied under the wear load from 5N to 16N and sliding speed from 8cm/s to 35cm/s. The weight of the specimen loss was measured. Scanning electron micrographs of the worn surface show a layer of oxide film formed on the worn surface. Oxidation wear mechanism controls the wear process. The spalling of the oxide is caused by the repeated rubbing fatigue mechanism.
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In the field of automobile industry, lightweight problems are very important in terms of reducing fuel and protecting environment. To satisfy these demands, the attempt to substitute aluminum automobile components for cast steel part has been actively carried out. To fabricate the aluminum automobile suspension part that has the same mechanical properties with cast steel part, design conditions such as shape and dimension of part shall be established. Therefore in this study, shape and dimension conditions of suspension part were proposed. Aluminum automobile suspension part was fabricated by semi-solid die-casting process under the obtained design conditions. Moreover to evaluate the possibility of application to the automobile component, stress and fatigue analysis were performed by using ABAQUS S/W and compared with those of conventional automobile suspension part.
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In order to investigate the fracture behaviors(penetration modes) and resistance to penetration during ballistic impact of surface hardening treated Aluminum, Titanium alloy laminates, ballistic tests were conducted. In this paper, Anodized Al 5083-H131 alloy laminates and nitrified Ti (Gr.2) alloy laminates were used to achieve higher surface hardness. Surface hardness test were conducted using a Micro victor's hardness tester and thickness of surface hardening treated specimens was measured by video microscope. Resistance to penetration is determined by the protection ballistic limit(
$V_50$ ), a statistical velocity with 50% probability far complete penetration. Fracture behaviors and ballistic tolerance, described by penetration modes, are respectfully observed at and above ballistic limit velocities, as a result of$V_50$ test and Projectile Through Plates (PTP) test methods. PTP tests were conducted with$0^{\circ}$ obliquity at room temperature using 5.56mm ball projectile.$V_50$ tests with$0^{\circ}$ obliquity at room temperature were conducted with projectiles that were able to achieve near or complete penetration during PTP tests. -
The main objective of this study is to consider the effect of fatigue crack behavior on the variable depth of micro hole defects in SM20C at the symmetric position. The fatigue crack propagation test is performed by rotary bending fatigue test machine. The relationship between crack length(2a), cycles(N) and crack growth rate(da/dN) are investigated in this study. The result from the rotary bending fatigue test under the applied stress at 250MPa turned out that the fatigue life illustrated almost constant when the depth of symmetric micro hole deflects is both part A and B at the hope depth(h) = 0.5mm.
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Deformation of the specimen was investigated on hydrogen absorption-desorption cycling. In order to study this problem, the cold rolled palladium thin plate as the specimen had been used. By using the electrochemical method, the palladium plate specimen was cyclically hydrogenated in the 0.1 mol
$H_2SO_4$ electrolyte. As results, it is noted that the thickness of the plate specimen gradually increased in increasing hydrogenation cycles whereas the width and the length decreased. Also, grains in the plate specimen were greatly deformed after hydrogenation cycling. But hydrogen absorption rate scarcely changed. -
This study investigated the shape deformation of ball projectile(5.56mn) under the low energy impact by the use of the drop weight impact tester. ball projectile(5.56mm) consisted of the copper face with a lead core. The impact conditions were changed with the variations of the mass and the drop height of the impact tup. Shape deformation of ball projectile(5.56mm) after low velocity impact was measured using a video microscope and CCD camera. The test result showed that impact energy by changing of drop height of the impact tup affected shape deformation of ball projectile(5.56mm). So, it is important to study the relativity between shape deformation of ball projectile(5.56mm) and ballistic protection of plate(such as hybrid composite laminates) under the high velocity impact.
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This paper deals with the effect of reinforced plate on the deflection of the rectangular plate, when the rectangular plate is reinforced with rectangular rigid body at the centroid of the plate. For Two boundary conditions such as simple supported and clamped boundary, this study derives deflection formula of reinforced plates with respect to the stiffness ratio and the length ratio of rigid body using the least square method. The results are as follows: 1. As
$r_e$ $\geq$ 1000, the maximum deflection with respect to$r_e$ converges into constant value. 2. Deflection formula with respect to$r_e$ is derived as the fifth order polynomial. -
This paper presents the effect of internal corrosion, external corrosion, material properties, operation condition, earthquake, traffic load and design thickness in pipeline on the failure prediction using a failure probability model. A nonlinear corrosion is used to represent the loss of pipe wall thickness with time. The effects of environmental, operational, and design random variables such as a pipe diameter, earthquake, fluid pressure, a corrosion rate, a material yield stress and a pipe thickness on the failure probability are systematically investigated using a failure probability model for the corrosion pipeline.
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Much research efforts have been made on the equal channel angular pressing(ECAP) which produces ultra-fine grains. In this paper the ECAP processes with Zr-702 alloy at elevated temperature and at room temperature are considered. Both two-dimensional and three-dimensional finite element analyses have been employed to investigate the deformation behaviors of specimen during ECAP process.
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Magnesium alloys are very attractive materials for appling to the development of autemobile parts or electric goods where light weight and higher stiffness. Due to higher ratio of strength vs. weight and stillness vs. weight, various magnesium alloys are well applied in much weight saving design applications though extrusion or die-casting process. However for the requisites of higher strength and weight savings, some new fabrication processes has been and it can be realized though the aid of injection modeling technology. To obtain the parametric data base for the injection molding process, various experiments were executed for AZ91D magnesium alloy. This paper propose the optimum condition of injection temperature, first and second pressure. the process was lined-up successfully often changing the injection unit. fluid pressure system from the conventional plastic injection molding process.
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Finite Element Method for 3-D static loaded passenger car tire on the rigid surface is performed for studying the stiffness of tire to compare with experimental data. The tire elements used for FEM are defined each component to allow an easy change for the design parameters. Also, a hyperelastic material which is composed of tread and sidewall has been used to consider a large deformation of rubber components. The orthotropic characters of rubber-cord composite materials are used as well. The air pressure, a vertical and a lateral load are applied step by step and iterated by Modified Newton method for geometric and boundary condition nonlinear simulation. This study shows nonlinear analysis method for tire and the bearing capacity of tire due to the external force.
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This study is focused to predict the behavior of Al foam with closed-cell structure during the 3 point bending test and the upsetting test according to aspect ratio. We calculated characters of aluminum foams with closed-cell structure and took the simulation. The effects on the aspect ratio of the cell was investigated parametrically. The analysis was carried out on two models, First, the bending test in elasticity of the rectangular beam, and Second, the upsetting test in plasticity of the circular cylinder. In the analysis, the deformation of the beam and the cylinder was influenced by the aspect ratio of the cell. Further, We assumed that the geometry of feared aluminum cell change the stress and strain in the test.
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The collimation mirror will be used for thermal vacuum testing of spacecraft. The reflection mirror system to generate parallel beam inside the thermal vacuum chamber. A 600mm diameter aspheric Collimation mirror was fabricated by ultra-precision single point diamond turning (SPDT). Aluminum alloy for mirror substrates is known to be easily machining, but not polishable due to its ductility. Aspheric large collimation reflector without a conventional polishing process, the surface roughness of 10nmRa, and the from error of
$\lambda/2 ~\lambda/4(\lambda$ =632.8 nm) for reference curved surface 600 mm has been required. The purpose of this research is to find the optimum machining conditions for reflector cutting of A16061-T651 and apply the SPDT technique to the manufacturing of ultra precision optical components of metal aspheric reflector. -
The cutting thickness of ultra-precision machining is generally very small, only a few micrometer or even down to the order of a flew manometer. In such case, a basic understanding of the mechanism on the micro-machining process is necessary to produce a high quality surface. When machining at very small depths of cut, metal flow near a rounded tool edge become important. In this paper a finite element analysis is presented to calculate the stagnation point on the tool edge or critical depth of cut below which no cutting occurs. From the simulation, the effects of the cutting speed on the critical depths of cut were calculated and discussed. Also the transition of the stagnation point according to the increase of the depths of cut was observed.
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Commutators of a starting motor for automobiles has been produced through various processes such as forging, segmenting, and assembling. And the conventional method producing an automotive motor commutator is not appropriate for saving material and cost, because it makes each segment separated one by one. Therefore a new process design is required in oder to avoid the assembling process. In this study, a new process design of the commutator of an automotive starting motor has been carried out to save material and manufacturing time by FE analysis. In the FE analysis, three forging processes are proposed for producing the copper(ASTM Cl1000) commutators of a starting motor. And forging experiments are performed to make an unsegmented commutator in order to verify the theoretically proposed process. And then, in order to get the final product, the forged commutator is passed through various postprocessing such as resin terming, and machining. From the experimental result, the forging process proposed from the FE analysis is verified to be an economical method for producing the commutator of an automotive starting motor.
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Recently, the sensor and actuator are developed with EAP(Electro Active Polymer). Common used of they is close at hand, the bio chip and Lab on a chip are researched. For developed bio and micro system, a researcher applies semiconductor fabrication or make it by his hand. But, this method takes long time and a tolerance is large So they are problem of common used. So In this paper we propose the new inject ion molder and micro mold. The micro mold is different from exist ing mold. In this paper, the fabration of micro mold is introduced to inject.
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Fabrication of micro carbon structures and patterns using laser-assisted chemical vapor deposition is studied. Argon ion laser and ethylene were used to grow micro carbon rod through pyrolytic decomposition of the reaction gas. The influence of reaction gas pressure and incident laser power on the diameter and growth rate of the micro carbon rod was experimentally investigated. The diameter of micro carbon rods increases linearly with respect to the laser power but is almost independent of the reaction gas pressure. Growth rate of the rod changes little with gas pressure when the laser power remains below 1W. When the carbon rod was grown at near threshold laser power, a very smooth surface is obtained on the rod. By continuously moving the focusing lens in the direction of growth, a micro carbon rod with a diameter of 28
${\mu}{\textrm}{m}$ and aspect ratio of 100 was fabricated. -
Some investigators who have tried to achieve the highly smooth surface finish using electrochemical processes have reported that high current density produced lustrous surfaces while the opposite conditions produced a passive layer and had a tendency to produce a black surface. However, processing at a low current density may produce a non-lustrous surface but the improvement of dimensional accuracy of the surface is significant. The surface with pulse process was a bit more lustrous than with continuous current but the black passive layer still could be found at grooved surface. There are two ways to achieve highly smooth surface finish. One is brushing it with a brush the other is electrochemical machining (ECM) with high current. The former method is the most common polishing practice, but not only may the surface obtained differ from operator to operator, but precision smooth surface on micro grooves are difficult to obtain. The latter one recently has been used to produce a highly smooth surface after EDM process. However, the material removal rate in ECM with high current is relatively high. Hence the original shape of the micro grooves, which was formed by electrochemical micro-machining (EMM) process, may be destroyed. In this study, an electrochemical polishing process using pulse current is adopted as a possible alternative process when micro grooves formed by EMM process should be polished. Mirror-like micro grooves with lustrous and smooth surface can be produced electrochemically with pulse current because the voltage and current used can be lower than the case of continuous current. This study will discuss the accurate control of physical and electrical conditions so as to achieve mirror-like micro grooves with lustrous and smooth surface without destroying the original shape of micro grooves.
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Klystron which is micro wave amplifier tube are mainly used in fields of science such as accelerator, nuclear fusion, broadcasting, communication fields, and defense industry fields, tract. The quality of Klystron anode and cavity are determined by form accuracy and roughness of the worked surface. Therefore anode and cavity are restricted the from accuracy strictly and the surface roughness be under Rmax 0.03S. As a work material of anode and cavity, the oxygen-free copper, that is used for optical pares of aerospace and laser mirror is selected. An outside diameter of material is
$\Phi$ 100 mm and an inside diameter is$\Phi$ 30~33 mm. In this study, to find the optimum ultra precision cuffing condition of oxygen-free copper with diamond turning machine, the surface roughness is examined for various diamond toot nose radius, main spindle speed, fred rate and depth of cut. As a result of experiment, we could machined the anode and cavity with a surface roughness within Ra 3.2 nm, a form accuracy within 0.01$\mu\textrm{m}$ . -
Although ceramic plates with many micro-hales are used as MCP (Micro-channel plate) for electron amplification, catalytic converters, filters, electrical insulators and thermal conductors in integrated circuits, the drilling of micro-hales in the ceramics is difficult because of their low thermal conductivity, high hardness and brittleness. Therefore, in this work, the machining of ceramic green body fellowed by sintering of green body was employed fur fabricating ceramic plates with many micro-holes. The micro-drilling of alumina green body was performed with diamond abrasive WC drills, and the cutting force w.r.t. drilling times was measured for the determination of toot life. From the investigation of the wear of micro-drill tip w.r.t. drilling times, the wear mechanism of tip during micro-drilling of ceramic green body was suggested.
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The polyimide nozzle and silicon restrictor inside a thermal micro actuator have been fabricated using state of the art laser micromachining methods. Numerical models of fluid dynamics inside the actuator chamber and nozzle are presented. The models include fluid flow from reservoir, bubble formation and growth, ejection through the nozzle, and dynamics of refill through restrictor. Since high tapered nozzle and restrictor are very important parameters for overall actuator performance design, a special setup for the beam delivery system has been developed. The effects of variations of nozzle thickness, diameter, taper angles, and restrictor shapes are simulated and some results are compared with the experimental results. It is fecund that the fluid ejection through the thinner and high tapered nozzle is more steady, fast, and robust and the tapered restrictor shows more satisfying refill than the zero taper one.
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This paper has studied to obtain the grinding characteristics and optimal grinding renditions of ceramic materials in the grinding with diamond wheel by the experimental plan method. The load on wheel by varying the feed rate was related with the surface roughness due to the minute destruction phenomenon of grains for the Si
$_3$ ${N^4} and Zr{O_2}$ . The depth of cut is related with the surface roughness because the grinding is carried out by grain shedding process due to the brittle fracture phenomenon for the${Al_2}{O_3}$ . The major factors affecting the surface roughness and the optimum grinding conditions were obtained with minimum experiments using the experimental plan method. -
This paper presents atomization characteristics of cutting fluids. To analyze the behavior characteristics of cutting fluid, analytical approach and experimental measurement were performed to predict the aerosol size, velocity and concentration due to cutting fluid atomization mechanism in machining operation. The established analytical model which is based on atomization theory analyzes the cutting fluid motion and aerosol generation in machining process. The predictive models can be used as a basis for environmental impact analysis on the shop floor. It can be also facilitate the optimization of cutting fluid usage in achieving a balanced consideration of productivity and environmental consciousness.
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During the hotwire cutting of EPS foam sheet, the dimensional accuracy and part quality of the cut par are highly dependent upon the thermal field in the EPS. The thermal field is determined by operating parameters such as heat input, cutting speed and cutting angle. The objective of this study is to investigate into the influence of cutting angle on the kerfwidth and part quality of the cut part in hotwire cutting of EPS foam using the experiments and the numerical analysis in the case of a single sloped cutting. In order to estimate an accurate temperature field, the transient thermal analysis using a moving coordinate system and the sloped heat flux model is carried out. From the results of the experiments and the analysis, it has been found that the effect of cutting angle on the kerfwidth and the melted area at the edge are 0.1 mm and 0.11 m
$m^2$ respectively. The results of the experiments show that the surface roughness is not appreciably influenced by the cutting angle. -
$WC-3%(Cr_3C_2)-2%(Mo_2C)-12%Ni$ carbides were ground with three different types of electroplated diamond wheels with respect to grain friability. The grinding ratio in the case of the highest toughness grains, A becomes the highest at the workpiece speeds of 40 and 70mm/min exhibiting larger effect with smaller workpiece speed. The grinding ratio with the medium toughness grain is higher than that of grain A at higher workpiece speeds than 100mm/min. The surface roughness becomes smaller with increasing the grain friability The increasing rate on surface roughness with the increase of workpiece speed becomes higher with using the grain of lower friability. -
In this work, a new non-lithographic micro-fabrication technique is presented. The motivation of this work is to overcome the demerits of the most commonly used photo-lithographic techniques. The micro-fabrication technique presented in this work is a two-step process which consists of mechanical scribing followed by chemical etching. This method has many advantages over other micro-fabrication techniques since it is simple, cost-effective, rapid, and flexible. Also, the technique can be used to obtain a metal structure which has sub-micrometer width patterns. In this paper, the concept of this method and its application to microsystem technology are described.
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In recent days the more use of CFRP composite is in the airplane, automobile, and sport goods, etc., the more necessity of research on it in this engineering. In this research, the CFRP composite specimen are fabricated by 48 CFRP plies with 8 orientation angles, and the specimens are drilled with 3 tools. The results are analyzed with consideration of cutting force, type of tools and fabrication condition. The specimens with each drilling conditions are also investigated with SEM. The optimal drilling conditions such as drill types and cutting force with respect to the fabricating condition are studied.
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An internal finishing process by the application of magnetic abrasive machining has been developed as a new technology to obtain a fine inner surface of pipe. In this paper, another method of magnetic abrasive machining in which the N and S magnetic poles are feed and a workpiece is rotated only is tried in a fine-pipe, and its finishing characteristics is experimently investigated by various effective factors such as feeding amplitude. From the experimental results, it is found that the feed effects of magnetic poles on the finishing characteristics are large in internal finishing.
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Two decisive mechanisms of the electrorhological polishing for a small part(for example, a aspherical surface in a micro lens) are explained. Firstly, non-uniform electric field generated in the polishing structure increases a shear stress of ER fluids which is maximized dramatically near the tool, therefore, substrate adjacent to the tool can be removed effectively by mixed abrasives in the ER fluid. Secondly, abrasives in a non-uniform electric field are governed by the dielectrophoretic phenomena. Abrasives move toward the tool because the field gradient is highest near the tool and then abrasives are actively holded in that area. This phenomena is observed and evaluated by the optical measurement.
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An understanding of tribological behavior in CMP(Chemical Mechanical Polishing) is one of the most important things to reveal the mechanism of material removal. In CMP, the contact type is thought to be semi-direct, elastohydrodynamic contact type from the Stribeck diagram, which is a combination of solid-solid direct contact and hydrodynamic lubrication with thin liquid film. This study is focused on the decay of friction force during CMP from two points of view, one of which is change of the real contact area and the other is the decrease of the elastic modulus of the pad caused by the increase of the temperature during CMP Experiments are implemented with elastic modulus measuring system and tool dynamometer. Results show that the decay of friction force during CMP results from the decrease of the real contact pressure working on an abrasive, which is induced by the decrease of elastic modulus of pad caused by the increase of temperature. And, the phenomenon is thought to be happen specially in the case that the weight concentration of abrasive in slurry is small enough.
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This research presents the new method to fabricate small features through applying chemical mechanical micro machining(C3M) for Al5052 and single crystal silicon. To improve machinability of ductile and brittle material, reacted layer was formed on the surface before micro-drilling process by chemical reaction with
$HNO_3$ (10wt%) and KOH(10wt%). And then workpieces were machined to compare conventional micro-drilling process with newly suggested one. To evaluate whether or not the machinability was improved by the effect of chemical condition, surface defects such as burr, chipping and crack generation were measured. Finally, it is confirmed that C3M is one of the feasible tools for micro machining with the aid of effect of the chemical reaction. -
In micro-machining, diamond tool is commonly used because it brings much better micro-machinability due to its edge sharpness. However, it is a big question even how thinly the sharp edge of a diamond tool can cut a ship from the workpiece surface. This paper is to investigate the critical cutting depth, at which the dominant cutting mode changes from chip formation to burnishing or vice versa, for a given edge radius. The theoretically critical cutting depth is 0.25
$\mu\textrm{m}$ (0.8$\mu\textrm{m}$ ) in cutting using a square type(V-type) diamond tool that has edge radius of 1$\mu\textrm{m}$ (1.5$\mu\textrm{m}$ ). Experimentally, the dominant cutting mode changes and cutting surface becomes better at critical cutting depth. To get high quality surface, depth of cut must be critical cutting depth because less plastically deformed substrate is left on the surface. -
Abrasive water-jet(AWJ) machining is a new cutting technology. The AWJ can cut various materials such as metal, glass and stone. However, the AWJ machining makes troubles including kerf, rounding and side taper. In this study, we investigated the correlation between parameters of abrasive water-jet machining and cutting characteristics. The machining parameters were the material thickness and the traverse speed. The experiment was conducted to cut the stainless steel(STS41) and the mild steel(SS41) specimens. The results of the experiment were presented as the relation between cutting conditions and troubles of a dimension error, a conner error, an uncut width and a kerf.
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Ultrasonic machining technology has been developed over recent years for the manufacture of and quality-assured precision parts for several industrial application such as optics, semiconductors, aerospace, and automobile application. The past decade has seen a tremendous in the use of ceramics in structural application. The excellent thermal, chemical and wear resistance of these material can be realized because of recent improvements in the overall strength and uniformity of advanced ceramics. Ultrasonic machining, in which abrasive particles in slurry with water are presented to the work surface in the presence of an ultrasonic-vibrating tool, is process which should be of considerable interest, as its potential is not limited by the electrical or chemical characteristics of the work material, making it suitable for application to ceramics. This paper intends to further the understanding of the basic mechanism of ultrasonic machining for brittle material and ultrasonic machining of ceramics based in the fracture-mechanic concept has been analyzed.
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watches, air bearings and printed circuit hoards (PCB). However, it is not easy to determine optimum cutting conditions since the micro drilling process is very sensitive to various disturbances. Also, undesirable characteristics to optimize the micro drilling are small signal-to-noise ratios, drill wandering motions and high aspect ratios. Thus, in this study, experimental design methods are applied to determine optimum cutting conditions. Suing the methods, three cutting parameters, fred, step and curving speed are optimized to minimize thrust forces. Obtained conditions are verified through required experimental works. As the results, it is shown that the experimental methods can be applied to micro drilling processes to determine Optimum Cutting Conditions.
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In this research, the mechanism of micro-ECM was investigated with potentiodynamic method and the optimal condition for micro-ECM was selected by voltage-current-time curve with potentiostatic method. From the experimental result. it was confirmed that anodic voltage curve could be used very effectively for determining the optimal condition of micro-ECM, and the micro part which has extremely fine surface could be fabricated by use of micro-ECM with point electrode method.
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Micro-EDM is generally used far machining micro 3-D structure. For micro-EDM, first of all, micro-electrode fabrication is needed and WEDG system is proposed for tool electrode fabrication method. When tool electrode is fabricated using WEDG system, its characteristics are under the control of many EDM parameters. Also relations between the parameters affect electrode fabrication. In this study, experiments are carried out to analyze effects of EDM parameters on micro-electrode fabrication. Experimental method and analysis are used to experimental design method. Factors used in experiments are composed of applied voltage, capacitance, wire feed rate, spindle rotating speed, machining time. As a result of experiments, wire feed rate, machining time and capacitance is proportional to gap distance(material removal), the other parameters(applied voltage, spindle rotating speed) and relations between the parameters have little influence on machining.
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In industrially advanced countries, environmentally conscious machining was eagerly studied because of ecological and economical reasons. As the environmental regulations become stricter, new machining technologies which takes environmental aspects into consideration are being developed. Industry and research institutions established applications for dry, semi-dry, oil-mist and compressed cold air machining. This paper investigates the performance of new compressed cold air system for environmentally conscious machining and evaluates machinability of dry and new compressed cold air machining. A series of tests are carried out using measuring equipments under dry and compressed cold air machining.
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This paper describes a research work of developing computer-aided design of a product with bending and piercing for progressive working. An approach to the system for progressive working is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in Auto-LISP on the Auto-CAD with a personal computer and is composed of four main modules, which are input and shape treatment, flat pattern layout, strip layout, and die layout modules. The system is designed by considering several factors, such as bending sequences by fuzzy set theory, complexities of blank geometry, punch profiles, and the availability of a press equipment. Strip layout drawing generated in the strip layout module is presented in 3-D graphic forms, including bending sequences and piercing processes with punch profiles divided into for external area. The die layout module carries out die design for each process obtained from the results of the strip layout. Results obtained using the modules enable the manufacturer for progressive working of electric products to be more efficient in this field.
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The pure Ti is taken annealing process for one hour at 90
$0^{\circ}C$ . The pure Ti is sufficient for ASTM B348 Grade2. The rolling mill roll the Ti-8Ta-3Nb(wt%) which became vacuum melting in arc furnace until the length is about 45mm and the thickness is about 6.05mm. Then it is made 6mm$\times$ 6mm$\times$ 44mm by wire cutting with EDM and it is made ∮ 6mm by rough cutting with the general purpose lathe. The machining accuracy of implant parts in the dental and medical science are decided by dimension, shpe, straightness, surface roughness. It is difficult to cut for the Ti alloy. It is caused problems of straight degree and surface roughness to the Ti alloy have many cases which length is smaller than diameter in cutting. Total 24 specimens different kind of 4 alloies are used in experiment to gain a cutting property. According to the cutting velocity, cutting depth, cutting temperature, feed and clearance angle experiments are performed. Conclusively it is expected that cutting depth of 0.5mm, feed velocity of 0.07mm/rev and cutting velocity of 80m/min could make a suitable result. -
There have been many researches performed on the formability of axisymmetric or rectangular cup shapes in the deep drawing processes. But non-axisymmetric deep drawing processes rely upon empirical knowledge of experts in most cases. Especially, there have been few researches for multi-stage elliptical deep drawing processes. In this study, formability and thickness distributions of elliptical yoke products were predicted by using finite element analysis. The results of the analysis were compared with those of experiments for validity.
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Outlet of gas has been a big problem in deforming rubber or plastic in pressing mold. Air vent has been used to solve the problem, but it has weak points such as the increased cost, the increased number of process, and vent marks on the surface of a produce. In this study, the sintering method is used for making porous metal mold. Porous metal mold has many open pores, which are very small. When Porous metal mold is used for pressing mold, all process would be made short, produce cost would be down, and it would not leave vent marks on the surface of a produce. Porosity varies from sintering and pressing conditions, which are the pressure of compacting powder, the length of sintering time, sintering temperature and sintering atmosphere etc. This study will find optimized sintering temperature condition for the Porous metal mold.
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In this study, it is important that we have an understanding of the metal flow for manufacturing condenser tube in porthole die extrusion, because this need to provide for household appliances market that is expected to grow into the major market of the cooling system hereafter. Condenser tube is mainly manufactured by conform exclusion. However, this method was not satisfied a series of the needs for manufacturing condenser tube as compared with porthole die extrusion. The deforming skill recently is required high-productivity, high-accuracy and reducing lead-time, thus it is essential to substitute conform exclusion by porthole die exclusion. Porthole die extrusion has many advantages such as improvement of productivity, reduction of production cost etc. In general, the porthole die extrusion process consists of three stages(dividing, welding and forming stages). In order to obtain the detailed mechanics, to assist in the design of proper die shapes and sizes, and to improve the quality of products, porthole die extrusion should be analyzed in as non-steady state as possible during the entire process to evaluate detailed metal flow, temperature distribution, welding pressure and extrusion lead, and therm stress analysis was practiced to obtain effective stress and elastic deformation value. A analytical results provide useful information the optimal design of the porthole die for condenser tube.
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Wet wire drawing process is used to produce fine wire in the industrial field. The production of fine eire by using wet wire drawing process with appropriate dies pass schedule would be impossible without understanding of relationship between process parameters such as material properties, dies reduction, friction conditions, drawing speed etc. However, up to new, dies pass schedule of wet wire drawing process has performed by trial and error of expert. Therefore, this study investigates the relationship between process parameters quantitatively and analyzes a conventional wet wire drawing process. Using the results, the conventional pass schedule can be redesigned to reduce the wire breakage during wet wire drawing. To verily the result of this study, the wet wire drawing experiment was performed. And the results between conventional process and redesigned pass schedule were compared. As the comparison of results, the wire breakage was considerably reduced in the redesigned pass schedule more than conventional pass schedule.
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Monitoring of the drill wear and hole quality change is conducted during the drilling process. Cutting force measured by tool dynamometer is a evident feature estimating abnormal state of drilling. One major difficulty in using tool dynamometer is that the work piece must be mounted on the dynamometer, and thus the machining process is disturbed and discontinuous. Acoustic transducer do not disturb the normal machining process, and provide a relatively easy way to monitor a machining process for industrial application. For this advantage, AE signal is used to estimate the abnormal state. In this study vision system is used to detect flank wear tendency and hole quality, there are many formal factors in hole quality decision circularity, cylindricity, straightness, and so on, but these are difficult to measure in on-line monitoring. The movement of hole center and increasement of hole diameter is presented to determine hole quality As the results of this experiment, AE RMS signal and measurements by vision system are shown the similar tendency as abnormal state of drilling. And detection of the abnormal states using BPNs was achieved 96.4% reliability.
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In this paper, drill tests were carried out by modifying drill geometry for burr minimization. Final objective of this study is to develop compatible drill shape for minimization of burr formation. These experimented results with modified drill are measured with laser sensor after performing drilling with variable material. Simultaneously, the cutting force and the torque of various drill geometry have been observed with same cutting condition to judge drill stability. As a result, burr was minimized in step drill with 75
$^{\circ}$ step angle at every material. -
In this paper, grinding characteristics of cylindrical plunge grinding in 200m/sec of grinding velocity was investigated by use of vitrified CBN wheel. From the experimental result, it was convinced that grinding power is decreased 2.5times and grinding efficiency is heightened 3times more according to increasing wheel velocity 80m/sec to 200m/sec And also, be expected to improvement of surface roughness and roundness by increasing the wheel velocity.
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Environmentally conscious machining and technology have been taking more and more important position in machining process. Since cutting fluid has some impact on environment, many researches are being carried out to minimize the use of cutting fluid. It can be Increased the environmental pollution through not using coolant any more or minimizing it. In this study, the cooling effects of cutting methods using the compressed cold air, dry cutting and cutting fluid will investigate in the blade machining. In order to examine the characteristics of cutting and tool in the environmentally conscious machining, this work investigates experimentally the degree of tool wear, cutting force and characteristics of surface roughness in relation to machining conditions and cooling methods.
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Drilling process is one of the most common, yet complex operations among manufacturing processes. The performance of a drill is largely dependent upon drilling forces. Many researches focused on the effects of drill parameters on drilling forces. In this paper, the stresses occurring in drilling process are analyzed by finite element method. The analytic drilling forces considering the drill parameters and drilling conditions are used. Also, with ANSYS, geometric modeling and mesh generation of drill is performed automatically. From the study, optimal drill design and drilling condition determination may be achieved.
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In this paper, after we make high speed gear requested high precision, we got data on the sound level is Max 60,000rpm for tooth modification. We make a decision about tooth modification after predicting exactly amount of tooth interference by FEM. The purpose of this research is that modified gear is to drive under stable sound level. To accomplish its, Beam elements are used to simulate the same condition as a real gear drive by FEM. From result of simulation and experiment, if it has holes to decrease whole weight of high speed gear, it is not good effect because it has much more deformation than not.
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The wavelet transform is a popular tool for studying intermittent and localized phenomena in signals. In this study the wavelet transform of cutting force signals was conducted for the detection of a tool failure in turning process. We used the Daubechies wavelet analyzing function to detect a sudden change in cutting signal level. A preliminary stepped workpiece which had intentionally a hard condition was cut by the inserted cermet tool and a tool dynamometer obtained cutting force signals. From the results of the wavelet transform, the obtained signals were divided into approximation terms and detailed terms. At tool failure, the approximation signals were suddenly increased and the detailed signals were extremely oscillated just before tool failure.
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Fused deposition modelling(FDM) is a rapid prototyping(RP) process that fabricates part layer by layer by deposition of molten thermoplastic material extrude from a nozzle. RP system has many benefit. One of the benefit would be the ability to experiment with physical objects of any complexity in a relatively short period of time. But it has a matter of surface roughness and geometric accuracy. We study on Influence of tangent line angle on surface roughness at fused deposition