Proceedings of the Korean Society of Precision Engineering Conference (한국정밀공학회:학술대회논문집)
Korean Society for Precision Engineering
- Semi Annual
- /
- 2005-8446(pISSN)
Domain
- Machinery > Precision Machines
2006.05a
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Actuator arm of HDD were machined with the slitting saw of tungsten carbide to clarify the cutting characteristics in terms of the roughness of machined surface, the burr size and the tool wear. An improved performance in all view of the surface machined, the tool life and the cutting efficiency was obtained at the cutting speed of 4,000rpm with the feed of 300m/min. The tool life increases with increasing the t/T value, whereas surface roughness decreases. The tool with alternate type of B and C edges has an effect to decrease the burr size.
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The quality of tool material is very important factor in machining evaluation. The characteristics of tungsten carbide, such as grain size and hardness, and density are depending on the variation of Co composition and WC size. In this study, the non-coated end mill which is made of ultra-fine tungsten carbide is investigated by measuring tool wear and tool lift test. The machining test is conducted with high hardened workpiece under high-speed cutting condition.
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In-process surface roughness prediction is studied in this research. To implement in-process prediction, spindle displacement is introduced. Machined surface's roughness is assumed to be expressed in terms of spindle displacement. In-process measurement of spindle displacement is conducted using CCDS (cylindrical capacitive displacement sensor). Two prediction models are developed. One is simple linear model between measured surface roughness and values by spindle displacement. The other is multiple regression model including machining parameters like spindle speed, fee rate and radial depth of cut. Relation between machined surface roughness and roughness by spindle displacement are verified.
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Laser welding of metals has been widely used to improve a wear resistance and a corrosion resistance of the industrial parts. The objective of this research works is to investigate the influence of the process parameters, such as the welding for metals with CW Nd:YAG lasers. The bead-on-plate welding tests are carried out for several combinations of the experimental conditions. In order to quantitatively examine the characteristics of the butt welding, the welding quality of the cut section, stain-stress behavior and the hardness of the welded part are investigated. From the results of the investigation, it has been shown that the optimal welding condition without defects in the vicinity of the welded area and with a good welding quality is 1400W of the laser power, 0.8m/min, 0.9m/min of welding speed and
$4{\ell}$ in of pressure for shielding gas. -
As the Mobile and Display technology are being developed quickly, new wireless devices are released in great numbers. They reduce existing devices' life time and demand a reduction of developing period of portable devices. With these demands, existing film cutting mold used many films of portable devices, especially LCD Display, needs to be more precise, and cheaper. In this research, we have analyzed machining characteristics of cutter shapes, materials, and cutting conditions for application to other films. Cutter edge was machined by slot cutting method and CAD program to select the cutter shape and cutter angle. Also, we have determined the optimal cutting conditions using high speed machining experiments to improve the productivity.
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We present a dispersive scheme of white-light interferometry that enables not only to perform tomographical measurements of thin-film layers but also to measure a refractive index without mechanical depth scanning. The interferometry is found useful particularly for in-situ 3-D inspection of micro-engineered surfaces such as liquid crystal displays, semi-conductor and MEMS structure, which requires for high-speed implementation of 3-D surface metrology.
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Absolute position measurement by lateral shearing interferometry of point-diffracted spherical wavesThe method measuring the absolute position of a point diffraction source emitting a spherical wavefront in three-dimension is proposed. Two-dimensional interference of spherical wavefronts is used to overcome ambiguity of phase order. The spherical wavefront is explicated by Taylor series expansion, from which a radius of curvature of a spherical wavefront and its center position in three-dimension are obtainable. The spherical wavefront is reconstructed by a modified lateral shearing interferometer, which uses single-mode fiber as a point diffraction source.
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This study performs to investigate deformation of wall thinning pipe and to find out the position of the internal thinning defect by shearography. Shearography is one of optical methods those have applied to nondestructive testing (NDT) and the strain/stress analysis. This technique has the merit of the directly measuring the first derivative of displacement, sensitivity of which can be adjusted by the handling of optical component in interferometer. In this paper, we tested carbon steel pipe locally wall thinned and loaded internal pressure and developed the nondestructive out-of-plane deformation analysis technique fur internal thinning defect of elbow by shearography. From the results, it was confirmed that this technique is proper to the practical application on the pipe line system with internal defect.
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The interior noise of KTX in tunnel has become an issue since the commercial operating in April 2004. The analysis of the interior noise of KTX in tunnel with concrete track shows sharply increased noise level in the range of 80Hz that is the natural frequency of the KTX carbody. We know that the booming noise inside KTX in tunnel with concrete track is generated by noise outside gangway and rolling noise at the carbody natural frequency. In this Study noise reduction methods are discussed on the basis of the comparison of the KTX and KHST noise characteristics. Alternatively, the effect of the modified mud-flap on the interior noise is introduced.
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A signal conditioning circuit for capacitive sensors was developed using a commercial single chip solution. Since capacitive displacement sensors can achieve high resolution and linearity, they have been widely used as precision sensors within the range of several hundred micrometers. However, they inherently have a limitation in low frequency range and some nonlinearity characteristics and so a specially designed signal conditioning circuit is needed to handle these properties. Up to now, several companies already have succeeded in the development of the capacitive sensors system and they are commercially available in the market. In this research, to construct the signal processing circuits more easily and simply, we used a universal LVDT signal conditioner (AD698). Since the AD698 provides one chip solution for a basic signal processing including modulation and demodulation using various internal components, we can build the processing circuits successfully with minimal additional circuits: a compensation circuits for the drift caused by the bias current of OP amplifiers and a fine adjustment circuit for the elimination of nonlinearity. The signal processing circuits shows nonlinearity less than 0.05% in the comparison with a laser interferometer.
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The most bottleneck of development of automation excavator system is the making mathematical linear model. Because of non-linear of control circuit, cylinder, join in hydraulic circuit, and heavy loading so on. Therefore, whatever robust controller is designed, real experimentation is necessary. But, a real experimentation has many risks. The excavator is expensive and large size. Therefore a development of experimentation system is difficult and not safe. Specially, there have a difficulty, because of big noise. So, on experimentation is difficult in school. Manufacturing pneumatic excavator modeland using system identification, design a system transfer function in this paper. Also, planning m-PID Controller using CDM, and examining usefulness applied to actuality model.
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In Nd:YAG laser welding, evaluation methods of welding flaw are various. But, the method due to fume shape is difficult to classification of welding flaw. The Nd:YAG laser process is known to have high speed and deep penetration capability to become one of the most advanced welding technologies. At the present time, some methods are studied for measurement of fume shape by using high-speed camera and photo diode. This paper describes the machining characteristics of SM45C carbon steel welding by use of an Nd:YAG laser. In spite of its good mechanical characteristics, SM45C carbon steel has a high carbon contents and suffers a limitation in the industrial application due to the poor welding properties. In this study, fume shape was measured by infrared thermal camera that is non-contact/non-destructive thermal measurement equipment through change of laser generating power, speed, focus. Weld was performed on bead-on method. Measurement results are compared as two equipments. Here, two results are composed of measurement results of fume quantities due to fume shape by infrared thermal camera and inspection results of weld bead include weld flaws by ultrasonic inspector.
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In this paper, power distribution module for car relay control with Control area network is developed. This module is called Intelligent power distribution module because it has microprossor which can communicate with other electric module such as ECU and Body control module and also has self-diagonasis function. The developed IPDM module is tested on vehicle and the good performance has been achieved.
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The operation of wheel-loader is mainly divided into steering and excavating. The existing wheel-loader is used by handle for steering operation and by joystic for excavating operation. When we do steering and excavating operation simultaneously, we feel so uncomfortable because we have to use handle and joystic simultaneously. Therefore, we need to develop eletro-joystic steering system instead of hydraulic-handle steering system. So we can improve driving convenience in industrial field. This paper analyze spool of steering wheel and joystic and drive open area diagram. As a result, we can know characteristics of each valve before developing new electro-joystic steering system for wheel-loader.
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The important factor to evaluate the running safety of a railway vehicle would be the interaction force between wheel and rail(derailment coefficient), for which is one of important factors to check the running safety of a railway vehicle that may cause a tragic accident. In this paper, analysis of coupling term between vertical load and lateral load for install load cell to wheel-set. This result is going to be utilized in formality that verify running safety of tilting vehicles.
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The performance of the direct adaptive time-delay filter depends on the select time-delay. In this paper, the authors introduce a new scheme to adapt the time-delay which is to be used in conjunction with the direct adaptive command shaping for the improved vibration suppression in flexible motion system. In order to formulate the time-delay adaptation scheme, the authors have analyzed the effect of the time-delay value on the performance of the direct adaptive command shaping filter. By modifying the direct adaptation formula based on the analysis result the authors have established a set of equations to adapt the time-delay toward the optimal value. Simulation results show the effectiveness of the proposed time-delay adaptation approach for the improved vibration suppression.
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In this paper, a dual stage servo mechanism has been developed for image tracking system to improve transient control performances such as small rise time, small overshoot, small settling time, etc. A secondary stage, a platform, actuated by a pair of electro-magnets is mounted on a conventional elevation gimbal. In this mechanism, the gimbal provides large range but slow motion and the platform provides small range but fast positioning. A sliding mode control is applied to the platform positioning to attain robust performances and stability in the presence of the disturbance related to dynamic coupling of the gimbal and the platform. Results from experiments illustrate that the suggested dual stage mechanism controlled by the sliding mode control is effective in improving transient responses and attenuating the disturbance related with dynamic coupling.
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A roughness measuring system which comprises an integrating sphere and a stabilized laser has been fabricated with the aim of measuring the roughness correction value which is necessary in gauge block measurement by optical interferometry. To calibrate the system, a Newton's ring interferometer has been introduced. The method how to calibrate the roughness measurement system has been described.
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Photoelasticity is widely and conveniently used methods for whole field stress analysis. In this paper, 8-step photoelastic phase shifting method was performed by using a multi-purpose polariscope to measure the fringe orders along a specified line on the specimen containing a square hole. The material of the specimen is made of Polycarbonate. The measurement results by 8-step phase shifting method were compared with the those calculated by ABAQUS.
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Gabion can be used for the purpose of preventing overflow of river and side loss of road. However the manufacturing process of the gabion is manually controlled especially to the joining process at the terminal part of gabion with small diameter wire. In this paper automatic feeding guide system was designed and fabricated to make automation. The fabricated system was tested in the factory level. Pneumatic system was considered as the main idea of the feeding system. 3/2-way and 5/2-way manual control valve, eight double-acting cylinders were used. Based on the theoretical simulation and actual test the fabricated system was well controlled. The system was applied to the patent.
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The main purpose of tunnel ventilation system is to maintain CO pollutant and VI (visibility index) under an adequate level to provide drivers with safe driving condition. Moreover, it is necessary to minimize power consumption used to operate ventilation system. To achieve the objectives, the control algorithm used in this research is reinforcement teaming (RL) method. RL is a goal-directed teaming of a mapping from situations to actions. The goal of RL is to maximize a reward which is an evaluative feedback from the environment. Constructing the reward of the tunnel ventilation system, two objectives listed above are included. RL algorithm based on actor-critic architecture and natural gradient method is adopted to the system. Also, the recursive least-squares (RLS) is employed to the learning process to improve the efficiency of the use of data. The simulation results performed with real data collected from existing tunnel are provided in this paper. It is confirmed that with the suggested controller, the pollutant level inside the tunnel was well maintained under allowable limit and the performance of energy consumption was improved compared to conventional control scheme.
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This paper describes a new concept of the robot that can climb on the vertical plane. The engineering design problem of the main structure is presented and the experimental results regarding a new mechanism of climbing on the vertical wall are discussed. The locomotive motion of the robot is realized by using a series chain of two caterpillar wheels on which 24-suction pads are installed. White each caterpillar wheel rotates on the vertical plane surface, the vacuum pads are activated in sequence based on the sequential opening by specially designed mechanical valves. The detail design feature of the valve is also described in this paper. The overall size of the robot is around 460 mm in width and length, respectively, and 200 mm in height. Its mass is slightly over 14 kg. The main mechanical structure of the robot consists of driving motors, vacuum caterpillar system, steering part, vacuum pump and battery. The performance of the robot is verified on the vertical wall.
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A Simulation model is developed to minimize the path tracking errors when the non-circular cutting is done by a VCM(voice coil motor) driven tool. The relationship between PWM(Pulse Width Modulation) duty ratio and velocity of voice coil motor is theoretically derived from combining the circuit equation for the coils and the motion equation for the magnetic rod of the voice coil motor. The path tracking errors are showed differently according to the rotational speed, the number of segments and the control period in digital control. Given a required accuracy in the non-circular cutting, the optimal values for those parameters are determined based on the developed simulation model.
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It is bringing out the importance of automated LCD testing equipment that satisfy a definite quality, confidence and testing speed, as LCD enterprises are recently expanding the production and facility investment in proportion to the sudden increase of LCD demand. So far, LCD inspection is however conducted by manual, or the confidence of existing testing equipment falls short of LCD enterprises's standard. It is therefore important to develop the testing equipment that determines the quality of product for production of an excellent LCD.
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A new neural network classifier is proposed for the automatic real-time surface inspection of high-speed cold steel strips having 11 different types of defects. 46 geometrical and gray-level features are extracted for the defect classification. 3241 samples of Posco's Kwangyang steel factory are used for training and testing the neural network classifier. The developed classifier produces plausible 15% error rate which is much better than 20-30% error rate of human vision inspection adopted in most of domestic steel factories.
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In this paper, design modification was performed to improve the structure of ex-developed 12 D.O.F Biped walking robot, KUBIR-1 similar with human beings. The motion of KUBIR-1 was slow and had a limited walking space. Hence I designed an improved BWR named KUBIR-2 with 12 degree of freedom. KUBIR-2 was designed to solve the following problems of KUBIR-1. First, KUBIR-2 was more simply designed in the four-bar-link mechanism, and its weight was reduced. Second, it had the built-in controller and motor driver. Third, walking velocity of KUBIR-2 was increased by improvement of speed and motion joint angle range. In addition to these, we modified the structure of the foot for more stable walking.
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Dancer systems are most widely used mechanism for attenuation of tension disturbances. Lately, demands fur high speed converting machines over 500mpm(m/min) are raising but domestic converting industries can not come up with the machines because capacities for a designing of the converting machine are restricted lower than 300mpm. Moreover roll-to-roll is attracted flexible display manufacturer's attention as a effective method for productivity. A constant tension level in the span before the first printing cylinder is the key of high speed quality printing. This paper presents a modeling and simulations of dancer systems on converting machines.
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In this paper, a new revolute cooperating robot arms with 12 d.o.f was developed for autonomous moving robots. The robot ann was designed to have the load capacity of 10 Kg. For this, a new joint actuator based on the fourbar link mechanism was employed. As a control system for the robot arm, a distributed control system was developed composed of the main controller and five motor controller for the ann joints. The main controller and the motor controller were developed using the ARM microprocessor and the TMS320c2407 processor, respectively. To validate the performance of the robot system, an experiment to support 10 Kg payload was performed.
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Waste vinyl tretreatment system has been developed by the joint project between KIMM and Woosung Co. General process for removal of impurities from waste vinyl is consisted of feeding, separating, cutting, washing, drying and recovering impurities. However, there are problems such as wastewater when washing of waste vinyl. In order to solve these problems we have developed new dry type cleaning system.
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In this study, automatic assembly and evaluation system fer phone camera module is conceptually designed. The designed core(Auto focus & UV curing, Image Test) equipments adopts a clustering mechanism and compactible structure using index table for minimum tact time. Using a ball screw actuator and absolute encoder in each axis, we can verifies the repeatability and position accuracy of system within
${\pm}3{\mu}m$ . In result of simulation test, the proposed system is expected up to 30% in productivity than manual operation. -
Design repository is considered an effective method to manage a set of heterogeneous design knowledge. In this paper, methodologies for modeling and managing different types of design knowledge - ontology for mold design task as well as mold components, rule bases, and library containing standard parts, material property, molding condition, etc. - in a design repository are described.
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LCD-BLU (Liquid Crystal Display - Back Light Unit) is one of kernel parts of LCD unit and it consists of several optical sheets(such as prism, diffuser and protector sheets), LCP (Light Guide Plate), light source (CCFL or LED) and mold frame. The LGP of LCD-BLU is usually manufactured by forming numerous dots with
$50{\sim}200{\mu}m$ in diameter on it by erosion method. But the surface of the erosion dots of LGP is very rough due to the characteristics of the erosion process during the mold fabrication, so that its light loss is high along with the dispersion of light into the surface. Accordingly, there is a limit in raising the luminance of LCD-BLU. In order to overcome the limit of current dot patterned LGP, optical pattern design with$50{\mu}m$ micro-lens was applied in the present study. Especially, the negative and positive micro-lens pattern fabricated by modified LiGA with thermal reflow process was applied to the optical design of LGP. The attention was paid to the effects of different pattern conditions to the brightness distribution of BLU with micro-lens patterned LGP. Finally, negative micro-lens patterned LGP showed superior results to the one made by positive in average luminance. -
Post industrial technologies have improved human standard of living, however, a host of negative environmental consequences from the unlimited industrial appetite have posed serious global challenges. Remanufacturing is an industrial manufacturing process that is to restore old products to perform like a new and to save energy, natural resources, landfill space and to reduce air pollution by less re-smelting. By extending product life cycle, remanufacturing gives us enormous opportunities for sustainable development of our society. This paper introduces current state of the art and future perspective in the field of automotive remanufacturing focusing on alternator and start motor. The results could be used as a basic information for further remanufacturing applications in Korea.
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In order to raise productivity of the OLED and realization of the OLED TV, it is required to improve the design of the board size glass panel. The large-size glass substrate has some difficulties regarding its deflection during handling operation due to its small thickness (0.7t) which is not even enough to stand its mass itself. This paper is demonstrating a new solution of this difficult through clamping and bending end condition, which helps to minimize the deflection of the glass substrate.
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Conveyor-type transporters have been widely used as a typical delivery system of semi-conductor, FPD and other IT-related products. However, as the IT-product is getting larger in size and higher in resolution, several problems are caused by mechanical contacts between the transporter and target object. In this context, recently, lots of efforts are being devoted for development of various contact-free handling systems to get rid of deffets and oil contaminations. The objectives of this paper are to characterize suspension mechanisms and to investigate air flow effects on air levitation transport system. For this purpose, a series of CFD analyses were carried out and the simulation data showed a good agreement with the corresponding experimental ones. It is anticipated that the promising result can be used as a basis for concept design of the transport system.
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Due to the capability of net shaping for complex 3D geometry, powder injection molding (PIM) is widely used for automotive parts, electronics and medical industry. In this study, an ultrasonic dental scaler tip produced by machining process was redesigned for the PIM process. An injection mold was designed and manufactured to produce the dental scaler tip by the PIM process.
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It presented the approach method for the station braking noise present condition and a braking noise reduction plan escape of the KTX train. The research which it sees the technical ground it will be able to accomplish the station braking noise reduction of the KTX vehicle with base the questing matter where the escape one thing is big there is a possibility of doing.
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The phase transformation behaviors of Ni-Ti shape memory alloys were investigated through a DSC(Differential Scanning Calorimetry). The annealing temperatures were applied from
$600^{\circ}C,\;700^{\circ}C,\;800^{\circ}C,\;and\;900^{\circ}C$ for their effects on the phase transformation behaviors. Based on the results of DSC, phase transformation behaviors of shape memory alloys can be predicted by Liang's phase transformation model or Tanaka's phase transformation model. -
The bipolar plate is a major component of the PEM fuel cell stack, which takes a large portion of stack cost. In this study, as alternative materials fur bipolar plate of PEM fuel cells, graphite composites were fabricated by compression molding. Graphite particles mixed with epoxy resin were used as the main substance to provide electric conductivity. Flow channels were fabricated by compression molding, and design of experiments (DOE) was applied to the tests to evaluate moldability. Results showed that land width and channel depth were two significant factors for moldability, and channel width had little influence on the moldability.
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High precision speed reducer which has a cycloid or involute teeth profile, used to in Robot. In this study, suggest to a new teeth profile, which has basically a triangle teeth profile. We had a stress analysis compare to convenient speed reducer for teeth profile. We has a good results in new teeth profile for strength, stress and stiffness.
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This paper presents the mechanics of the link of a double-action link-type hydraulic die set for the enclosed die forging. The force exerted on the link is statically investigated and its structural analysis is carried out.
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This study examined the effects of the tempering temperatures(
$360-420^{\circ}C$ ) on the mechanical properties of the carbon tool steel (SK4M) for flat spring. Hardness test, tensile test and fatigue test were performed at room temperature($20^{\circ}C$ ). The tensile strength and yield strength of$390^{\circ}C\;and\;420^{\circ}C$ tempered SK5M were 0.93-0.97 times and 0.81-0.87 times those of$360^{\circ}C$ tempered SK5M, respectively. The fatigue limit of$360-420^{\circ}C$ tempered SK5M were 35-40% of tensile strength of$360-420^{\circ}C$ tempered SK5M, respectively. -
This study deals with the Transmission Error of gear tooth profile by modifying a Profile and lead of a surface of Tooth. First, we experimentally confirmed that the Transmission Error is a synthesis of the sliding Velocity between both gears. Since various types of Transmission errors appear in the experiments, we introduced definition of Transmission Error and The Optimism Design by modifying a surface parameters The test stand's performance is then evaluated through a series of multiple torque transmission error tests. Comparisons are made between data recorded before and after the test stand's redesign, and subsequently repeatability studies are performed to verify the veracity of the measured data. Finally, the experimental results are compared to the analytical predictions of two different gear analysis programs.
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Cold gas dynamic spray or cold-spray is a deposition process, which causes deformation of a thin substrate. The deformation is usually convex to the deposited side. In this research, the main cause of the deformation was investigated using 6061-T6 aluminum alloy. The effects or anisotropic coefficient or thermal expansion (CTE) or the deposited layer by cold-spray and residual stress were studied by experiments and finite element analysis. The Hole Drilling method was applied to measure residual stress in the cold-spray layer and substrate. The data obtained by the experiments were used for the analysis of substrate deformation. From the result of the analysis, it was concluded that compressive residual stress was the main reason of substrate deformation while CTE had little effect.
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The purpose of this paper is pulsation-analysis of the swash plate type axial piston pump for excavator and the method of side branch hose application, which is used normally in construction equipments. In this paper, draw the mathematical modeling for pressure pulsation mechanism of the swash plate type axial piston pump for excavator, expression the flow pulsation in the pipelines by transfer matrix method, programmed simulation for pulsation by AMEsim software, and the reliability of that was verified by the comparison with the experimental results.
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Wear of valve seating face and seat insert seating face influence the performance of engine, so they are important. To manufacture good quality valve and seat insert which have wear resistance the relations between wear factors and wear of the two seating faces have to be inspected. Cycle number is one of the important wear factors wearing the two seating faces and it can translate into mileage in rear car. But little is blown. Test variable is only cycle number and the cycle numbers are
$2.0{\times}10^6,\;4.0{\times}10^6\;6.0{\times}10^6,\;8.0{\times}10^6$ . And the other test conditions were fixed. Rmax of valve seating face and seat insert seating face increase linearly as cycle number is increased. Rmax of valve seating face were smaller than seat insert seating face in each cycle number. Reaction production by tribological reaction and sliding wear was found on the two faces. -
The creep properties have been evaluated for type 316LN stainless steel welded by the SAW method. The creep tests were conducted with different stress levels for both the base and weld metals at
$550^{\circ}C\;and\;600^{\circ}C$ . The results of the creep-rupture time of the weld metal did not show a large difference when compared to those of the base one, though it exhibited a little lower value at$600^{\circ}C$ . The creep rate of the weld metal was lower than that of the base one at the same stress and rupture-time conditions. The creep-rupture ductility of the weld metal is found to be decreased by about 60%, compared to the base one. This is due to the decreasing of tensile elongation and the increasing of the yield stress in the weld metals. -
This paper shows the design optimization of the paper feeding mechanism under dynamic behavior by using commercial codes of RecurDyn/MTT2D and RecurDyn/AutoDesign which are developed by functionBay, Inc. A virtual mockup for dynamics analysis of the paper feeding mechanism is build on RecurDyn/MTT2D and is simulated. Flexible paper is represented as a series of rigid bars connected by revolute joints and rotational spring dampers. Paper is fed by a contact and friction mechanism on rollers or guides. The slip of the paper and nip force of rollers are measured to estimate the system performance. After a simulation, these performances are automatically send to RecurDyn/AutoDesign which is a sequential approximate optimization tool based on the response surface modeling. RecurDyn/AutoDesign makes the approximate objective function and computes the optimized design points of the design variables and gives them to analysis tool. And then the simulation is repeated with the updated design variables. These processes are repeated until finding a tolerable design optimization. In this paper, a paper feeding mechanism is introduced and it is optimized with the proposed algorithms.
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Various parametric methods, Larson-Miller (L-M), Orr-Sherby-Dorn (O-S-D), Manson-Haferd (M-H) parameters, and minimum commitment method (MCM), were used to predict longer rupture time from short-term creep data. A number of the creep data were collected through literature surveys and experimental data produced in KAERI for predicting the creep type of type 316LN SS. Polynomial equations for predicting the creep life were obtained by the time-temperature parameters (TTP) and the MCM. standard error (SE) and standard error or mean (SEM) values were compared for the each method with temperatures. The TTP methods were good in the creep-life prediction, but the MCM was much superior to the TTP ones at
$700^{\circ}C\;and\;750^{\circ}C$ . The MCM was found to be lower in the SE values compared to the TTP methods -
A new MR cylinder with built-in valves using Magneto - Rheological fluid (MR valve) is proposed for fluid power control systems. The MR fluid is a newly developed functional fluid whose obvious viscosity is controlled by the applied magnetic field intensity. This MR cylinder, which is composed of cylinder with small clearance and piston with electromagnet, has the characteristics of simple, compact and reliable structure. This paper presents a method to control the pressure of MR cylinder by using Generalized Predictive Control (GPC) algorithm. The differential pressure is controlled by applying magnetic field intensity to MR fluid. The use of GPC controller is to generate a control sequence by minimizing a cost function in such a way that the future system output is driven close to reference over finite prediction horizons. Experimental results from real time control using GPC method compared with conventional PID control method are also shown in this paper.
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Vibration of a non-linear system under random excitations was evaluated by probabilistic methods. The non-linear characteristic terms of a system structure were quasi-linearized and excitation terms were remained as they were. An analytical method where the square mean of error was minimized was used. An alternative method was an energy method where the damping energy and restoring energy of the linearized system were equalized to those of the original non-linear system. The numerical results were compared with those obtained by Monte Carlo simulation. The comparison showed the results obtained by Monte Carlo simulation located between those by the analytical method and those by the energy method.
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In these days, almost urban railway vehicle has been serviced under the random load application. But it is very important that fatigue lift prediction fur structures is major factor of safety. So do this, it is required that fatigue assessment method for cumulative damage approach while Korea domestic regulations only has endurance limit approach. With this endurance limit approach, fatigue lift prediction is impossible. In this research, it will be present that fatigue assessment for urban transit structure by using of cumulative damage approach method and related theories.
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The objective of this paper is to investigate into bending and failure characteristics of ISB panel with dimple shapes as inner structures. Through three-points bending test, the force-displacement curve and the failure shape are obtained to examine the deformation pattern, characteristic data including maximum load and displacement at the maximum load and failure pattern for the ISB panel. In addition, the influence of design parameters for ISB panel on the bending stiffness and failure mode has been found. From the results of the experiments, it has been shown that bending and failure characteristics of the ISB panel can be controlled by the ratio of radius and the direction of the material.
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Prioritizing the design specifications among many alternatives is necessary at the stage of concept design. Design specifications have trade-offs between cost and performance, and the relationships among them, in the standpoint of various functional requirements, are complex. AHP(Analytic Hierarchy Process) method is one of the most popular ways of solving the priority setting problem. However, it is impossible to monitor the interim findings in the middle of the process, it is hard to predict the difference when changing pairwise comparison conditions, and the operation done by one person makes it hard to share the process simultaneously. This paper shows a new method of priority setting in this kind of decision making problem. This method is designed to support the realtime priority setting among many design specifications with regards to many functional requirements. A new algorithm and visualization methods are introduced, and the usability is verified in an exemplary concept design stage.
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In the case of mechanical control systems, it is highly useful to be able to provide a compact model of the mechanical system to control engineers using the smallest number of variables, while still providing an accurate model. The reduced mechanical model can then be inserted into the complete mechanical control system models and used for system-level dynamic simulation. In this paper, a moment-matching based model order reduction (MOR) which reduces the number of degrees of freedom of an original finite element model via the Arnoldi process is considered to study the dynamic responses of a HDD actuator and suspension system.
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Usually, hydraulic cylinder is widely used as the actuator in the equipment of construction machines, airplane and military machines. In case of these devices, due to use under severe environment such as water,
$SiO^2$ and dust, etc. seal which has high packing ability and long service life has been required. These characteristics are largely influenced by material and geometries of seal such as approach angle, withdrawal angle and interference. Recently, many a study about seal material has been performed so that many materials have been developed. But the concrete studies including the relationships between geometry of seal and sealing performance have hardly been performed yet. Therefore, in this study, we predicted the deformation behavior and contact normal distribution of dust seal with the variation of geometries of seal lip using finite element analysis. And based on the results of analyses, we discussed the effects of the design variables fur sealing performance of the dust seal. -
The characteristics of the tool system give many effects into the costs and qualities for the finished components. Therefore, a tool life is one of the important issues on cold forging industry. However, since variables related with tool life are many complicated, the studies for solution should be investigated by the systematic research approach. In this study, heat-treatment of tool material is investigated to improve the tool life. Deep cryogenic treatment of tool steel is very efficient to improve the wear resistance due to the fine carbide. And, it is investigated that the shape and dimension of tool give effect into both tool life and quality of forged product.
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We introduce a novel approach for generating constant scallop height tool paths. We derive a Riemannian metric tensor from curvature tensors of a part surface and a tool surface. Then, we construct geodesic parallels from the newly constructed metric. Those geodesic parallels constitute an asymptotically-correct family of constant scallop height tool paths.
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This paper presents a study on the effect of feedrate changes on the fatigue life of Al 7075-T6 specimens before and after shotpeening. For this purpose. five groups of specimens, each of which consists of eight specimens, were first machined at five different feedrates (0.05, 0.10, 0.15, 0.20 0.25 mm/rev). Half of eight specimens in each group were then peened and the others remained un-peened Finally, the fatigue life of each specimen was measured by using 4-point rotatry bending machine. Comparison of fatigue life among ten sets of specimens is presented.
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This paper presents a micro-positioning platform based on the unique parallel mechanism recently developed by the authors. The platform has a meso-scale rectangular shape whose size is
$20{\times}23m$ . The stroke is 5 mm for both the x- and y-axis and 100 degrees for the${\alpha}$ -axis(the rotational axis along the x-axis). The platform is actuated by the three sets of two-stage linear actuators: a linear motor for rough positioning and a piezo actuator for fine positioning. The platform is already assembled. Experimental results of the positioning measurements and control performance are presented. -
A cylindrical capacitive displacement sensor (CCS) was developed and applied for monitoring end milling processes. Dynamic characteristics of a spindle-assembly were measured using the CCS and a designed magnetic exciter. The technique to extract the spindle displacement component caused only by cutting from the measured signals using the CCS was proposed in the paper. Using CCS signals and FRF (Frequency Response Function) derived from dynamics of the spindle tool system, dynamic cutting forces are estimated quantitatively.
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A precise linear motion stage supported by magnetically preloaded air bearings is introduced where preloading magnetic actuators are combined with permanent magnets and coils to adjust air bearing clearance by controlling magnetic force actively. Each of the magnetic actuators has a permanent magnet generating nominal magnetic flux for required preload and a coil to perturb the magnetic force resulting adjustment of air-bearing clearance. The characteristics of porous aerostatic bearing are analyzed by numerical analysis, and analytic magnetic circuit model is driven for magnetic actuator to calculate nominal preload and variation of force due to current. A 1-axis linear stage motorized with a coreless linear motor and a linear encoder is built for verifying this design concept. With the active magnetic preloading actuators controlled with DSP board and PWM power amplifiers, the active on-line adjusting tests about the vertical, pitching and rolling motion were performed, and the result shows very good linearity.
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This paper proposes a controller design analysis for three-axis CNC systems considering both contouring and tracking performance. The proposed analysis inclusively combines axial controllers for each individual feed drive system together with cross-coupling controller at the beginning design stage as an integrated manner. These two controllers used to be separately designed and analyzed since they have different control objectives. The proposed scheme includes a stability analysis for the overall control system and a performance analysis in terms of contouring and tracking accuracy. Computer simulation is performed and the results show the validity of the proposed methodology.
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This paper proposes the Embedded Linux System that can overcome the shortcomings of conventional CNC machine system. Linux is free of charge with the open source library and tools that can be used in the development of Kernel. Besides, Application is easily available through countless open source, allowing simple mending for seamless porting. This study have developed the study about NC Program automation Load System based on Embedded Linux and the ordered controller.
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This paper describes estimation method for 2D position error of planar XY stage from measured profiles of guide-ways. The XY stage usually moves along its guide ways. The motion error of each stage has effect on 2D position errors of XY stages and affected mainly by profiles of guide-ways. To estimate 2D position error and flatness of stages, the profiles of guide-ways were measured and used in motion error estimation.
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In this paper, we proposed XP KMPR-1050 negative tone resist to replace SU-8 resist for multi-layer micro-structures and thick plating mold fabrication using UV-LIGA process. XP KMPR resist proposed in this paper can be easily striped using a common stripping solution such as NMP without damage of micro-structure. The conditions for the fabrication of XP KMPR micro-structure were optimized by adjustment of exposure and post-exposure bake(PEB). The
$140{\mu}m$ -thick and an aspect ratio at least 10 micro-structure and multi-layer structures were successfully fabricated through the process conditions. Through-mold electroplating and PR striping of XP KMPR has been successfully demonstrated. -
A fluorine-doped diamond-like carbon (F-DLC) stamp which has high contact angle, high UV-transmittance and sufficient hardness, was fabricated using the following direct etching method: F-DLC is deposited on a quartz substrate using DC and RF magnetron sputtering, PMMA is spin coated and patterned using e-beam lithography and finally, O2 plasma etching is performed to transfer the line patterns having 100 nm line width, 100 nm line space and 70 nm line depth on F-DLC. The optimum fluorine concentration was determined after performing several pre-experiments. The stamp was applied successfully to UV-NIL without being coated with an anti-adhesion layer.
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A research on scaffold fabrication has been progressed in many research groups. However, the mechanical properties of existing biodegradable materials are still not satisfactory. But, PPF (poly (propylene fumarate)) has a good mechanical property in comparison to other biodegradable materials. Nevertheless, the viscosity of the synthesized PPF is too high to fabricate structures using micro-stereolithography. Therefore, the viscosity of the resin was made low by adding the diethyl fumarate and this material could be used in micro-stereolithography apparatus. Then, a photoinitiator was added for photo crosslinking of the DEF/PPF resin. 2.5D and 3D scaffolds were fabricated our system and curing characteristics of the resin were analyzed through the experiment.
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We describe a novel method of scanning probe nanofabrication using a AFM(atomic force microscopy) tip with assistance of Femtosecond laser pulses to enhance fabrication capability. Illumination of the AFM tip with ultra-short light pulses induces a strong electric field between the tip and the metal surface, which allows removing metal atoms from the surface by means of field evaporation. Quantum simulation reveals that the field evaporation is triggered even en air when the induced electric field reaches the level of a few volts per angstrom, which is low enough to avoid unwanted thermal damages on most metal surfaces. For experimental validation, a Ti: sapphire Femtosecond pulse laser with 10 fs pulse duration at 800 nm center wavelength was used with a tip coated with gold to fabricate nanostructures on a thin film gold surface. Experimental results demonstrate that fine structures with critical dimensions less than
${\sim}10nm$ can be successfully made with precise control of the repetition rate of Femtosecond laser pulses. -
Nowadays, great attention has been shown to the question of ultrasonic linear motor for accomplishing the high positioning accuracy and high driving force in the semiconductor and optical industry. Ultrasonic linear motors have many advantages such as simple structure, quick response, ability to maintain position without energy consumption, and electromagnetic effect. And BLT has attracted attention to accomplish large vibration amplitude and large mechanical force. Authors designed and developed the new type of ultra sonic linear motor with multi support mechanism, achieved 75N of output force and 0.45m/s of velocity.
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Development of sorting machine for photo diode and its control system is addressed. The sorting machine for optical communication device requires high positional precision because the alignment is one of the most important point in the sorting process. This sorting method describes how to detect the target chip's angle and position from the wafer. The machine vision system is used for the feedback control. This sorting machine is implemented by motion controller, machine vision and various solenoid valve and is interfaced with RS-232c, GPIB and PCI communication. This system gets the position accuracy within
$1{\mu}m$ with our experiments. -
UV-NIL is a promising technology for the fabrication of sub-100 nm features. Due to non-uniformity of the residual layer thickness (RLT) and a strong possibility of defects, many UV-NIL processes have been developed and some are commercially available at present, most are based on the 'step-and-repeat' nanoimprint technique, which employs a small-area stamp, much smaller than the substrate. This is mainly because, when a large-area stamp is used, it is difficult to obtain acceptable uniform residual layer thickness and/or to avoid defects such as air entrapment. As an attempt to enable UV_NIL with a large-area stamp for high throughput, we propose a new UV-NIL tool that is able to imprint 4 inch wafer in a low vacuum environment at a single step.
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A novel nanofabrication process has been developed using two-photon crosslinking (TPC) for the fabrication of three-dimensional (3D) SiCN ceramic microstructures applicable to high functional 3D devices, which can be used in harsh working environments requiring a high temperature, a resistance to chemical corrosion, as well as tribological properties. After sequential processes: TPC and pyrolysis, 3D ceramic microstructures are obtained. However, large shrinkage due to low-ceramic yield during the pyrolysis is a serious problem to be solved in the precise fabrication of 3D ceramic microstructures. In this work, silica nanoparticles were employed as a filler to reduce the amount of shrinkage. In particular, the ceramic microstructures containing 40 wt% silica nanoparticles exhibited relatively isotropic shrinkage owing to its sliding free from the substrate during pyrolysis.
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A novel approach to the manufacture of biocompatible ceramic scaffold for tissue engineering using micro-stereolithography system is introduced. Micro-stereolithography is a newly proposed technology that enables to make a 3D micro structure. The 3D micro structures made by this technology can have accurate and complex shape within a few micron error. Therefore, the application based on this technology can vary greatly in nano-bio fields. Recently, tissue-engineering techniques have been regarded as alternative candidate to treat patients with serious bone defects. So many techniques to design and fabricate 3D scaffolds have been developed. But the imperfection of scaffold such as random pore size and porosity causes a limitation in developing optimum scaffold. So scaffold development with controllable pore size and fully interconnected shape have been needed for a more progress in tissue engineering. In this paper, bone scaffold was developed by applying the micro-stereolithography to the mold technology. The scaffold material used was HA(Hydroxyapatite) nano powder. HA is a type of calcium phosphate ceramic with similar characteristic to human inorganic bone component. The bone scaffold made by HA is expected, in the near future, to be an efficient therapy for bone defect.
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Micro-stereolithography technology is used for fabricating of 3-dimensional micro-structures. In some cases, this technology is more economical and simpler than MEMS and LIGA technologies based on semiconductor process. In this research, the micro-sterolithography apparatus that is more economical and simpler than current micro-stereolithography apparatus was developed. This apparatus uses UV lamp and optical fiber as a light source and tight delivery system, respectively.
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In this paper, an analytical laser ablation model with Maxwell equation will be addressed by considering relationship between laser ablation and material. The Maxwell equation consists of four equations: two Gauss laws for electric and magnetic fields, Faraday's law, and Ampere's law. This analytical model will be calculated by employing Finite Difference Time Domain (FDTD). This method also makes it possible to simulate the laser beam propagation in a wide range of materials, such as metals, semiconductors, and dielectrics. Therefore, in this study, a numerical model for short pulse laser interaction with materials is developed, focusing on the accurate description of laser beam propagation and ablation process into the material with each pulse.
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Surface pattern of tribological applications is an attractive technology of engineered surface. Therefore, friction reduction is considered to be necessary for improved efficiency of machines. This study investigated the effect of friction property fur angles of micro-scale crosshatch grooved surface pattern on bearing steel flat mated with pin-on-disk. We obtain sample which can be fabricated by photolithography process. We discuss friction property depend on an angle of cross-hatch grooved pattern. We can verify the lubrication mechanism as a Stribeck curve, which has a relationship between the friction coefficient and a dimensionless parameter under the lubrication condition. It was found that the friction coefficient was related to angle of crosshatch on surface, even when surface pattern was the same density.
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Chemotaxis, or preferential motion due to presence of a chemical gradient, is an important factor in sperm fertilization of eggs in that it is the first interaction between sperm and egg. In the present study, we aim to quantify the possible chemoattractive role of the jelly coat. The chemotaxis of the sperm of sea urchin was demonstrated with the effective motility coefficient by a microfchannel made of polydimethysiloxane (PDMS). The relevance of these findings is that they provide insight on the first steps towards egg fertilization.
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The purpose of this study was to evaluate the smoothness of the gait pattern according to shoe, walking speed, and slope. Eleven male university students used three types(running shoes, mounting climbing boots, elevated forefoot walking shoes) of shoes at various walking speeds(1.19, 1.25, 1.33, 1.56, 1.78, 1.9, 2.0, 2.11, 2.33m/s) and gradients (0, 3, 6, 10%) on a treadmill. Three-dimensional motion analysis (Motion Analysis Corp, Santa Rosa, CA, USA) was conducted with 4 Falcon high speed cameras. The results showed that elevated forefoot walking shoes had the lowest value of normalized jerk at the heel, which means that elevated forefoot walking shoes had the smoothest walking pattern at the heel. In contrast, elevated forefoot walking shoes had greater normalized jerk at the center of mass (COM) at most walking speeds, which means that the smoothness of gait pattern at the center of mass is the lowest for the elevated forefoot walking shoes. This movement at the COM might even have a beneficial effect of activating muscles in the back and abdomen more than other shoes.
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A Study on the Internal Structure of the Mandibular First Premolar using the Finite Element AnalysisMost existing studies for stress analysis of teeth have employed small number of teeth, and used big element size using F-E models. Therefore, the results are not accuracy enough for showing the internal stress variation. 15 males' and 13 females' mandibular first premolar are employed for internal structure's study of teeth and small element size for a FE model are used. According to these processes, stress distribution of internal parts of teeth are well shown, and the stresses are varied a lot between enamel layer and dentine layer, but there is little variation on pulp chamber.
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Understanding chondrocyte behavior inside complex, three-dimensional environments with controlled patterning of geometrical factors would provide significant insights into the basic biology of tissue regenerations. One of the fundamental limitations in studying such behavior has been the inability to fabricate controlled 3D structures. To overcome this problem, we have developed a three-dimensional microfabrication system. This system allows fabrication of predesigned internal architectures and pore size by stacking up the photopolymerized materials. Photopolymer SL5180 was used as the material for 3D scaffolds. The results demonstrate that controllable and reproducible inner-architecture can be fabricated. Chondrocytes harvested from human nasal septum were cultured in two kinds of 3D scaffolds to observe cell adhesion behavior. Such 3D scaffolds might provide effective key factors to study cell behavior in complex environments and could eventually lead to optimum design of scaffolds in various tissue regenerations such as cartilage, bone, etc. in a near future.
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The aim of the 3D medical imaging is to facilitate the creation of clinically usable image-based algorithm. Clinically usable imaging algorithm for image analysis requires a high degree of interaction to verify and correct results from registration algorithms, such as the Insight Toolkit (ITK) and the Visualization Toolkit (VTK) which are the class libraries. ITK provides segmentation algorithms and VTK has powerful 3D visualization. However, to apply those libraries to the medical images such as Computerized Tomography (CT), the algorithm based on the interactive construction and modification of data objects are necessary. In this paper we showed the 3D registration about mandibular premolar of human teeth acquired by micro-CT scanner. Also, we used the ITK to find the contour of pulp layer of premolar, furthermore, the 3D imaging was visualized with VTK designed to create one kind of view on the data of 3D visualization. Finally, we evaluated that the volume model of pulp layer would be useful for the tooth morphology in dental medicine.
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Many authors issued the feature-preserving averaging technique according to positioning and scaling process using landmarks, which represent the geometric characteristics of three dimensional surface models. Such a technique should be done by manual procedure, choosing and marking the landmarks on each bone surface before averaging process. In this study, we produced another averaging technique without having to use such manual procedure, and made averaging models from three dimensional surface data that were reconstructed from computerized tomography images of Digital Korean Project. The bone models were subjected to orthogonal coordinator system. These models were transformed to coincide mass center and to align principal axis. Then, bone models were scaled according to average length data of sample bone models on all axis(x, y, z). After establishing voxellar hexahedron space which contain all sample bone models, we counted the number of overlapping for each voxel. We generated the three dimensional average surface by displaying the yokels that have more overlapping number than boundary number. The boundary number was decided when the average volume of each bone equal to the volume of bone that would be averaged. Using this technique, we can make a feature-preserving averaging volume of bones.
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In this study, the effect of stem-end design on contact pressure and stress distribution in revision TKR was investigated using finite element method. The finite element model of tibia, including the cortical bone, the cancellous bone and canal, was developed based on CT images. The stem models with various stem lengths, diameters and frictional coefficients, and press-fit effects were considered. The results showed that the longer stem length, the stronger press-fit, the bigger stem diameter, and the higher frictional coefficient increased both peak contact pressure and the highest Von-Mises stress values. We hypothesized that peak contact pressure and Von-Mises stress distribution around the stem, may be related to the stem end pain. The results of this study will be useful to design the stem endand reduce the end-of-stem pain in revision TKR.
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When a water jet is injected on the body surface, the pressure and shear stress on the surface are important physical parameters in determining the body surface wash out and physical stimulus. We used the force plate in order to measure the surface average pressure for different nozzle types and distances between a nozzle and a plate. We used the nozzles with a hole dimeter of 1.8, 2.9, 3.2mm, and the shower heads with 10 holes (hole diameter, 1mm) and 20 holes (hole diameter, 1mm). The distances between a nozzle and a plate was 10, 20, 30, 40cm. The results showed that the surface forces were not affected by the distances between a nozzle and a plate. Further numerical studies will be performed to predict wall shear stress based on the measured pressure data.
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Some researchers proposed positive effects of whole body vibration (WBV) on osteoporotic trabecular bones of animals. In the present study, the correlation between the improvement of morphological characteristics and the effect of WBV was investigated and analyzed in OVX rats. The rats were randomly assigned to 5 groups: control, sham, WBV 17Hz, WBV 30Hz and WBV 45Hz. The WBV groups were exercised on a vibration platform (magnitude :
$1mm_{peak-peak}$ , frequency : 17Hz, 30Hz and 45Hz, 30 minutes/day for 5 days/week). The 4th lumbar on rats was scanned by In-vivo Micro-CT at the week 0(just before WBV) and the week 8(after WBV). Structural parameters of the 4th lumbar, based on two dimensional (2D) scan image data, were investigated and analyzed. The quantitative decrement rate of trabecular bone on WBV groups with 30Hz and 45Hz were lower than control and sham groups. The results showed the positive effect of WBV on osteoporotic bones of OVX rats. -
Image Guided Surgery(IGS) system has been developed to provide exquisite and objective information to surgeons for surgical operation process. It is necessary that registration technique is important to match between 3D image model reconstructed from image modalities and the object operated by surgeon. Majority techniques of registration in IGS system have been used by recognizing fiducial markers placed on the object. However, this method has been criticized due to its invasive protocol inserting fiducial markers in patient's bone. Therefore, shape-based registration technique using geometric characteristics of the object has been invested to improve the limitation of IGS system. During Total Knee Replacement(TKR) operation, it is challenge to register with high accuracy by using shape-based registration because the area to acquire sample data from knee is limited. We have developed region-based 3D registration technique based on anatomical landmarks on the object and this registration algorithm was evaluated in femur model. It was found that region-based algorithm can improve the accuracy in 3D registration. We expect that this technique can efficiently improve the IGS system.
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A 3-D finite element model of human thoracolumbar spine (T12-L2) was reconstructed from CT images. Various anterior and posterior instrumentation techniques were performed with long cage after corpectomy. Six loading cases were applied up to 10 Nm, espectively. The rotations of T12 with respect to L2 were measured and the stiffnesses were calculated as the applied forces divided by the segmental rotations. The posterior fixation technique increased the stiffness of the spine the most. The addition of anterior rod from 1 to 2 increased the stiffness significantly without posterior fixation, but no effect was found with posterior fixation. We found that different fixation techniques changed the stiffness of the spine.
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A patient table considering x-ray transparency, mechanical safety and compact multi-axis moving mechanism has been developed. The goal of medical imaging technology is to keep radiation exposure of patients during x-raying to a minimum. In order to obtain clear pictures at low dose, however, the x-ray table which supports the patient must be sufficiently permeable to radiation to allow good image resolution. The table top is made of low density foam for x-ray transparent effective area and structural aluminum plate to connect moving mechanism under the table, covered with thin carbon fiber. This sandwich construction is very rigid and lightweight, so the table top can handle relatively heavy load comparing to its cantilevered structure which is unavoidable as long as cooperate with C-arm radiography. To verify the design results finite element static analysis and experimental tests have been done. According to the verification the results well satisfy certification guide lines as a medical device.
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In these days, various kinds of rapid prototyping processes are available, such as stereo-lithography apparatus(SLA), fused deposition modeling(FDM), selective laser sintering(SLS), 3 dimensional printing(3DP), and laminated object manufacturing(LOM). For detailed informations about mechanical properties of those parts, benchmark tests are carried out. SLS and EOS part has an advantage in compressive strength, SLA has in hardness, FDM part has in impact strength, and LOM part has an advantage in tensile strength and heat resistance. The change of building direction in layered manufacturing processes of FDM and LOM severely weakens the tensile and impact strength.
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A solid freeform fabrication (SFF) system using selective laser sintering (SLS) is currently recognized as a leading process and SLS extends the applications to machinery and automobiles due to the variousmaterials employed. In order to develop a more elaborate and rapid system for fabricating large objects compared to existing SLS, this study employs a new selective dual-laser sintering (SDLS) process. Also, this paper will address development of an SFF system which employs the dual laser system and the unique scanning device. Experiments were performed to evaluate the effect of a scanning path and fabrication parameters on sintering process and to fabricate the various 3D objects using polymer powder.
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Direct laser sintering (DLS) technology for the resign coated sand is one of attractive technologies to produce molds and cores for the foundry industry rapidly and cost effectively. The objective of this case study is to develop casting pilot models using computer simulation technology, DLS RP machine and industrial computed tomography. The proposed casting design was verified by the Z-Cast software in the fields of fluid flow and solidification during the casting process. Casting parts with aluminum alloy using the post-curing treated sand moulds and cores are accurate to dimension and defect free.
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In the solid freeform fabrication (SFF) system using selective laser sintering (SLS), polyamide-12 powder is currently recognized as general material. In this study, some kinds of polyamide-6 powders with different shape and particlesize were fabricated to investigate the formability, the microstructure and mechanical properties. Also, to develop a more elaborate and rapid system, this study employs a new SLS device with a 3-axis dynamic focusing scanner system instead of the existing fe lens used in commercial SLS. Polyamide-6 powders having the average size of 100 m were treated thermally in order to keep the spherical symmetry in shape. These polyamide-6 powders were mixed with polyamide-12 powders having the average size of 50 m to give the bimodal distribution of size. These mixed powders showed the better fabrication in the selective laser sintering process because the smaller particles of polyamide-11 played an important role in the compact packing of powders by filling the void space between the large particles of polyamide-6. Also, Experiments have performed to evaluate the effect of a scanning path and sintering parameters by fabricating the various 3D objects.
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It will not be an exaggeration to say that one of the most important features of RT (Rapid Tooling) technology is to easy manufacturing complex shape of cooling channel in injection mold. That is, RT technology is hardly influenced complex shape of tool, Therefore, mold designer can optimize the position and shape of cooling channel whatever they want. In this study, we optimized cooling channel through CAE analysis to solve the problem; prototype-connector-mold applied conventional cooling channel, locally warped by internal stress: The effect of three-dimensional cooling channel was supported by simulation result. But it is impossible to produce injection mold applied three-dimensional cooling channel through machining operation. Therefore, we produced the prototype-connector-mold with three-dimensional cooling channel using Direct Metal Laser Sintering (DMLS) process, and get good-quality prototype-connector without warpage.
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To analyze the dynamic characteristics of the bundle drawing process, we employed a Random Phase Spectrum method to generate stochastic test signals that had a given autocorrelation function. And the spectra of the dynamics of the process outputs were obtained, based on the dynamic model of the bundle drawing process. Results showed that the RPS method was very effective to generate stochastic signals that had an exponential function form. The drawing process had the traits that there existed a special frequency range, incurring the process resonance.
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Studies on some biodegradable polymers and other materials such as hydrogels have shown the promising potential for a variety of surgical applications. Postoperative adhesion caused by the natural consequence of surgical wound healing results in problems of the repeated surgery. Recently, scientists have developed absorbable anti-adhesion barriers that can protect a tissue from adhesion in case they are in use; however, they are dissolved when no longer needed. Although these approaches have been attempted to fulfill the criteria for adhesion prevention, none can perfectly prevent adhesions in all situations. Overall of this work, a new method to fabricate an anti-adhesion membrane using biodegradable polymer and hydrogel has been developed. The ideal barrier for preventing postoperative adhesion would have the following properties; it should be (i) resorbable (ii) non-reactive (iii) easy to apply (iv) capable of being fixed in position. In order to fulfill these properties, we adopted solid freeform fabrication method combined with surface modification which includes the hydrogel coating, therefore, inner or outer structure can be controlled and the property of anti adhesion can be improved.
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Sandwich structures, which are composed of a thick core between two faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. In this paper, we have investigated the buckling protection of an inner structure plate and the useful corrugated configuration for contact, and the fabrication method of the inner structure plate for large area using the continuous molding process. Also, we have guaranteed the accuracy of the molding process through the micro corrugated mold fabrication and analyzed aspect properties of the inner structure plate fabricated for a large area using the partial mold process.
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We have successfully termed brown colored patterns inside of a transparent borosilicate glass generally known as BK7, laying the focus of near infrared Ti: sapphire femtosecond laser beam in the bulk BK7 glass. It is important to keep the laser power well below the damage threshold of BK7 in forming the color center. Thanks to the low laser power, there was no laser induced mechanical damage such as cracks or threads in the color formed area. From the absorbance spectrum and its gaussian fitting, we found the band gap of BK7, 4.21eV, and three absorption edges.
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The CAM software for drill grinding has been developed to save time, reduce cost for tool manufacturing and obtain accuracy of tool. In this paper, the developing software for drill will be presented including calculation and simulation of machining processes using 5-axes CNC grinding machine. The algorithm fer helical flute grinding was applied into calculating NC data. The software will generate NC code for machining by using input data of tool geometry, wheel geometry, wheel setting, machine setting. These NC code files will be used in simulator as input file. The simulator provides some functions for simulating machining processes, inspecting and measuring tool geometry.
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The effect of manufacturing parameters on friction characteristics of motorcycle break system was studied using a disk-on-pad type friction tester. Such parameters conditions have an effect on the frictional factor such as applied load, sliding speed, and number of ventilated disk hole. However, it is difficult to know the mutual relation of these factors. In this study, the friction characteristics using design of experiment containing 3 elements were investigated for an optimal condition for the best motorcycle break system employing Full factorial design. From this study, the result was shown that the applied load in frictional factors was the most important, next to sliding speed, number of ventilated disk hole.
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This paper presents an investigation on the characteristics for new micro tool dynamometer by using the ultrahigh-speed air turbine spindle. Recently, the ultrahigh-speed micro flat endmilling has been investigated actively due to request of accuracy improvement and productivity of die and mould manufacturing. To perform efficient ultrahigh-speed micro flat endmilling, evaluation of ultrahigh-speed machinability must be studied preferentially and it can be identified by investigation of cutting force. The cutting forces in ultrahigh-speed micro flat endmilling can be measured by micro tool dynamometer. But general dynamometer has low natural frequency and so is improper for measuring very high frequency cutting forces in ultrahigh-speed micro flat endmilling. In this study, the micro tool dynamometer which has very high natural frequency is newly designed.
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Laser surface hardening technologies have been used to improve characteristics of wear and to enhance the fatigue resistance for mold parts. The objective of this research work is to investigate the influence of the process parameters, such as power of laser and defocused spot position, on the characteristics of laser surface hardening for the case of SKD61 steel. CW Nd:YAG laser is selected as the heat source. The optical lens with the elliptical profile is designed to obtain a wide surface hardening area with a uniform hardness. From the results of the experiments, it has been shown that the maximum hardness is approximatly 740 Hv when the power, focal position and the travel of laser are 1,095 W, +1mm and 0.3 m/min, respectively. In addition, the hardening width using the elliptical lens was three time larger than that using the defocusing of laser beam.
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In recent years, the demands of the aspherical glass lenses increase since it is difficult to obtain the desirable performance in the plastic lens. Glass lens is manufactured by the forming with high precision mold core. This paper presents the analysis of optimal grinding condition of tungsten carbide(WC, Co0.5%) using design of experiments(DOE). The process parameters are turbin spindle, work spindle, feedrate and depth of cut. The experiments results are evaluated by MINITAB software.
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In this study, we have investigated the micromachining of PZT to fabricate interdigitated electrodes of electro active material actuator using Nd:YAG laser We have observed groove shapes of PZT with changing beam power, scanning speed, gas, and so on to find optimum conditions of the laser processing for PZT grooves. As a result, this method has been applied to the laser micromachining for grooves in PZT surface, and we could have optimum parameters of Nd:YAG laser Finally it was shown that the laser micromachining of PZT can substitute fer bonding, etching and deposition processes in fabricating electro active material actuator embedded with interdigitated electrodes.
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As the technique of high-speed end-milling is widely adopted to machining field. The investigation for microscopic precision of workpiece is necessary for machinability evolution. The environmental pollution has become a big problem in industry and many researcher have investigated in order to preserve the environment. The environmentally conscious machining and technology have more important position in machining process. In the milling process, the cutting fluid has greatly bad influence on the environment. The damaged layer affect mold life and machine parts in machining. In this study, the cutting force, the surface roughness, micro hardness and residual stress is evaluated according to machining environment. Finally, it is obtained that the characteristics of damaged layer in environmentally conscious machining is better than that in conventional machining using cutting fluid.
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In order to calculate the maximum undeformed chip thickness in grinding operation, it is necessary to estimate the successive cutting point spacing. In the past it is obtained by experiments. In this paper, the average successive cutting point spacing has been estimated using the given grinding input conditions.
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Shape memory alloy, Nitinol is used for medical stent, artificial human joint, antenna of artificial satellite, fire door, temperature sensor...etc. It is important for some nitinol product high precision and clean surface. In this study, we experiment about deburring of edge and surface of nitinol work piece with micro electrolytic-deburring. We made an observation in case electric currents are
$1A{\sim}4A$ , above 5A and each machining times. -
Ultrasonic machining technology has been developed over recent years for manufacturing the quality-assured precision parts fur several industrial application such as optics, semiconductors, aerospace and automobile application. Ultrasonic needle horning is widely used in cutting(drilling) of non-conductive, brittle workpiece materials. This paper intends to understanding of the basic mechanism of ultrasonic needle horning. And frequency analysis program is used to easily predict the natural frequency of ultrasonic vibration cutting tools.
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For the machining of freeform surface, fly cutting is one of the key technology to meet profile accuracy and surface roughness simultaneously. Fly cutting can be applied to manufacturing of optical components with complex profile. In this study aluminum alloy was machined in the process of ultra precision fly cutting and investigated optimum machining conditions in terms of feed-rate, pitch per cycle and depth of cut.
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The disk cam mechanism can produce a positive motion with relatively few components. This paper introduce a shape design of cam using the relative velocity method and a precision machining technology for using Bi-arc method. The paper gives a machining information at each point using the Bi-arc method and the analysis method of the cutting error due to the moving path of the cutter, so that we can lead to the optimum design in a disk cam mechanism.
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Micro drilling is a very important machining method to produce precise parts or small molds. General macro-program for drilling is a non-efficient method because of many movements to safety height. In this research new macro-program was suggested to raise machining-efficiency. New micro-drilling method caused the much reduction of machining time and the same tool life.
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For longer than picosecond pulses, bulk damage inside defect-free dielectrics involves the heating and multiplication of spurious electrons by the incident laser beam and transfer of this energy to the lattice. The situation is quite different for femtosecond pulses which are shorter than the time scale for electron energy transfer to the lattice. Damage caused by these pulses is produced with smaller statistical uncertainty and is controllable on a microscopic scale. These properties can be exploited to produce laser devices such as arrays of damage dots for all optical memories with high data storage density or arrays of parallel grooves to form transmission gratings. In this work, we observed characteristic of the femtosecond laser machining in BK7 and fused silica.
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Spherical glass lenses are used in many optical industries. The curvature, eccentricity and height of a tool affect the surface roughness and curvature of lenses. The purpose of this study is the development and performance of a self-diagnostication ultra-precision lens polishing machine. In this paper, structure analysis is performed to reduce maximum displacement and to maintain outside the resonance region by CATIA V5. A spherical center setting gage is developed to increase accuracy of the manufactured lenses. The surface roughness, curvature and thickness of the manufactured lenses are measured and studied.
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In this paper, the development of an error measurement system of 5-axis mill & turn machine tool presented by double ball bar test, which has been widely used to measure the overall accuracy of machining center. and the reliability of an error measurement system of 5-axis mill & turn machine tool was secured by the direct cutting test.
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For developing 5-axis laser cutting systems, many problems such as rotating of laser head or table, 5-axis tool path generation and collision avoidance between laser head and product should be solved. In this paper, a five-axis laser cutting machine with table swivel and rotary type configuration is developed. The five axes (X,Y,Z,A,B) are controlled and interfaced to PC via MMC board. Two kinds of CAM S/W such as commercial 5-axis CAM S/W(Euclid) and UG-API are engaged to generate NC code for the developed 5-axis laser cutting machine.
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In this study, the morphology of the change of primary Al phase in A356 alloy by two kinds of electromagnetic stirrers(vertical and horizontal) were investigated to obtain the globular structure. The effects of the stirring current, the stirring time and the pouring temperature were determined. The greater stirring current and longer stirring time were to get the finer the Al phase. However, over a certain stirring current and stirring time, the primary Al was merged together and was increased. The reason is the degree of breakdown of initial dendrites has been decreased by the collision and coalescence of particles with increasing stirring current and stirring time. The optimum conditions and difference of the two kinds of electromagnetic stirrers have been investigated for rheology forming with controlled solid fraction.
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Recently FPD(Flat Panel Display) is used in various field to display enormous information. So cutting technique of flat panel display is needed for producing variety display merchandises. In present, cutting methods of flat panel glass includes breaking process. But this process occurs many glass particles. This glass particles are directly related badness of merchandise and falling productivity. In this paper, to cut front substrate glass of LCD and to get optimized cutting condition are tried fur eliminating breaking process with developed glass cutting machine using a Piezoelectric ceramics actuator. It is known that the vibration of Piezoelectric Ceramic have effect in crack proceeding through the analysis of fracture section.
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Tensile and anisotropy test were performed to evaluate the mechanical properties of coated and uncoated steel. These results were used to predict the deference of formability between two sheets. Cup-drawing test was performed to verify formability of two sheets. Also, Cup-drawing test could predict the coefficient of friction and the forming limit. Finite Element Method of cup-drawing was performed to assess the deference between two sheets considering frictional characteristics. This result was compared with the former results.
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In this investigation, the authors propose a novel method of Enveloping Helical gear generation by shaping operation and a math model to simulate its manufacturing process. The tooth geometry of the Enveloping Helical Gear is analytically determined by simulating the conjugate motion between the workpiece(Enveloping Helical gear) and cutting tool(shaper cutter) in the generation process. It is expected that such math modeling capability will give engineers an opportunity to correct manufacturing related issues in the design phase and thereby reduce the developing period.
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This paper presents the performance improvement of a Nozzle/Ball type servovalve with variant drain orifice. First of all, the configuration of the novel servovalve is proposed. Then, the static characteristics are investigated under blocked load condition, and its dynamic characteristics are analyzed by using the linearized flow-pressure relationship. Finally, the performance at the null condition of the proposed servovalve is numerically evaluated through the comparison study with the convention at counterparts.
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This paper presents the displacement sensor based on astigmatic method that has a small measurement range. The sensor has the characteristic that the measuring range is changed easily by exchanging a objective lens or distance between a objective lens and a collimator lens. The measuring range and resolution is evaluated by a laser interferometer.
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The ESPI(Electronic Speckle Pattern Interferometry) is a real time, full-field, non-destructive optical measurement technique. In this study, ESPI is proposed for the purpose of vibration analysis for new material, composite material. Composite materials have various complicated characteristics according to the ply materials, ply orientations, ply stacking sequences and boundary conditions. Therefore, it is difficult to analysis composite materials. For efficient use of composite materials in engineering applications the dynamic behavior, that is, natural frequencies, nodal patterns should be informed. If use Time-Average ESPI, can analyze vibration characteristic of composite material by real time easily. This study manufactured laminated composite of symmetry, asymmetry two kinds that is consisted of CFRP(Carbon Fiber Reinforced Plastics) and shape of test piece is rectangular form.
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This study was intended to research the displacement characteristics of dampers for Korea hish-speed rolling-stock for the purpose of developing the protective and maintenance technology of damper. For this, we measured the displacements of dampers in the actual running conditions of high speed railway vehicles. Displacement data were analyzed depending on the service sections, with which the valuable data necessary for maintenance in the future could be obtained.
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A new method for the electrostatic suspension of disk-shaped objects is proposed which is based on a time-optimal control scheme and deploys only high-voltage power supplies that can deliver do voltages of positive and/or negative polarity. This method possesses the unique feature that no high-voltage amplifiers are needed which leads to a remarkable system simplification and objects can be suspended stably even in vacuum environment. Using this scheme, an Aluminium disk employed in a 3.5-inch HDD was suspended stably at an airgap of 0.3mm.
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In this paper, the ECG monitoring system on mobile platform was proposed, which is very useful to gather, storage and diagnose ECG signal. The existing ECG monitoring system is for indoor environment but this system is for outdoor environment, especially for automobile system. The developed system consisted of data logger using microprocessor and data server fur diagnosis ECG signal. We develop the data acquisition system hardware and data monitoring system for ECG signal.
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A Study on the Development of High Precision Cam Profile Measuring System using Laser InterferometerCam mechanisms are one of the most popular devices for generating irregular motion and are widely used in many industrial areas. The purpose of this study is the development of high precision measuring system fur measurement data acquisition and analysis of a manufactured cam profile. The developed system is composed of servo motor, CNC controller, rotary encoder, and laser interferometer And also, this system is non-contact measuring type. The developed system takes only 5 minutes to measure a cam profile and to analyze the measuring data while the CMM(coordinate measuring machine) takes about 1 hours even by a skilled operator.
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Brake noise is classified according to frequency territory: judder, groan and squeal. Squeal noise of disk brake is a noise and self excited vibration with frequency of
$1{\sim}10Khz$ caused by the friction force between the disk and the pad of the automobile. Passengers in a vehicle feel uncomfortable. It causes unstable characteristic to the brake system when you try to stop the vehicle. Thus this study aims to find in which conditions the vehicles are stable during the braking hour and find ways to decrease a squeal noise and the vibration by measuring various factors including squeal noise and self excited vibration between the pad and disk brake system during the braking hour. From the result the countermeasure for a squeal noise and a vibration decrease is established. Also the analyzed data is found to be useful and can be applied to the actual brake model. -
This paper presented a new experimental gain tuning technique for a Multi-Axis Servo System. First, the investigation for proportional gain of velocity control loop by using a Dynamic Signal Analyzer (DSA) was performed. Using the FUNCTION characteristic of DSA based on the Bode plot, the Bode plot of open loop transfer function was obtained. In turn, the integral gain of a servo controller can be found out by using the Integration time constant extracted from the Bode plot of open loop transfer function. In the meanwhile, the positional gain of the servo controller has been obtained by using the Bode plot of the closed loop transfer function. We have also proposed the technique to find out an optimal parameter of a notch filter, which has a great influence on vibration reduction, by using the damping factor extracted from the Bode plot of closed loop transfer function.
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Fundamental research is conducted in order to develop measurement system for E-beam focus position compensation. In this paper, simulation results using Fresnel's formula shows effect of photoresist film thickness according to incident conditions. Also, electromagnetic simulator is developed based on Boundary Element method (BEM) and several results confirm the feasibility of the simulator.
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An intelligent arm-wrestling system is recently developed in our laboratory that is comprised of an arm-force generation mechanism and a control system that detects the maximum arm-force of a user in the early stage of the match, generates a different game scenario each time, and executes force feedback control to implement the scenario. This paper presents the mathematical model of the force control system of the intelligent arm-wrestling system, and some improvements of it via experimental frequency responses using a control signal analyzer.
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As a development of technology, electric power steering system which uses an electric motor came to use in recent and it can solve the problems with hydraulic power steering system. In this paper, vehicle model and electric power steering system are combined to fulfill full vehicle model. By simulation effect of motor torque assist through electric power steering revealed effective, and full vehicle model are proved reasonable through comparison with real car experimental datum.
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This paper analysised Oil-Mist-Detector applied Capacitance Sensor which protects Diesel engine & human from explosion by detecting density of oil mist distribution. Assuming that distance between oil mists is same, Capacitance sensor plates & all oil mists could be analogized to capacitors. From equivalent circuit of Oil-Mist-Detector, variation of Capacitance which is related to Oil Mist's diameter & density of oil mist distribution is obtainable.
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Tension control performance is very important in high-speed printing machine. One of the major factors that effect to tension control performance is the process of roll changing. Even if the turret arm moves during roll changing process and the span length of the unwinding system varies, it is customary to neglect it in motion and tension control and to consider it as a disturbance. In this paper, its effect is modeled nonlinearly and compared with linear model, and an effect of an infeeder dancer is analyzed under the condition with no unwinder dancer. We verify the performance of the proposed method via simulation in the high-speed printing machine.
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In this paper 3-point weighing method is adopted to measure the unbalance moment of small-sized precision spinning elements using electronic scales with 0.1 mgf resolution. Firstly methods to eliminate the fixture error and to reduce the effects of frictional force that is known as side effect, are proposed. A measuring system is developed and various experiments are performed to verify the proposed approach. The measured and calculated values are analysed in statistical methods, and this provides the errors of the measuring system. The results show that the proposed theory and test procedures gives reliable unbalance moments and gravitational centers.
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The essential tasks to operate the welding robot are the acquisition of the position and/or shape of the parent metal. For the seam tracking or the robot automation, many kinds of contact and non-contact sensors are used. Recently, the vision sensor is most popular. In this paper, the development of the system which measures the profile of the welding part is described. The total system will be assembled into a compact module which can be attached to the head of welding robot system. This system uses the line-type structured laser diode and the vision sensor It implemented Direct Linear Transformation (DLT) for the camera calibration as well as radial distortion correction. The three dimensional shape of the parent metal is obtained after simple linear transformation and therefore, the system operates in real time. Some experiments are carried out to evaluate the performance of the developed system.
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This paper introduces an approach of method to compensate accuracy error of diagonal direction. The measurement of squareness error is an important parameter in performance test of two axis Linear Motor and this exerts influence on accuracy error of diagonal test. However, previous knowledge management approaches are limited in deviation measurement of optical axis or restrictive elements of diagonal measurements using laser interferometer. But this proposed method calculated diagonal accuracy error which was occurred by squareness error and compensated squareness error using orthogonal correction method of PMAC. From this result, diagonal accuracy error is significantly reduced. This experimental results show that geometric error of squareness error is easily corrected by dynamic coordinate correction.
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In general, atomic force microscope (AFM) used for metrological purpose has measuring range less than a few hundred micrometers. We design and fabricate an AFM with long measuring range of
$200mm{\times}200mm$ in X and Y axes. The whole stage system is composed of surface plate, global stage, microstage. By combining global stage and microstage, the fine and long movement can be provided. We measure the position of the stage and angular motions of the stage by laser interferometer. A piezoresistive type cantilever is used for compact and long term stability and a flexure structure with PZT and capacitive sensor is used for Z axis feedback control. Since the system is composed of various actuators and sensors, a real time control program is required for the implementation of AFM. Therefore, in this work, we designed a multi-axis control program using a FPGA module, which has various functions such as interferometer signal converting, PID control and data acquisition with triggering. The control program achieves a loop rate more than 500 kHz and will be applied for the measurement of grating pitch and step height. -
Currently A demand of high precision workpiece is increasing in industry. At present, roundness measuring machine using Air bearing, coordinate measuring machine that are used from measurement station. but these machines will not be able to apply to In-line process. because of like these machine's price are very expensive and measurement time is long. also, the complexity of conventional roundness measurement method based on fourier transform, it makes difficult to development analysis program. This work present new architecture of a Out-diameter measuring system fur analysis of roundness of product. In this system, the influence of table motion errors is minimize by using two LVDT sensor and knife edge contact tip. We are produce a test machine and make an experimenter on Out-diameter of test bearing. The measurement result compared with roundness measuring machine.
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The conventional strain measuring device is costly and complicated - it is not simple to understand its structure. Hence, strain gage and the A/D converter are assembled to come up with a load and a strain measuring device. The device was tested for measuring the strain in a loaded specimen and the experimental results were compared to those obtained by a commercial strain indicator.
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We developed wire frame drive unit based on SMA for the 3D Shape display. Our basic concept is wire frame combination connected with a chain form which can create various shapes and it compared with pin array mechanism which is not able to display mushroom shape. It imitates antagonist mechanism of human musculoskeletal system. we create similar motion using repair-relaxation mechanism and locking mechanism by SMA. Therefore, in this paper, we propose SMA control solution for actuating repair-relaxation mechanism and locking mechanism. In our control system. we use optical sensor and quantitative angle between wire frames for closed loop control. And we supply amplified current for SMA by circuit composed of transistor and apply PWM signal to circuit for efficient control. So, wire frame drive unit enable diversity angle control based on sensor data. And then combination of wire frame drive units will create various objects.
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Water leak for the water-cooled generator stator windings affects seriously the availability and the reliability of power plants. Generally, water absorption test is conducted in the power plant during outage in order to confirm if leak part is in the bars or not. In this paper, it is described that the capacitance of winding bars is measured by using the developed water absorption instrument system and the water absorption of winding bars is evaluated by using the stochastic methods. The good results by proposed diagnosis technique can be got. It is expected that the reliability of diagnosis for water absorption is increased if the proposed methods are applied to evaluate the water absorption of stator winding bars.
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The camera and reduction mechanism that are equipment outdoors camera for general CCTV are miniaturization trend gradually. The foreign countries began to sell variableness speed type camera drivels that do DC voltage by motive power recently. But, Domestic is state that enterprise which has technology connected with this does not exist. We need optimum control program design, an internal organs technology, actuator interface and a driver design technology that have position control special quality of high accuracy as a necessary technology for CCTV camera drivers. Also, we need detailed mechanism design and a manufacture technology of camera drivers that behave variable speed essentially.
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In this paper, the possibilities of the Infra-red sensor in sensing and control of the bead geometry in the automated welding process are presented. Infra-red sensor is a well-known method to deal with the problems with a high degree of fuzziness so that the sensor is employed to build the relationship between process variables and the quality characteristic the proposed above respectively. Based on several neural networks, the mathematical models are derived from extensive experiments with different welding parameters and complex geometrical features. The developed system enables to select the optimal welding parameters and control the desired weld dimensions during arc welding process.
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In this work, we developed an equipment for automatic quality control of fuel pump motor using vibration analysis. The equipment automatically performs a series of tasks such as aligning and conveying the motor, attachment/detachment of an accelerometer, data acquisition, vibration analysis, and classification, etc. Compared to previous manual operations, the developed system is able to provide considerable savings in both time and cost.
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In process for production of Rubber Scheme Product that have the most inferior Working Environment is Medicine mixture and Scheme processing. Applying automation and Environment Treatment technology to the hazardous chemical and mixture processing, Through developed 'Mixture Automatic Machine for hazardous chemical Interruption type that is occurred at mixing rubber medicines', we try to decline worker's intensity of labour, Also overcomes solution of work evasion phenomenon and manpower supply and demand's difficulty by forming agreeable working environment and through the automatic scheme and mixture processing by preventing that hazardous chemical had known as disease causes of various importance disease is exposed to worker during the work. and we plan to do so that production of high added value product may be available.
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This paper is about the development of automatic inspection system of welded nuts on Support hinge using machine vision for the improvement of working condition. Until now, projection welding process was performed by operator. Also, inspection of welded nuts is performed manually and recorded by the operator's naked eye. So these processes caused the produce of poorly-made articles. To improve this manual operation, inspection system using machine vision is introduced. Test algorithm, lighting system and program showed good results to the designed inspection system and led to the increment of productivity.
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This paper is about the development of surface inspection of bearing inner and outer race using machine vision. Before this system is developed, most inspections are performed by workers' naked eye. To improve both the inconvenience and incorrectness, another new tester is introduced. This system has the three sections mainly. First one is the mechanism section which transfers bearing manufactured from previous process line to the testing process in plant. Another is the inspection system which is composed of two parts: computer vision and measurement system using laser diode which inspects the defects of the bearing inner or outer race. The other is the pneumatic cylinder part controlled by Programmable Logic Controller(PLC). The system which is developed shows favorable results, and that has the advantage of convenience and correctness compared to previous system.
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In this paper, steering systems for mobile robot with permanent magnet wheels are discussed. The mobile robot with permanent magnet wheels can have three different types of steering and driving configurations; two-wheels, three-wheels, four-wheels. By a Two-WD(Wheel Driving) system, driving and steering characteristics are controlled by ratio of each wheel speeds. Three-WD system is steered by a front wheel and driven by rear wheels. Four-WD system has better stability than two wheel system. Usually the permanent magnet wheel has nearly none slip. Thus turning radius of the mobile robot with three-WD and four-WD System will be increased and the steering and driving system will be complicated. To solve this problem, two magnet wheels with two dummy wheels are used in this study. fuming radius of the developed mobile robot is small and the structure of the robot is simple. It is possible to move forward, backward, to turn left and right, and to rotate freely with two-WD. This study proved that two-WD system is very suitable fur the mobile robot with permanent magnet wheels.
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Indicating product quantity by real time can be benefit both worker and management. Worker can compare real product quantity with its target and can adjust working speed to match with goal. Therefore, so called JPH equipment developed to indicate target quantity of product. As a main processor PIC16F877 was used and FND display were used to indicate current time, elapsed time, JPH value and target amount of product. Values like JPH and starting time, etc. are can easily be set by
$4{\times}4$ numeric keypad and display datum likes target amount of product, current time and elapsed time, etc are displayed on FND by RS232 serial transmit. The operation of JPH equipment are tested and verified through long term test and are proved acting properly on working conditions. -
A new cleaning robot system for live-line tension insulator string was developed to prevent an insulator failure, which can have severe effects on national security as well as national industry and economy. The robot moves along the insulator string using the clamps installed on its two moving frames. Especially, unlike the existing cleaning robots using jets of water or water/air, the robot system adopts dry cleaning method using a rotating brush and a circular motion guide. This robot system has control architecture consisting of a master control unit and two slave control units. We confirmed its effectiveness through experiments.
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A transfer loading system for 21' RF band assembly box was developed in the present study. The weight of a box is approximately 60kgf End total weight of one day job per person is about
$4,000kg_f$ . For an efficient design and manufacturing process, three dimensional design and engineering technique were applied to the presented system. Motion analysis for a popup unit and structural analysis for belt part subjected to the load of box weight were performed, respectively. It was found that the evasion of duty and labor intensity is reduced after appling the developed system to manufacturing field of small and midium business. -
In this paper, automatic sunvisor system is introduced for driver's safety and convenience. This system has the mechanism which keeps the sun off without obstruction of driver's sight. The mechanism can make the sunvisor move forward or rotate left while remaining inside inner roof. The control system consists of a CPU, a motor driver, light sensors, and the algorithm that can control the movement of sunvisor efficiently. When the light sensors take the sun light, they give the signal to the CPU and the CPU calculates the best position of the sunvisor with the information of driver's eyes height. Then, the CPU gives the signal to motors that can move the sunvisor.
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In many manufacturing processes such as web formation, manufacturing of paper and nonwoven, fabric weaving, etc., planar sheets are transported and at the same time appropriate tension is imposed. The input material rolled up on beams is fed by unwinding the beam and the processed is then taken up on beams by winding it. While processed, the planar sheets are thrown under the processing load of impulse form, which causes irregular thickness of the processed sheet. To improve the quality of the product, a dynamic model is needed and the dynamic characteristics is to be analyzed by simulation. This study shows that density variation dynamics of the in-process-sheet in the machine direction can be described at each moment of disturbing impacts in forms of difference equations, while the impacts and tension, the time-dependency of the material properties were taken into account. Simulation showed the most serious variation of the density occurred in the process starting phase. The starting velocity curve with step form showed the least variation of the density. As the time order of the function of the starting velocity cure becomes higher, the density variation gets greater.
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This paper presents dynamics of register error on a compensator roll type converting machine. Though a register control is an important aspect of a converting machine, it has not been taken into account as a main subject. Lately, demands for high speed converting machines over 500mpm(m/min) are raising but domestic converting industries can not come up with the high speed machines because capacities fur designing of the converting machine is restricted lower than 300mpm. Moreover register control is the key to product flexible displays through roll-to-roll systems. In this paper, a compensator roll type register controller is analyzed using mathematical model of register error. A case study for reducing transient register errors is discussed.
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Recently, it is concentrated on productivity improvement in high speed operation by converting industries. Register error is becoming the one of the most issued problem. Moreover register control is the key to product flexible displays through roll-to-roll systems. This paper presents a derivation of register error modeling. And the dynamics of register error is simulated under various conditions. Register error is affected by both roll velocity and tension between the front and back span. And dynamics of register error is to be an interaction in succeeding spans.
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Recently, as the infocomindustry is developed, the semiconductor industry as well as the optical industry such as the optical communication and the optical instrument is developed rapidly. The transmission, storage and processing of information has been reaching an limit because amounts of information increase rapidly. The more quickly the optical communication is developed, the more sharply the demand of optical elements increase. The transport and inspection process is time consuming and the error rate is high, because this process are not automated in case of an optical lens. In this paper, the pick-up system that can hold optical elements and be transferred by the ultrasonic transport system is developed. The inspection system that distinguishes between the existence and the nonexistence of a defect is connected easily to pick-up system. The pick-up system separates the optical glass lens by results of the inspection. The automation program is developed by visual c++ programming.
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The research and development of an actuator are accelerating in the robotics industry. The electricity polymer and SMA actuator are designed simply and are produced a lot of forces per unit volume. Their motions are similar to human's motion, But the repeatability of the electricity polymer actuator is lower. The reaction velocity of the SMA actuator is slow and the travel is short. In this paper, the dynamic characteristic of the segmented SMA is studied. The SMA wire is divided by using the Thermo-electric module(TEM) to control each of segments independently. The MOSFET circuit is used to supply constant currents fer the Thermo-electric module(TEM). The hysteresis and displacement of the SMA wire according to load are measured.
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Transport systems which are the important part of the factory automation have much influence on improving productivity. Object transport systems are driven typically by the magnetic field and conveyer belt. In recent years, as the transmission and processing of information is required more quickly, demands of optical elements and semiconductors increase. However, conventional transport systems are not adequate for transportation of those. The reason is that conveyor belts can damage precision optical elements by the contact force and magnetic systems can destroy the inner structure of semiconductor by the magnetic field. In this paper, the levitation transport system using ultrasonic wave is developed for transporting precision elements without damages. Vibration modes of each flexural beam are verified by using Laser Scanning Vibrometer.
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A novel mathematical modeling in web transport systems for Continuous Annealing Processes (CAP) is proposed. Despite of thermal and weight effects in dynamics of web transport systems, the conventional mathematical model does not consider those effects. Disregard of these effects causes the low manufacturing quality of webs in CAP. In order to improve the manufacturing quality of webs in CAP, moreover, precise tension control is required based on the mathematical model. Therefore, an advanced mathematical model considering thermal and weight effects in CAP should be established. The effectiveness of a novel mathematical model is evaluated by comparing the performances of the PI tension control system based on the proposed mathematical model with that based on the conventional one through the computer simulation.
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Compound semiconductor manufacturing environment also has been emerged as mass customization and open foundry service so integrated manufacturing system is needed. In this study, we design data acquisition system of compound semiconductor fabrication that has monitoring and control of process. The developed DAS is consisted of key-in system inputted by operator and automatic acquisition system by GEM protocol. And we implemented them in the actual compound semiconductor. It is expected that using developed system would offer precise process information to buyer, reduce a lead-time, and obey a due-dates and so on.
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The requirement to reuse a design knowledge have been enlarged with the automation of a design system. A design knowledge gives logical and technical meanings to design data of a problem area. The representation of the knowledge is distributed and developed independently. For this reason, we need a general methodology with a semantic interoperability of design knowledge. In this paper, we accept previous requirements by using semantic query system with ontology repository.
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Recently, many researches have been done to improve optical performance of LCD-BLU(Back Light Unit). One of the most important parts in LCD-BLU is LGP(Light Guiding Plate). Micro-patterned LGP is known to have different optical characteristics depending on their shape, pattern density and size, etc. In the present study, a micro-optical patterned LGP mold was fabricated using LiGA process. The difference in the optical characteristics between positive and negative patterned LGP's was investigated by fixing the density, location and size of each pattern. It was found that the negative patterned LGP showed better optical characteristics than positive one.
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This study is concerned about the development of tower type automatic tool changer. The tower type automatic tool changer is developed to reduce stand-by time by shortening tool change time. The developed system can store more number of tools in small space. A structural analysis for the machine is carried out to check the machine design using commercial software, CATIA V5. In the result of structural analysis, the safety of the developed system is confirmed.
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Powder injection molding(PIM) is widely used for many parts in the field of automotives, electronics and medical industries, due to the capability of net shaping for complex 3-D geometry. Powder injection mold design fur the dental scaler tip, a component of medical appliance, was presented. In comparison with conventional machining process, powder injection molding has many advantages, specially in price and dimensional stability, for molding dental scaler tip which has complex geometry. Both product design and mold design for dental scaler tip were presented. The 'rapid mold' concept was applied to manufacture the various forms of dental scaler tip.
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In the future, a machine will be more improved in the form of advanced concept with collaborative ability in M2M(Machine to Machine, Mobile to Machine) environment for u-Manufacturing system. This paper tried to standardize M2M and design advanced concept machine. The M2M is front-end system for implementing autonomous ubiquitous environment. The advanced machine in M2M will be a collaborative machine with knowledge-evolutionary ability such as u-Machine(Ubiquitous machine), Vortal(Vertical Portal) machine and P2P(Peer to Peer) machine. Such advanced concept machines will be the key subject for M2M cooperation.
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The research regarding the epicyclic gear system development for a rate of high-reduction embodimentAmong various gear system, planetary gear system has the best characteristics in high efficiency, excellent strength capacity, easy convertible speed control, and compact design aspect. Strength of gear is considered as the most important design factor. We have studied tooth form and the planetary gear system that have high reduction gear ratio is created by using the involute curve.
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PAM-STAMP is a widely used program which deals with press forming analysis. A blanking used in the press process depends on the experience of the workers. Thus it causes some waste material and demands a lot of time and many costs at the manufacturing mold. So we need to optimize of the blanking size. We have studied the optimal blanking size of the Brace Center Pillar using an Inverse module in PAM-STAMP
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There are many methodologies fur doing analysis of system's reliability in early design stage. Among the methods, PRISM is, as compared to MIL-HDBK-217, a newly developed technology but not easy to use. Because PRISM provides models that predict a part failure rate and field database, called EPRD and NPRD that can be combined with prediction models. This paper presents some capabilities of the prediction models in PRISM and usability of EPRD and NPRD database in system level reliability prediction.
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The automatic inspection system is developed for the formed end part of automotive fuel pipe. The developed system has functions of outer diameter and formed end length measurement by LVDT(linear variable differential transformer) together with burr cleaning of automotive fuel pipe. The measured data are managed and controlled in real time by embedded SPC(statistical process control) program. The system is composed of mechanical part, electronic part and developed software system. These three parts operate automatically by mutual communication with each other. The developed system showed good results in finding inferior goods and efficiency improvement of the fuel pipe production line. It also eliminated the unreliable manual inspection processes and improved the confidence of product quality.
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This paper proposes an Molding error compensation method that improves accuracy with geometry information of injected parts using three-dimensional measuring instrument. a traditional mold design has been conducted by an experience-based trial and error, whereby generally the mold designer would decide the gate location and processing conditions. as a natural consequence, almost all creats inferior goods. It's just a process of trial and error and caught in a vicious circle. Due to this reason, this paper uses a three-dimensional measuring instrument, a commercial analysis package of injection molding(Moldflow, MPI) to analysis a state of flux. In addition to that axiomatic approach.
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Importance of using an injection molding analysis has been increased. However the application of it has not been increased because the results of analysis do not sometime match to practical molding. Therefore, the difference of flow analysis and practical molding should be decreased. This study presents reasons of the difference for the location of weld-line in the flow analysis and practical molding on automobile bumper molding.
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Recently, a lot of work and interest has been devoted to the development of multiaxial fatigue parameters for fretting fatigue life prediction. Many of these parameters have been reviewed in the literature for simple geometries like a cylinder-on-flat contact configuration. The purpose of this study was to estimate fretting fatigue life using critical plane approach which is one of the multiaxial fatigue theories.
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This paper presents the robust design of gripper part for a high-speed LCD (Liquid Crystal Display) transfer system. In this paper, the 1st DOE (Design of Experiment) is conducted to find out main-effect factors fur the design of gripper part. Thirty-six experiments are performed using
$ANSYS^{(R)}$ and their results are statistically analyzed using$MINITAB^{(R)}$ , which shows that the factors, i.e., First-width, Second-width, Rec-width, and thickness of gripper part, are more important than other factors. The main effect plots shows that the maximum deflection and mass of gripper part are minimized by increasing First-width, Second-width, Rec-width and thickness. The 2nd DOE is conducted to obtain RSM (Response Surface Method) equation. The CCD (Central Composite Design) technique with four factors is used. Optimum design is conducted using the RSM equation. Genetic algorithm is used for optimal design. Six sigma robust design is conducted to find out a guideline for control range of design parameter. To obtain six sigma level reliability, the standard deviations of design parameters are shown to be controlled within 5% of average design value. -
The important factor to evaluate the running safety of a railway vehicle would be the interaction force between wheel and rail(derailment coefficient), for which is one of important factors to check the running safety of a railway vehicle that may cause a tragic accident. In this paper, when interaction force between wheel and rail happens to wheel-set of tilting vehicles, it analyzes stress distribution and verified safety.
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Hydraulic circuit breaker is the most popular type of electric power circuit breaker because of its superiority of operating performance and capacity. For the improvement of hydraulic circuit breaker's operating performance, it is very important to analyze its dynamic behavior characteristics. In this study, hydraulic circuit is modeled, analyzed and experimented. As a result, the experimental data agree well with the numerical ones, and the numerical results can be applied to the design and the improvement of hydraulic electric power circuit breaker.
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Today, the Artificial Intervertebral Disc (AID) is being developed by increasing the oblique of the endplate gradually. In other words, Ultra-high Molecular Weight Polyethylene (UHMWPE) which is apply to the sliding core of the AID, does not change the shape but alters the oblique of endplate. However, the unreasonable increase of degree of freedom (DOF) can result in the aggravation of the bone fusion and the initial stability and it can also lead to the increase of the concentrated force in core. For these reasons, it is necessary to develop the advanced techniques, which choose the most adequate DOF. In this study, the new optimized modeling of the sliding core and the endplate, the fatigue characteristics, the crack propagation and the formation mechanism of wearing debris was studied and the minimizing technique will be derived from this research.
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During demonstrations of a process conditioning spent nuclear fuels, it is necessary to transport and handle Spent fuel road cuts from Post Irradiation Examination facility to Slitting device in The hot cell. the spent fuel pellets which are highly radioactive materials are separated with its clad and are fed into the next conditioning process. For this, a spent fuel rod, 3.5 m long, is cut by 25 cm long which is suitable length for the decladding process. These rod-cuts are packed into the capsule and are moved to the ACPF(Advanced spent nuclear fuel Conditioning Process Facility). In the ACPF, Once the capsule is unloaded in the ACPF, Capsule is taken out one-by-one and installed on the decladding device. In these processes, the crushed spent fuel pellet can be scattered inside the facilities and thus it contaminate the hot cell. In this paper, we developed the specially designed transportation and storage device for spent nuclear fuel capsules.
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This study was carried out to analyze the effect of wind load on the structural stability of a container crane according to the change of the boom shape using wind tunnel test and provide a container crane designer with data which can be used in a wind resistance design of a container crane assuming that a wind load 75m/s wind velocity is applied in a container crane. Data acquisition conditions for this experiment were established in accordance with the similarity. The scale of a container crane dimension, wind velocity and time were chosen as 1/200, 1/13.3 and 1/15. And this experiment was implemented in an Eiffel type atmospheric boundary layer wind tunnel with
$11.52m^2$ cross-section area. Each directional drag and overturning moment coefficients of a container crane according to the change of the boom shape were investigated. -
This study is carried out to analyze the stability of a container crane in according to the change of a wind direction and a machinery house location when a wind load of a wind velocity, 75m/s was applied on the state stowing a container crane by a heavy wind. A design wind load applied to this study was calculated in observance of 'Load Criteria of Building Structure'. And we analyzed the reactions of each supporting points according to appling a wind direction to an interval of
$10^{\circ}\;in\;0^{\circ}{\sim}180^{\circ}$ and the structure stability of a container crane according to changing a machinery house. location occupying 15% of a container crane weight. From a results of this study, we presented a design criteria of an overturning disturbance equipment, tie-down. -
Thermoplastic elastomer(TPE) can be molded by conventional injection molding. Therefore TPE injection molding could be analyzed by commercial flow analysis software. However there are a little of gaps on CAE simulation results and practical molding. In this study, the properties of TPE were measured and applied to CAE simulation for comparing the simulation flow pattern and real flow pattern. The pattern that was controlled by injection time was match. The pattern that was controlled by injection stroke and rate was not match.
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The knuckle crane mainly consists of six parts such as swing, main boom, outer boom, extension boom, hydraulic rotor and knuckle. And the hydraulic rotor is connected at the end of extension boom has rotor block, rotor body, rotor vane. In this study, we carried out kinematics analysis of the hydraulic rotor block curvature for a knuckle crane. Then, we showed the formula to establish the radius of a circumscribed circle to form the rotor block curvature. Third, we analyzed the stress at each point of the rotor block curvature according to the contact angle. From the result of this study, we designed the rotor block curvature with a proper contact angle for a knuckle crane to guarantee the stability of hydraulic rotor.
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In this study we dealt with the relationship between the initial clamping force and the sliding distance in the wedge type rail clamp. The sliding distance is determined by the wedge angle and the initial clamping force. In order to derive the relation formula between the wedge angle and the sliding distance, we ad opt 5-kinds of the wedge angle, such as 2, 4, 6, 8,
$10^{\circ}$ . And then we analyze the effect of the initial clamping force on the sliding distance. -
The mechanical behaviors of multi-layered foam core sandwich composite were investigated through a 3-point bending test. The sandwich specimens were obtained from sandwich panel consisting of aluminum faces and urethane foam core. Three types of sandwich specimens such as a single structure, a double structure and a triple structure were considered. The span of sandwich specimens were varied from 170mm to 350mm. According to the results, the flexural and shear properties of multi-layered sandwich composite were found to be higher than those of single-layered sandwich composite.
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Ventilated disc was improved for reducing judder and heat. But the crack among vent holes occurs due to stress concentration. We investigate the stress distribution of vent holes. The vent holes with shape of a right angle, a chamfer and rounding was analyzed. The result of FEA was that rounded vent holes have a minimum stress. Also Maximum stress distributed within holes. Therefore We suggest that the rounded vent holes is good to reduce the crack.
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A brake disk in railway vehicle is safety part. Requirements not only in performance but also in comfort, serviceability and working lifetime are high and rising. In this study, we carried out fatigue test and thermal stress analysis. To determine a pressure distribution, contact pressure analysis precede thermal stress analysis. Especially, characteristics of the brake disk were analyzed in considering intial velocity, and thickness of a frictional plate. Form the comparing the results of experiment and FEM analysis, fatigue characteristic and fatigue life assessment ok a brake disk of railway vehicle were performed.
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This article provides a dynamic analysis model for huge marine engine that examined analytically variation effects of frequency response by fitting of transverse stays such as hydraulic type. First, vibration analysis using the three dimensional finite element models for the huge marine engine has performed in order to find out the dynamic characteristics. Second, three dimensional finite elements model for the huge marine engine was modifued so that generate forcing nodes in crosshead part and top bracing nodes in cylinder frame part. Third, a system matrix and output matrix was derived for the general siso(single input single out) state space model. Finally, developed state space model for the three dimensional finite elements model for the huge marine engine without the additional modifying process.
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The cycloidal reducer is one of the velocity controlling equipments in machinery. It has advantages of the higher reduction ratio, the higher accuracy, the easier adjustment of the transmission ratio and the smaller workspace than any other kinds of the reducers. This paper proposes a simple and exact approach for the lobe profile design of the two teeth difference cycloidal plate gear, which is different from the standard cycloidal reducer, by means of the principle of the instant velocity center in the general contact mechanism and the homogeneous coordinate transformation.
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Gears are essential and useful elements which power is transmitted from a source to a driven equipment. Therefore, it is very important to design gears correctly. Two important points in the gear design procedures are capacities of the gears's bending strength and pitting resistance. This paper deals with two subjects about spur and helical gears : analyzing for strength and wear capacities, and design of face width. Also, this paper proposes the analytical program which is developed for computer aided design and analysis This program is based on the American Gear Manufactures Association(AGMA) Standards.
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This study introduces the testing results of the composite carbody which is applied to tilting train. The composite carbody is made of aluminum honeycomb structure materials like a sandwich. The static load test was performed to evaluate the structural characteristic and stability of the composite carbody. Considering the vertical, compressive, twisting load and 3-point supporting type as a testing terms, the structural stability of a carbody was evaluated.
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This paper presents the optimal design of Robot-Arm part use Design of Experiment(DOE). The DOE(Design of Experiment)was conducted to find out main effect factors for design of Robot-Arm part. In this design of Robot-Arm, 5 control factors include numbers of 4 level are selected and we make out L16 orthogonal array. Using this orthogonal array, find out optimal value and main effect factors of object function for design of Robot-Arm part by 16 times of test. We evidence this optimal value by using CATIA V5 Analysis.
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The Effect of Variable Electric Fields on the PZT Characteristic and Laminate Configuration in LIPCAThe advanced piezoelectric ceramic composite actuator, which is called LIPCA with the FRP and the optimization of the laminate configuration, was performed to maximize the stress transfer and the fiber bridging effect. This study evaluated the effect of variable electric fields on the PZT characteristic, laminate configuration and fatigue characteristics under the resonance frequency, which meant the largest performance range and the changes of its interlaminar phase were also evaluated by stages. In conclusions, Comparing with the fatigue lift of intact LIPCA, the fatigue life of LIPCA embedded by the artificial delamination was decreased up to 50%. The micro void growth and the coalescence of epoxy were actively made at the interlaminar phase subject to the large tensile stress.
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LMTT(Linear Motor based Transfer Technology) is a new type of transfer system used in the maritime container terminal fur the port automation, and largely consists of a controller, shuttle car, and rail. The shuttle car is divided into the frame part, the driving part, and wheels. In order to design this system, various researches on each part of it must be conducted. In this study, we dealt with the optimum design for the frame part of the shuttle car designed from previous studies on the strength of the frame with respect to the number of cross beams to minimize the weight of the shuttle car and to satisfy design criteria of cargo-handling systems in container terminal. For the optimization of the frame, thicknesses of each beam were adopted as design variables, the weight of the frame as objective function, and stress and deflection per unit length as constraint condition.
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In the present paper, approximate plastic limit load solutions for pipe bends under combined internal pressure and bending are obtained from detailed three-dimensional (3-D) FE limit analyses based on elastic-perfectly plastic materials with the small geometry change option. The present FE results show that existing limit load solutions for pipe bends are lower bounds but can be very different from the present FE results in some cases, particularly for bending. Accordingly closed-form approximations are proposed for pipe bends under combined pressure and in-plane bending based on the present FE results. The proposed limit load solutions would be a basis of defective pipe bends and be useful to estimate non-linear fracture mechanics parameters based on the reference stress approach.
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A finite-element based approach to socket shape design of a concave piston assembly for a high pressure hydraulic pump of an excavator is presented in this paper. The approach is applied to developing a concave piston assembly which fulfills its strength requirement and it is verified that the predictions are in good agreement with the experiments.
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Recently, the flat display modules such as plasma or TFT-LCD employ thin crystallized panels which are normally weak to high level transient mechanical energy inputs. As a result, anti-shock performance is one of the most important design specifications for TFT-LCD modules. However, most of large display module designs are generated based on engineers own experiences. Also, a large-scale analysis to evaluate complex material and structural behaviors is one of interesting topic in diverse engineering and scientific fields. The utilization of massively parallel processors has also been a recent trend of high performance computing. The objective of this paper is to introduce a parallel process system which consists of general purpose finite element analysis solver as well as parallelized PC cluster. The parallel processing system is constructed using thirty-two processing elements and the finite element program is developed by adopting hierarchical domain decomposition method. In order to verify the efficiency of the established system, an impact analysis on thin and complex sub-parts of flat display modules is performed. The evaluation results showed a good agreement with the corresponding reference solutions, and thus, the parallel process system seems to be a useful tool fur the complex structural analysis such as IT related products.
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Almost all injection molds have multi-cavity, which are designed with geometrically balanced runner system in order to made filling balance between cavity to cavity during injection molding. However, filling imbalance has been existed in the geometrically balanced runner system. In this study, we made an experiment and surveyed that are filling balanced variation according to molding condition with thermoplastic vulcanizate (TPV). Also, we conducted experiments in order to know the influence of filling balance for runner core pin (RC pin).
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In this study, the tempering effect on the wear characteristics of induction-hardened SPS5 steel was investigated. For this purpose, three tempering conditions were applied to control the hardness of heat-treated SPS5 steel. Ball-on-disk wear tests have been performed using zircornia balls on the tempered specimens to determine the variation of wear characteristics. The results showed that friction coefficient decreased with increasing hardness for induction hardening conditions. This seems to occur because real contact area between specimen and mating ball was affected by the specimen hardness.
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It is very difficult to analyze the dynamic characteristic because railway vehicle is a very complex system which are connected various mass element with railway vehicle system. To realize and analyze actual phenomenon has restriction that usual commercial software calculates creep force under creep theory about wheel-rail contact mechanism as basic analyzing, and approach about contact point are based on two dimensional non-linear contact theory and simplified Hertzian contact which considers just displacement change on the YZ plain. Therefore, to solve these problems there should be a new approach difference with existing one. In this research, a new algorithm for finding wheel-rail contact position, calculation method of contact force and applied force will be presented.
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This study was aimed to verify the stable interruption characteristics between power collector and 3rd rail type conductor rail for the Korean-standardized rubber-tired AGT light rail vehicle. At the test track for the Korean-standardized rubber-tired AGT light rail vehicle, interruption ratios, stresses, vibrations, and contact force variations were measured by test conditions, having various train speed. As the results, it was verified that developed 3rd rail type conductor maintains interruption characteristics, which can supply stable electric power.
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In this paper, we propose the ergonomics design method in shape design applicable which considers the user interface for railroad. This study focuses on ergonomics design and sensibility engineering design, user interface, which should be considered from the conceptual design stage of the rolling. Human's sensitivity and User Interface of railroad investigated ergonomics studies of several type. The sensibility engineering design made approach of user center design in railroad design. New design railroad to satisfaction passenger's various desire, to safety and convenient through high technology, to sufficient passenger's aesthetic sense. Therefore, we have application to properly of ergonomics design element in railroad design. we expert visual design and user interface help greatly in excellent railroad design.
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CATIA V5 is one of the most preferred softwares in product design for domestic and industrial use. But with the development of the IT industry, design data by CATIA V5 can easily be hacked and stolen especially via the internet and through assistance storage medium. The design data could be protected through executive, physical and technical security system. The best way to maintain confidentiality of data from unauthorized access is to have a cryptosystem of the technical security. In this paper, a cryptosystem for the protection of design data was being proposed. The memory contains the file information made by the New and Open function of CATIA V5. No error can be expected even if the file changed before of after the application of Save and Open function, A cryptosystem was constructed in CATIA V5 by inserting crypto algorithm before and after the I/O process. The encryption/decryption algorithm of each function was based on the complex cipher, which applied permutation cipher and transpose cipher. The file security system was programmed in CAA V5 and Visual C++.
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This paper deals with a hex-dominant mesh generation using an advancing front method for three-dimensional geometries. Hexahedral and prismatic meshes are generated inwardly by offsetting from initial boundary mesh. When the meshes intersect with each other after offsetting, overlapped meshes are improved by node relocation method. In order to generate conforming mesh, pyramid elements are inserted between hexahedral and tetrahedral elements. Sample meshes fur several geometries are presented and analized to demonstrate the effectiveness of the proposed algorithm.
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According to the industrialization the using of polymers is increased by their mechanical or commercial demands. At now, the using of polymers is become bigger and bigger than yet. On the other words, our whole life is covered by the polymers. Due to the extended polymer using, the material cost is higher and higher. Therefore, the people used the polymer foaming process using the gas. The polymer foaming using the pentane or butane gas is prohibited by the government cause of the explosiveness and non-environmental friendly. Therefore, the members of MIT invented the Micro-cellular Polymer Foaming in 1980. The Micro-cellular Polymers has many cells in the polymer matrix. By compare between non-foamed polymers, the Micro-cellular Polymers have low material cost, soundproof and shock less. The purpose of this study is to study the twice foamed polymer by batch process. To know the reaction by step of microcellular foaming process, we measure the density of polymer. And to viewing the cell morphology, we used the scanning electron microscopy(SEM).
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This paper proposes a hexahedral mesh generation scheme based on mapping approach and improves the drawback of sweeping algorithm. In order to improve the drawback, the algorithm in this paper generates hexahedral meshes by three dimensional element mapping first. Then hexahedral meshes are equivalent to geometry of the volume by mapping and smoothing. Sample meshes are constructed to demonstrate the mesh generating capability of the proposed algorithm.
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This study proposes a new simulation method of high speed rotor system with the dynamic model using multi body dynamic analysis tool and with a new phase modulating technique as a system control algorithm. A dynamic model of high speed rotor system was built by, ADAMS, commercial multi body dynamic program. The phase modulating technique is a new control algorithm for a rotor system. This algorithm can control system using an adaptive proportional gain and an adaptive phase which are obtained from periodical input signal. To make control system, a ADAMS model and component parameters and phase controller was composed by Matlab Simulink And simulate it.
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In this study, three dimensional(3-D) orifice model was developed fur automobile trunk hinge. Using that model the flow analysis was conducted to estimate pressure tendency of orifice model according to the variations in the design factors such as oil viscosity and orifice size.
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To estimate the fatigue life of flange-shaft assembly, fatigue test for flange material and bending fatigue test for flange-shaft assembly were conducted. Also, finite element analysis for flange-shaft assembly was conducted. Then, we have changed the obtained P-N curve to S-N curve using the finite element analysis results which were stress values at the location of fracture. The S-N curve of flange material itself was almost consistent with that of flange-shaft assembly, so it seems that the fatigue life of flange-shaft assembly could be estimated by using S-N curve for flange material and the stress at the location of fracture calculated by finite element methods.
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In this study, the effect of the temperature of magnesium slurry was investigated by mechanical stirring method. The evaluations of rheological behavior of AM50A magnesium alloy were measuring of viscosity and microstructures in the semisolid state. The apparent viscosity was investigated at continuous cooling rate using a concentric cylinder viscometer. Measurement of viscosity measures torque that act to stirrer rotating in slurry doing continuous cooling using torque-meter and expressed by POWER-LAW. Microstructures were observed after mechanical stirring that enforce time at steady state temperature of solid fraction.
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The limited slip differential(LSD) is a device which enables the driving force to be transmitted from one slipping wheel to another wheel in such case that the car is stuck in clay or snow. When the unwanted slipping occurs on one wheel, the LSD temporarily restraints the differential motion to transmit the driving force in the other wheel. So far, many types of LSD were developed such as mechanical lock type, disk clutch type, viscous coupling type, torsion type and multiple clutch type. we designed a new type of the hydraulic LSD which uses the principle of trochoid gear pump.
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This study focused on the introduction of the self healing technique for polymeric composites and evaluated the healing efficiency by the use of the interlaminar toughness fracture test. The DCPD (dicyclopentadiene) and ENB (5-ethylidene-2-norbornene) were used for the healing agent and the Grubbs' catalyst was used for the catalyst. According to the results, healing efficiency was found to be 37.9%, 22.3%, 26.3%, 22.8%, 30.8%, 30.8%, 33.0%, 33.4% for mode II fraction of 0%, 20%, 35%, 50%, 65%, 80%, 90%, 100%, respectively.
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Generally, the vertical roll process is used to achieve extensive width reduction in hot strip mill. However, it is difficult to avoid the defects such as dog-bone and seam-defect. The sizing press has been developed in response to the defects mentioned above. Especially, this study is carried out to investigate the deformation of slab by two-step sizing press. The deformation behavior in the width sizing process is more favorable than that in conventional vertical rolling edger. The objective of this study is to determine the optimal anvil shape parameters in the sizing press with two-step die from the viewpoint of edge-seam length. In general, the edge-seam defect occurs parallel to the rolling direction at both edges in horizontal rolling process after sizing press. The optimal combination of the parameters is determined by FE-simulation and Artificial Neural Network (ANN). The slab deformation in sizing press with convex anvil is analyzed by FE-simulation. The most suitable profile of the anvil is also discussed fur the improvement of trimming loss because of the side seam defect by FE-simulation and ANN.
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This research proposes a novel method of shape display to present 3-dimensional objects. Shape displays allow us to feel the actual volume of the object, unlike conventional 2D visual displays of 3D objects. The proposed method employs a wire frame structure to present 3D objects. The wire frame is composed of small units driven by shape memory alloy(SMA) actuators. The drive unit is analogous to the agonist-antagonist system of animal musculoskeletal systems, where the SMA actuators serve as agonist and antagonist muscles. The force in the SMA actuator is controlled by electrical current. The drive unit is equipped with the locking mechanism so that it can sustain the external force exerted by the user as well as the own weight of the wire frame structure. By controlling the current into the SMA actuator and locking mechanism, we call control the angle of the drive unit. A chain of drive units enables presentation of 2 dimensional objects. 3 dimensional presentations are possible by collecting the chains of drive units.
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It is attempted to find out the optimal shape of U-type bellows using the finite element analysis. The design factors, mountain height, length, thickness, and the number of convolutions are considered and the proper values are chosen fur the simulation. The results show that as the number of convolutions reduces, the volume decreases while the stress increases. However, as the number of convolutions increases, the volume increases above the standard volume and the stress obviously increases. In addition, the effect of the thickness of bellows on the stress is very large. Both of the mass and stress are decreasing at a certain lower value region. Also, we investigated shape optimization with considering maximum stress distribution tendency.
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The influence of the heat sources on LED junction temperature are Engine room air, Back plate, Electric power device, and so on. LED lamp cooling system is considered to be an important subject fur high light efficiency. Because LED Chip will be problem When LED junction temperature be over
$135^{\circ}C$ , In this Study, The Looped Heat Pipe System is considered to prevent LED Chip fall. The LHPS is consist of evaporator part, condenser part, heat pipe part. The working fluid of LHPS is HCFC-123. In this study, to prevent LED Chipfall, we study thermal characteristics for Looped Heat Pipe System with LED lamp. -
By the reason of increased demand of high productivity, the researches on manufacturing process and equipments for reducing cycle time have been made in many directions of a machine tool industries. Among these, this paper proposed method of decreasing displacement in MC(machining center). Factors affecting displacement are a motor mass, head thickness, column thickness and base thickness. In this paper We could find design factors has much influence on decreasing the unclamping time using the Taguchi method and optimized the level of the factors using
$ADAMS^{(R)}$ . -
High speed machining is the core technology that influences the performance of machine tools, and the high speed motor spindle is widely used fur the high speed machine tools recently. The important problem in this spindle is to reduce and minimize the thermal effect by motor and bearing. In this study, the analysis of thermal characteristic of spindle is performed according to the cooling methods of housing by using finite element method. This result can be applied to the design and manufacture of the high speed spindle.
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Development of a feed drive system with high speed, positioning accuracy and thrust has been an important issue in modern automation systems and machine tools. Linear motors can be used as an efficient system to achieve such technical demands. By eliminating mechanical transmission mechanisms such as ball screw or rack-pinion, much higher speeds and greater acceleration can be achieved without backlash or excessive friction. However, an important disadvantage of linear motor system is its high power loss and heating up of motor and neighboring machine components on operation. For the application of the linear motors to precision machine tools an effective cooling method and thermal optimizing measures are required. In this paper presents an investigation into a thermal behavior of linear motor cooling plate. FVM employed to analyze the thermal behavior of the linear motor cooling plate, using the ANSYS-CFX.
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According to the demand of high productivity, the interest of manufacturing skills is growing in the industrial society. Especially the long spindle becomes important these days. The rotating accuracy of the spindle concerns the centrifugal force. In detail explaining, it is influenced by the speed of the spindle. In this study, we would show changes of the distance caused by a rotating speed of the spindle using a software,
$ADAMS^{(R)}$ . And because of the gravity of the spindle's mass, we would find the static droop of the long spindle. -
This paper describes a processing verification technique for developing about end-milling cutters. Developed software is processing verification module for manufacturing. By using cutting simulation method, we can obtain center points of finding wheel via Boolean operation between a grinding wheel and a cylindrical workpiece. The obtained CL data can be used for calculating NC data. After then, we can simulate by using designed grinding machine and NC data. This research has been implemented on a commercial CAD system by using the API function programming. The operator can evaluate the cutting simulation process and reduce the time of design and manufacturing.
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Multi-tasking machines are widely used in machine tool industries nowadays. This study focuses on the effect of load on the structure stabilities of laser multi-tasking machine which is comprehensively combined turning center and laser machine. For design of the machine, simulation of structural analysis is carried out varying number of elements. The analysis is carried out by FEM simulation using the commercial software, CATIA V5. This method showed a proper number of elements can be selected to obtain good result by reduced computation time.
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A method for obtaining smooth, jerk bounded feed rate profile in high speed machining has been developed. This study proposes a NURBS interpolator based on adaptive feed rate control with a well developed look ahead algorithm which takes into account the machining dynamics as well. Limitation of jerk and proportional torque rate result in smoothened loads on the machine which effectively reduces excitation of the resonant frequencies of the machine. It is found that the values of the feed rate of the down stream sharp corner have profound effect on the feed rate of the upstream sharp corners. By using a windowing scheme the feed rate profile obtained after look ahead method is re-interpolated to reduce the jerk related problems. This is compared with the adaptive NURBS interpolator to show the effectiveness of the proposed method. Simulation results indicate that the consideration of 'ripple effect' is important in avoiding jerk and thereby increasing the machining accuracy.
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Electron beam manufacturing system can be used to make patterns that are smaller than can a photolithography. In this system, High voltage generator is a fundamental element for stable beam. We used high voltage with transformer. However, this instrument has several problems (for examples, dimensions, buying parts, simplicity of control circuit). For solving these problems, a commercial product is considered. This is developed for SEM(Scanning Electron Microscope). In this paper, we designed a control circuit for a commercial product and analyzed performance.
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This paper reports on the development of a scanning probe microscopy(SPM) tip with caborn nanotubes. We used an electric field which causes dielectrophoresis(DEP), to align and deposit CNTs on a metal-coated SPM tip. Using the CNT attached SPM tip, we have obtained an enhanced resolution and wear property compared to that from the bare silicon tip through the scanning of the surface of the bio materials. The carbon nanotube tip align toward the source of the ion beam allowing their orientation to be changed at precise angles. By this technique, metal coated carbon nanotube tips that are several micrometer in length are prepared for scanning probe microscopy.
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This paper present experimental results by non-contact mode Atomic Force Microscopy using high aspect ratio tips (HAR-T). We fabricated the carbon nanotube tip based on dielectrophoresis and the carbon nano probe by focused ion beam after dielectrophoretic assembling. In this paper, we measure AAO sample and trench structure to estimate HAR-T's performance and compared with conventional Si tip. We confirmed that results of HAR-T's performance in non contact mode was very superior than conventional tip.
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A single-wall carbon nanotube (SWCNT) has been studied as a material of Nano-Eletro-Mechanical-System (NEMS) device together with various nanowires. In order for oscillation of a multi-wall carbon nanotube (MWCNT) or a single-walled carbon nanotube (SWCNT) on plane surface, it needs suspension of a CNT across trench electrodes. So we propose fabrication method of a MWCNT resonator using dielectrophoresis and show successful results of suspeneded MWNT. Thin electrodes with large gaps could not suspend small diameter MWNT but thicker electrodes could. Thin MWNT could be suspended only when the electrode gap was reduced.
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In this work, we present the comparison between
$d_{31}\;and\;d_{33}$ mode characterization using the PZT micro-actuator for large displacement. The PZT micro-actuator consisted of Si, PZT, and Pt layer on SOI wafer. The electrode shapes were laminated and interdigitated for$d_{31}\;and\;d_{33}$ mode, respectively. In order to characterize the actuation mode, we measured the displacement using laser interferometer. The maximum displacement of d31 mode was$12.2{\mu}m$ at 10V, the actuation characterization of d31 was better than that of d33 mode. We estimated that displacement of d33 mode would be larger than that of d31 above 30V. -
Piezoelectric transformers based on lead zirconate titanate(PZT) have been received considerable interest because of their wide potential applications in transformer, oscillator, resonance sensor, actuator, acoustic transducer, as well as active slider for hard disk drives. However, for the applications which need a small power supply such as thin and flat displays, micro-robot, micro-system, it is especially necessary to integrate the passive components because they typically need more than 2/3 of the space of the conventional circuit. So, we have fabricated the piezoelectric micro-transformer to supply energy for micro-systems using PZT thin films and MEMS technologies.
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High aspect ratio of nano hairs on a plastic substrate is molded using thermoplstic materials including COC, PP, PC and PMMA. As a template for molding nano hairs, AAO membrane is adopted, which is 60um thick and 13mm in diameter. This membrane has about 109 of through-holes of which diameter is around 200nm. This AAO membrane and the pellet of materials are stacked in the mold and pressed to mold after heating up to be melted. The AAO membrane is removed using KOH to obtain the molded nano hairs. As a result, the diameter of the molded hairs is around 200nm and the length is
$2um{\sim}60um$ depending on the molding conditions and materials. -
Aligned carbon nanotubes(CNTs) array were synthesized using direct current plasma-enhanced chemical vapor deposition. The nickel microgrids catalyzed the growth of carbon nanotubes which take on the area of the nickel microgrids. Selective growth of areas of nanotubes was achieved by patterning the nickel film. CNTs were grown on the pretreated substrates at 30%
$C_2H_2:NH_3$ flow ratios for 10min. Carbon nanotubes with diameters about 20 nanometers and lengths approximately 720 nanometers were obtained. Morphologies of carbon nanotubes were observed by FE-SEM and TEM. -
Self-assembled monolayers (SAMs) formed by the adsorption of alkanethiols, HS(CH2)nX, where X is an organic functional group, onto gold surfaces have attracted widespread interest as templates for the fabrication of molecular and biomolecular microstructures. Previously photopatterning has been thought of as being restricted to the micron scale, because of the well-known diffraction limit. So, we have explored a novel approach to nanofabrication by utilizing a femtosecond laser.
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This paper presents the results of miniaturized micro milling machine tool development for micro precision machining process. Finite element analysis has been performed to know the relationship between design dimensional variables and structural stiffness in terms of static, dynamic, thermal aspects. Design optimization has been performed to optimize the design variables of micro machine tool to minimize the volume, weight and deformation of machine tool structure and to maximize the stiffness in terms of static, dynamic, and thermal characteristics. This study presents the assessment of the technology incentive for the minimization of machine tool in the quantitative context of static, dynamic stiffness, thermal resistance and thus the accuracy implications.
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The purpose of this paper is to investigate the relationship between CMP(Chemical Mechanical Polishing) characteristics of ITO thin film and friction signal by using the CMP monitoring system. Suba 400 pad and MSW2000 slurry of the Rohm & Haas Co. was used in this experiment to investigate the charateristics of ITO CMP. From this experiment, it is proven that the coefficient of friction is related to uniformity of the removal rate of the ITO thin film. Therefore, the prediction of polishing result would be possible by measuring friction signal.
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Chemical-mechanical polishing, the dominant technology for LSI planarization, is trending to play an important function in micro-electro mechanical systems (MEMS). However, MEMS CMP process has a couple of different characteristics in comparison to LSI device CMP since the feature size of MEMS is bigger than that of LSI devices. Preliminary CMP tests are performed to understand material removal rate (MRR) with blanket wafer under a couple of polishing pressure and velocity. Based on the blanket CMP data, this paper focuses on the consumable approach to enhance MEMS CMP by the adjustment of slurry and pad. As a mechanical tool, newly developed microstructured (MS) pad is applied to compare with conventional pad (IC 1400-k Nitta-Haas), which is fabricated by micro melding method of polyurethane. To understand the CMP characteristics in real time, in-situ friction force monitoring system was used. Finally, the topography change of poly-si MEMS structures is compared according to the pattern density, size and shape as polishing time goes on.
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This paper introduces an improved surface matching algorithm that can be used to reconstruct the surface topography of an object that is scanned from multiple overlapping regions by an AFM. The essence of the image matching technique is stitching two neighboring images intentionally overlapped with each other. To enhance the computational efficiency, this paper introduces a pyramid matching algorithm which makes use of reduced images for primary images. The results show that the proposed image pyramid matching algorithm is useful fer enhancing the computational efficiency.
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This paper represents a ultra precision rotational device where the smooth impact drive mechanism(SIDM) is utilized as a driving mechanism. Linear motions of piezoelectric elements are converted to the rotational motion of disk by frictional forces generated between the rotational disk and the friction bars which are attached to the piezoelectric elements. This device was designed to drive a rotational disk using slip-slip motion mechanism based on stick-slip motion mechanism. Experimental results show that the angular velocity was increased in proportion to the magnitude of supplied voltage to piezoelectric element. In our device, the smooth rotational motion was obtained when the driving frequency has been reached to 500Hz under the driving voltage of 100V. The amount of step movement has been revealed to be
$3.44{\times}10^{-4}$ radian. -
Picosecond (ps) laser micro-machining has emerged as an attractive method of fabricating high-precision microstructures, especially in metals. In this paper, a metallic mold for diffraction gratings is fabricated with a mode-locked 12 Ps
$Nd:YVO_4$ laser. Laser pulses with a wavelength of 355nm are irradiated on the surface of NOK 80, a mold material, to generate line patterns. In order to minimize the line width, laser power is set just above the ablation threshold of NOK 80. Results show that the spectrum from the fabricated mold is good enough for some industrial application. -
To establish fabrication techniques for nano structure understanding of focused ion beam (FIB) milling process is required. In this study the mathematical model containing the factors related to FIB milling is developed to acquire the optimal fabrication condition. Then, the model is verified by comparison with various nano pattern fabricated in actual FIB system. Consequently, it is demonstrated that the nano patterns with the smallest pitch can be fabricated using developed FIB milling model.
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In the microstereolithography which can make 3-D microstructures, curing depth is different according to exposure energy. Curing depth has to be controlled to fabricate complex 3-D microstructures with overhang shape. It becomes increases when the exposure energy increases. And photocurable resin is cured when the exposure energy is bigger than critical energy. So optimal exposure energy has to be found to fabricate overhang structures without being gel. To make thinner layer, UV absorber is used and exposure pattern is changed. In this paper, we find curing characteristics according to exposure energy, and fabricate microstructures with overhang shape.
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SU-8 can be implemented as a mask for micro Abrasive Jet Machining (micro-AJM) process [1]. In this paper, we will evaluate the quality of micro grooving result on glass substrate by micro-AJM process which using SU-8 as a mask. It was evaluated on width and edge profile of the micro grooving. The result was having distortion compare with the master film used to pattern the SU-8 mask. The value of distortion with other properties which came along with it, such as depth and surface roughness, can be optimized in order to fabricate micro-channel for micro-fluidic application.
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Electrostatically actuated nanoscale tweezers are fabricated on micro processed electrodes using FIB-CVD. Heavily doped electrode works as interconnection platform for controlling nanoscale devices. Short bent pillars are deposited to control the gap distance of main tweezers fabricated on bent ones. Two types of tweezers which have different gap distances are fabricated and tweezing motion was successfully demonstrated. The threshold voltages at snap-down of the pillars are dependent on the initial gap distance of the unactuated pillars, and the measured values were 93V for 3.6um and 30V for 2.2um. The dimension of nano tweezers and initial gap distances are controllable as demonstrated and we expect more complicated 3-dimensional shapes are also possible.
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Tribological properties of a Magneto-Rheological(MR) fluid in a polishing process are studied. For this polishing process, abrasive wear model is proposed as a function of shear force, normal force and actual mean velocity of MR particles at workpiece surface. Experimental conditions are changed by varying the gap distance between workpiece and tool and the rotational speed of tool. From the experimental results, a modified Stribeck curve is obtained, and the friction coefficient turns out to have linear relationship with a modified Sommerfeld number. The validity of the wear model is supported by additional experiments performed for measuring material removal rates.
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The electrode wear in micro-EDM significantly deteriorates the machining accuracy. In this regard, electrode wear needs to be compensated in-process to improve the product quality. Therefore, there are substantial amount of research about electrode wear. In this study a control method for micro-EDM using discharge pulse counting is proposed. The method is based on the assumption that the removed workpiece volume is proportional to the number of discharge pulses, which is verified from experimental results analyzing geometrically machined volume according to various number of discharges. Especially, the method has an advantage that electrode wear does not need to be concerned. The proposed method is implemented to an actual micro-EDM system using high speed data acquisition board, simple counting algorithm with 3 axis motion system. As a result, it is demonstrated that the volume of hole machined by EDM drilling can be accurately estimated using the number of discharge pulses. In EDM milling process a micro groove without depth variation caused by electrode wear could be machined using the developed control method. Consequently, it is shown that machining accuracy in drilling and milling processes can be improved by using process control based on the number of discharge pulses.
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In-plane type micro piezoelectric micro grippers with pneumatic lines for manipulation biological cells and micro parts were designed, fabricated, and characterized. Micro grippers were fabricated through the final micro-sanding process after wafer level bonding between the etched 4' Si wafer with pneumatic channels and 4' glass wafer. Displacements between two jaws of fabricated micro grippers were linearly increased with applying voltages to piezoelectric actuator. In the case of applying 80 V, the displacement between two jaws was
$160{\mu}m$ . Using fabricated micro grippers, manipulation tests for biological cell and micro parts with the sizes less than$100{\mu}m$ are in process. -
Determination of elastic properties of nano-scale materials using nano-indentation tests is well established, but that of plastic properties is not yet clear. This paper presents a method to extract plastic properties from nano-indentation test, together with results from detailed elastic-plastic FE analysis. It shows that the plastic properties determined from this method are not unique, in the sense that a number of different plastic properties can give the same load-displacement response from nano-indentation test. possible ways to overcome such problems are discussed.
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Size reduction of micro-aperture using additional deposition is presented in this study. PECVD process was used for additional deposition. Rate of deposition is different with deposition direction because corners of shadowmask membrane have a taper. Deposition into backside showed better than deposition into frontside with size reduction. Shadowmask membrane with two materials has stress because of the difference of a coefficient of thermal expansion The cantilever of membrane bend to opposite direction of deposition. Deposition to both frontside and backside could reduce inside stress.
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It is well-known that the mechanical properties of MMT (montmorillonite) nanocomposites are better than those of conventional composites. One of problems in fabricating MMT nanocomposites is a dispersion of nanoparticles in the composites. In this study, tensile tests were performed using universal testing machine to determine the effect of clay reinforced on the MMT/epoxy nanocomposites. It was found that the elastic modulus of nanocomposites was higher than that of pure epoxy irrespective of surface modification. Because MMT clay hod Strain of nanocomposite as a result of reinforced effect
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Simulation of micro electrical discharge machining (micro-EDM) process using finite element analysis is proposed. Multiphysics model which has three steps; heat transfer analysis, structural analysis and electric field analysis is developed for simulation. Machined surface for successive five discharges is simulated using developed multiphysics model. Machined surface roughness was simulated under two discharge conditions and the simulated results are compared with actual machined surfaces. From the comparison it is demonstrated that the model can accurately predict the machined surface with the error less than
$0.5{\mu}m$ . -
According to development of medical science and engineering, people has made efforts to solve tile discomfort of body accident as well as the life span. Many cases that reduce pain of a hip joint or limitation of motion using Revision Total Hip Replacement are getting increased. However it has not proved which material is the most appropriate. Scientists are still studying about materials of the artificial joint. In accordance with advance of science, the materials are Betting better. Recently, when Revision Total Hip Replacement is performed, typical materials are Ti-alloys Ceramics. We have studied materials of artificial joints and analyzed which one is better for human's body.
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Recently intradiscal electrothermal therapy is introduced, which is a new and minimally invasive technique fer the treatment of discogenic low back pain. This procedure involves the percutaneous threading of a flexible catheter into the disc under fluoroscopic guidance. The catheter, composed of thermal resistive coil, heats the posterior annulus of the disc, causing contraction of collagen fibers and destruction of afferent nociceptors. This study tries to investigate the effects of the important factors of this procedure such as heat source temperature and heat applying time on the temperature distribution within the intervertebral disc. This study utilized both computer simulation and the experiment for the verification of finite element analysis. FE analysis was carried out with ANSYS v7.0 (ANSYS Inc, USA) using 10,980 number of brick element and 12,551 number of node. The functional spinal units of 5 month old swine were used for the experiment and the temperature was monitored using 10 channel temperature measurement device MV200. Through this study, it was able to analyze the temperature range of inner intervertebral disc by two mechanisms which are known to alleviate pain clinically. The results showed that when the heat source temperature was kept up 80 degree for 1,020 seconds, the temperature of inner annulus reached at 45 degree up to the distance of 15.6mm from heat source, which explains coagulation of inner annulus by heat. When the same heat source was used, the temperature of inner nucleus reached at 60 degree up to the distance of 9mm from heat source, which explains contraction of inner nucleus by heat.
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The goal of total disc replacement is to restore pain-free mobility to a diseased functional spinal unit, by replacing the degenerated disc with a mobile bearing prosthesis. SB Charite III is named commercial product as the Artificial Intervertebral Disc (AID). SB Charite III consists of sliding core and endplate made by Ultra-high Molecular Weight Polyethylene (UHMWPE) and cobalt chrome alloy, respectively. To evaluate the effect of von-Mises stress in AID, and three-dimensional finite element model of AID analysis was preformed for four different loading types of sliding core. Consequently, endplate was compared with a compressive preload at 400N and flexion moment at
$3{\sim}9Nm4 . Therefore, this research has obtained result that von-Mises stress of sliding core in AID disc by radius curvature. -
In this study, a commercial fixation device, BioFlex, which was designed with shape memory alloy(SMA) for dynamic stabilization of spine was biomechanically evaluated. The finite element model of intact lumbar spine from L1 to S was developed using CT images. Also, low FE models of 2-level(L4-L5-S) and 3-level(L3-L4-L5-S) posteriori fixation using titanium(Ti) rod and BioFlex(SMA) rod. The rotations of bone segments in the intact model and four models were predicted. Although the rotations of the BioFlex fixation model were smaller than those of the intact model, they were relatively larger than those of Ti fixation. The present can be applied for not only evaluation of the stability of interbody fixator, but also development of new implant.
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The aim of this study was biomechanical analysis of shelf operation in patients with dysplastic hip joint by finite element contact analysis. Two dimensional CT images were used to construct the finite element models to analyze the contact pressure, and the 3D expansion of the Ninomiya's method was used in the calculation of the resultant force in the hip joint. The surgery recovered the center-edge angles to the normal anatomical range and increased the contact areas in two patients. The maximum contact pressures and von-mises stresses were decreased. The present study provides the biomechanical guideline of optimal surgical parameters to maximize the surgical efficiency and the clinical outcomes in dysplastic hip joint using the shelf operation.
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Occlusal loading is considered as the main factor of noncarious cervical lesions. The goal of this study is to identify stress distribution using three dimensional finite element analysis, when occlusal loading is applied on the cervical lesion of human tooth. A finite element model was constructed from micro-CT image and three kinds of static force(500 N) were assumed. In all cases stress concentrates on the same area in the cement-enamel junction. This finding is consistent with published experimental results.
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It is necessary to have a model that describes the anthropometry of the crash victim with a sufficient accuracy Koreans, however, do not have their own pedestrian dummies to be used in pedestrian collision tests. They have to use European and American dummies for their safety analysis. In this study scaled pedestrian dummies were constructed by using MADYMO. The dummies represent Korean average males and females aged from 25 to 29. The scaled Korean dummies and MADYMO human models were used to obtain and compare the pedestrian dynamic behaviors and injury criteria during the impact events.
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The products designed by human sensibility and ergonomics are given good impression. Especially the touch feeling on the human skin is very useful sensibility for quality of products. Elasticity and viscosity of human skin is very important element in product design based on ergonomics. In this paper, we describe a sophisticated method for measurement of dynamic viscoelasticity characteristics of human skin. For this measurement, we developed a measurement system assembled with load cell, actuator, amplifier and data acquisition system. The
$MATLAB^{TM}$ is used to analyze the data and fit a approximation curves. -
In the proposed research plan, the effects of anisotropic and time-dependent mechanical properties on nanoindentation measurements of osteonic lamellae in a human cortical bone are investigated. The most popular method(Oliver-Pharr method) in nanoindentation data analysis is based on the assumption of elastic isotropy. Since cortical bone has exhibited anisotropy, it is necessary to consider the effects of anisotropy on nanoindentation measurement for cortical bone. By comparison with the contact area obtained from monitoring the contact profile in FEA simulations, the Oliver-Pharr method was found to underpredict or overpredict the contact area due to effects of anisotropy. The mount of error depended on the indentation orientation. The indentation modulus results and were also similar to moduli calculated from mathematical model. The Oliver-Pharr method has been shown to be useful for providing first order approximations in analysis of anisotropic mechanical properties of cortical bone, although the indentation modulus is influenced by anisotropy.
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Manufacturing industry is changing rapidly. Prototyping with rapid manufacturing is a part of every business in many companies and prototypes are used efficiently as a part of the production development process. Sheet metal forming has traditionally been a technology area where prototyping has been extremely expensive and efficient options for low volume have been limited. This paper describes the process for incremental sheet forming technologies to make the prototype for a brake dust shield of vehicles, which includes the remodeling method to make a base mold and tool path for sheet metal forming and 5-axes laser cutting machine to trim the prototype product.
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Micro pyramid pattern and its array are designed to enhance the brightness and its uniformity of LGP which is one of key parts in LCD. The designed micro pyramid patterns are fabricated on a Si-wafer first through MEMS process and then a Ni-stamper is electro-plated from the Si pattern master. Adopting the fabricated Ni-stamper, LGPs are injection molded at different mold temperatures and the fidelity of the pattern replication is estimated for each molding conditions and pattern locations. The replicated patterns are found to have some defect such as local short shot or micro weld line which are believed to have negative effect on the performance of the LGP.
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Researches about micro technology travel lively in these days. Such many researches are concentrated in the field of materials and a process field. But properties of micro materials should be known to give results of research developed into still more. In these various material properties, reliability data such as mechanical, optical, thermal property, etc is the basic property. In this paper, it is measured that is material properties of main BLU(Back Light Unit) components in LCD(Liquid Crystal Display). The pattern shape of prism sheet, diffuser film and reflective plate are measured by variable 3D scanning equipments. It is researched which is the method to measure an optimal 3D pattern shape in each components.
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Split and recombine type reaction module was made by electrical discharge machining. The reaction module has special features to well mix the two reactants which have high flow ratio or high concentrations difference. It could be achieved by deviding one flow equally by two and inserting second flow in between. The mixing performance was measured by a parallel competing reaction with iodide-iodate system. The result shows that the developed three inlets micromixer has better mixing efficiency than comercialized Y type micromixer.
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It is so difficult to small amounts of two or more fluid species into single in microchannel because flows are usually laminar. In this regard multilamination micro mixer including recirculation zone is presented. Alternating feed micro channels make multilamination and converging-diverging channels form recirculation zone. Multilamination with geometric focusing decreases diffusion path ana recirculation zones make vortex. In this paper flow patterns and mixing properties of multilamination micro mixer including recirculation zone were investigated by Computational Fluid Dynamics (CFD). The CFD results provided qualitative information on mixing.
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A micro-size caterpillar mixer has been recently used fur desktop chemical factory and so attractive due to small investment fund for arranging the factory and high efficiency by mixing in sub micro-level region. We report the fabrication of caterpillar mixer and its surface treatment for enhancement of mixing performance. We used the
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3-methyl-2-cyclopentenone is a valuable reaction intermediate for various high value added products. 3-methyl-2-cyclopentenone is not only expensive but also difficult to produce. 3-methyl-2-cyclopentenone can be synthesized by base catalyzed intermolecular aldol condensation. In this work, we studied a simple and practical method for synthesizing 3-methyl-2-cyclopentenone. Experimental results showed the advantages of the continuous flow process using a microreactor with kenic mixers for the synthesis of 3-methyl-2-cyclopentenone.
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This study focuses on a determination of amount of Pt in the Pt/C for catalysts of polymer electrolyte membrane fuel cells (PEMFC). PEMFC offer low weight and high power density and being considered fur automotive and stationary power applications. The PEMFC behavior is quite complex is influenced by several factors, including catalysts and structure of electrode and membrane type. Catalyst of electrode is important factor for PEMFC. One of the obstacles preventing polymer electrolyte membrane fuel cells from commercialization is the high cost of noble metals to be used as catalyst, such as platinum. To effectively use these metals, they have to be will dispersed to small particles on conductive carbon supports. The optimal amount of Pt in Pt/C was investigated by using polarization curves in single cell with
$H_2/O_2$ operation. -
Mobile fuel cell is highlighted in these days because mobile fuel cell can contain more energy than existing batteries. Nowadays mobile devices like cellular phone, PMP(portable multi-media player), notebook, and etc. need more energy, But existing batteries like Li-ion or Ni-MH batteries are not going to satisfy such demands. In this paper, mobile fuel cell is developed. Its size is 50*70*8mm and it is made of aluminium plates. The fuel cell type is PEM and the fuel is pure hydrogen and oxygen.
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The miniature fuel cells have emerged as a promising power source for applications such as cellular phones, small digital devices, and autonomous sensors to embedded monitors or to micro-electro mechanical system (MEMS) devices. Several chemicals run candidate at a fuel in those systems, such as hydrogen. methanol, ethanol, acetic acid, and di-methyl ether (DME). Among them, hydrogen shows most efficient fuel performance. However, there are some difficulties in practical application for portable power sources. Therefore, more recently, there have been many efforts for development of micro-reformer to operate highly efficient micro fuel cells with liquid fuels such as methanol, ethanol, and DME In our experiments, we have integrated a micro-fuel processor system using low temperature co-fired ceramics (LTCC) materials. Our integrated micro-fuel processor system is containing embedded heaters, cavities, and 3D structures of micro- channels within LTCC layers for embedding catalysts (cf. Figs. 1 and 2). In the micro-channels of LTCC, we have loaded
$CuO/ZnO/Al_2O_3$ catalysts using several different coating methods such as powder packing or spraying, dipping, and washing of catalyst slurry. -
This paper presents the effects of different operating parameters on the performance of a proton exchange membrane (PEM) fuel cell by a three-dimensional computational fluid dynamics (CFD) model. The effects of different operating parameters on the performance of PEM fuel cell studied using pure hydrogen on the anode side and air on the cathode side. The various parameters are temperatures, pressures, humidification of the gas steams and various combinations of these parameters. In addition, geometrical and material parameters such as the gas diffusion layer (GDL) thickness and porosity as well as the ratio between the channel width and the land area were investigated.
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In recent years, the higher flatness level in wafer shape has been strictly demanded with a high integration of the semiconductor devices. It has become difficult for a conventional wafer preparing process to satisfy those demands. In order to meet those demands, surface grinding with in-feed grinder is adopted. In an in-feed grinding method, a chuck table fur fixing a semiconductor wafrr rotates on its rotation axis with a slight tilt angle to the rotation axis of a cup shaped grinding wheel and the grinding wheel in rotation moves down to grind the wafer. So, stability of the grinder structure is very important to aquire a wafer of good quality. This paper describes the features of the in-feed grinder and some FEM analysis results of the grinder structure.
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In this study, the ultra precision centerless grinder for ferrule grinding was designed. As the good-qualified ferrule is required a precise and fine grinding, grinding machine for ferrule must have a high accuracy and a sufficient stiffness. The centerless grinder is composed of the high damping concrete bed, grinding wheel spindle unit, regulating wheel spindle unit, feeding table and dressing unit. For a newly developed centerless grinder, hydrostatic system with high precision feeding and high stiffness was proposed.
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Fiber optic connector, ferrule, is a device to connect and align fiber optics cable on fiber-optic communication system. In general
$ZrO_2$ ceramic ferrule is manufactured by grinding process because the demands precision is very high. For the precision grinding machining, it is very important that structure of co-axial ferrule grinding system is optimized. In this paper, Structural analysis was performed to analyze bed and frame structure of co-axial grinding machine. Deformation and modal analysis for natural frequency was performed using ANSYS design space program to analyze structural characteristics. New improved model of bed and frame structure was proposed based on initial basic model. Therefore, we estimated the structural characteristics precision co-axial grinding machining system. -
To enhance the precision and productivity of ultra precision aspheric surface micro lens, the development of ultra-precision grinding system and process for the aspheric surface micro lens are described. In the work reported in this paper, an ultra-precision grinding system for manufacturing the aspheric surface micro lens was developed by considering the factors affecting the grinding surface roughness and profile accuracy. This paper deals with mirror grinding of an aspheric surface micro lens by resin bonded diamond wheel and spherical lens of BK7. The optimization of grinding conditions on ground surface roughness and profiles accuracy is investigated using the design of experiments.
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In silicon wafer manufacturing process, the grinding process has been adopted to improve the flatness of water. The grinding of wafer is usually used by the infeed grinding machine. Grinding conditions are spindle speed, feed speed, rotation speed, grinding stone etc. But grinding condition selection and analysis is so difficult in grinding machine. In the intelligent grinding system based on knowledge many researchers have studied expert system, neural network, fuzzy etc. In this paper we deal grinding condition selection method, Taguchi method and Genetic Analysis.
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High speed machining experiment on the inclined surfaces of hardened mold steel(STAVAX at hardness HRC 53) is carried out using the long-neck type ball endmill. Surface texture and roughness are compared fur various cutting conditions. Tool overhang length greatly affects the roughness of machined surface. It is found that, fur this type of long-neck endmill, the chip load should be carefully selected by reducing either the axial depth of cut or feedrate to avoid tool vibration. Feedrate adjustment is more appropriate method in terms of tool wear.
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Generally, progressive type GMP process is more efficient than batch type because there are advantages that problems of each stage(heating, press, cooling etc.) are easily grasped and a time of production is shortened. But if single cavity is used in progressive type GMP process, there is disadvantage that productivity is decreased. So, in order to improve productivity of progressive type GMP process, it is essential to secure multi cavity mold technic. In this study, as a fundamental study to develop multi cavity used in glass lens molding, we conducted a compression test for PBK40.
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In this study, the characteristics of Electrical Discharge Machining (EDM) with the electrode materials were investigated. EDM experiments have been carried out on electrodes with eight different copper-based and graphite-based materials. From the results, the copper-based electrodes showed excellent surface roughness than the graphite-based electrodes. But graphite based electrodes have advantages in economic aspects.
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RTP (rapid thermal pressing), one of micro-pattern replication techniques like hot embossing, is focused on achieving shorter cycle time. DFSS(Design for Six Sigma) has been applied in order to enhance the completeness of the development process for RTP system. According to DIDOV roadmap, we derived design concepts and subsequently decided the main performances, design factors, and components for RTP system. In the design process of RTP system using finite element analysis, it was realized that its structural characteristics affect large area replicability. Optimizing structural design factors, based on CAE, it was checked out that its large area replicability could be improved in a virtual test. Finally, we have a plan to validate the large area replicability of the developed RTP system, by performing micro-pattern replication tests with polymeric sheets.
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In this study, the automatic packaging system for small injection molding product is developed. In most of injection molding company, many problems such as manpower problem, productivity decline and inferiority rate increase are occurred since processes after injection molding are executed by hands. The automatic system which is developed is for packaging small injection molding products as 6mm ball. Finally, many problems of injection molding process are resolved and the productivity will increase by applying developed system to field and this technique lays the groundwork for developing similar automatic system.
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Recently, the demand of high-productivity injection mold increases since the consumption of packaging grows in the world. Stack mold is composed of more than two molds and it has very high productivity and economic efficiency. In advanced country, stack mold which has
$4Level{\times}96cavity$ was developed already but, in occasion of domestic mold industry, there is no study of stack mold. In this study, stack mold which has$2Level{\times}4cavity$ is developed for securing the technique of manufacturing high-productivity mold. -
In this paper, the rubber behavior was calculated for obtaining the optimal process condition which is for producing a transformer with a given performance. This study was carried out using the computer simulation of injection mold filling and packing simulations. In order to remove the crack of product, proper locations of the runner and cooling system configurations could be determined. Based on these results, the transformer is developed by injection molding and guidelines of part design, mold design and processing conditions are established. Finally, the cast savings, cycle time reduce and improvement of productivity will be obtained.
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In this study, an injection mold of tensile test specimen was manufactured by international standard. Pressure and temperature in the cavity of the injection mold was measured by sensors. Simulation of injection molding process was performed with the same condition of experiment and linear structural tensile analysis was also performed with the initial condition of the residual stress induced by injection molding analysis. Normalized elastic coefficient of tensile test was compared with that of structural analysis. It was shown that the residual stress induced by injection molding has an effect on both the experiment of tensile test and linear structural analysis.
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This paper presents an integrated machining error compensation method based on PNN(Polynomial Neural Network) approach and inspection database of OMM(On-Machine-Measurement) system. To efficiently analyze the machining errors, two machining error parameters are defined and modeled using the PNN approach, which is used to determine machining errors for the considered cutting conditions. Experiments are carried out to validate the approaches proposed in this paper. In result, the proposed methods can be effectively implemented in a real machining situation, producing much fewer errors.
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Printing technology has begun to get into the spotlight in many ways due to the low cost effectiveness to existent semi-conductor process. It also has very useful application areas, not only paper printing but also patterning for LCD color tilter, Photovoltaic patterning, RFID antenna, OLED, and so on. In this study, an apparatus of gravure offset printing was developed for fine line width printing. The pattern was composed of
$20{\mu}m$ size of continuous lines of which pitch size was$40{\mu}m$ . The printed pattern shows that it is possible to make around$20{\mu}m$ line-width printing pattern. The roll-to-roll printing system for fine line-width printing based on primary experiment is presented. For testing of multi-layer printing, the system was designed to be capable of printing two different materials from each printing unit using gravure-offset printing method and have a function of alignment of two printed materials. -
In this paper, we present a design, analysis, fabrication and performance test of the novel DoD metal-jet system for application to the high-density and high-temperature-melting materials. Based on the theoretical analysis, we design the metal-jet print head system and fabricate the metal-jet system, which can eject the droplet of lead-free metal solder in the high-temperature. In the experimental test, we set up the test apparatus for visualization of the droplet ejection and measure the Ejected droplet volume and velocity. As a result, the diameter, volume and the velocity of the ejected droplet are about
$65-70{\mu}m$ , 145-180 pl and 4m/sec. We also fabricate vertical and inclined 3D micro column structures using the present molten metal inkjet system. The measured geometries of the micro column structures are about height of$2,100{\mu}m$ , diameter of$200{\mu}m$ and aspect ratio of 10.5 for vertical micro column and$1,400{\mu}m$ of height and$150{\mu}m$ of diameter for$65^{\circ}$ -inclined micro column, respectively. -
Drop-on-Demand (DOD) inkjet printing technology, especially piezo-typed, has been paid attention by industries due to its inherent nature of unbeatable material usage and low cost manufacturing cost. Despite of these key advantages over any other competing manufacturing technologies, the primary disadvantage has been considered as its limited capability to produce fine resolution patterns with a commercially available DOD inkjet print head. Although the main effort has been focused on the production of a DOD inkjet print head with smaller nozzles to overcome this challenging issue, an alternative approach could be taken and it would enable to expand the employment of DOD inkjet printing technology to applications requiring fine patterns further more.
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Recently, research for the micro printing technology has begun to get into the spotlight. It is due to the superior price competitiveness to existent semi-conductor process for manufacturing some parts of display unit, electronic paper, RF-ID information device, and so on. This paper present screen printing process not for paper publication but for parts of electronics such as PDP wall, LCD CF, and so on. There are two major issues. The first one is how to get a fine and even line pattern. The other one is how to get the same patterns in large area. In this research, we present the design, equipment, and process control of screen printing in order to overcome these issues.
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We studied about the manufacture of the drain-source contacts for OTFTs(organic thin-film transistors) by using screen printing method. The conductive fillers used Ag and carbon black. The conductive contacts with
$100{\mu}m$ of channel length were screen printed on a silicon dioxide gate dielectric layer and, the pentacene semiconductor was deposited via vacuum deposition. As a result of studying various conductive pastes, we could obtain the OTFTs which exhibited field-effect behavior over arrange of drain-source and gate voltages, similar to devices employing deposited Au contacts. By using screen-printing with conductive paste, the contacts are processed at low temperature, thereby facilitating their integration with heat sensitive substrates. -
A novel thermal transfer method was developed to form the phosphor screen for VPT(Video Phone Tube). This method have advantages of simple process, clean environment, saving raw material and running-cost comparison of electrodeposition, spin coating of conventional methods. But now applying phosphor screen for thermal transfer method has been formed three layers (phosphor layer, ITO layer and thermal adhesive layer) on the PET film as substrate. This is complex process, run to waste of raw-material and require of high cost. Also ITO paste at present has been imported from Japan. To improve these problems, we have manufactured phosphor screen formed by two layers (phosphor layer and ITO layer). We have developed ITO paste that had both conductive and excellent thermal transfer abilities, made it of domestic raw-material.
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The flexible organic thin film transistor (OTFT) array to use as a switching device for an organic light emitting diode (OLED) was designed and fabricated in the microcontact printing and low-temperature processes. The gate, source, and drain electrode patterns of OTFT were fabricated by microcontact printing which is high-resolution lithography technology using polydimethylsiloxane(PDMS) stamp. The OTFT array with dielectric layer and organic active semiconductor layers formed at room temperature or at a temperature tower than
$40^{\circ}C$ . The microcontact printing process using SAM(self-assembled monolayer) and PDMS stamp made it possible to fabricate OTFT arrays with channel lengths down to even nano size, and reduced the procedure by 10 steps compared with photolithography. Since the process was done in low temperature, there was no pattern transformation and bending problem appeared. It was possible to increase close packing of molecules by SAM, to improve electric field mobility, to decrease contact resistance, and to reduce threshold voltage by using a big dielecric. -
In this study, we used the ESD method to prepare the protein microarrays for observation the stem cell responses to pattern size, space and shapes. The ESD method allows a reduction in spot size, high efficiency of substance transfer, and high rate in fabrication as a result of ability to simultaneously deposit thousands of identical spots. Typical electro spraying conditions for the deposition of proteins were a voltage of
$3{\sim}5keV$ and the humidity under 30%. The patterns of masks have a variety of shapes, spaces, and hole sizes from 10 um to$300{\mu}m$ . Three kinds of proteins(collagen, fibronectin, and vitronectin dissolved in PBS) are deposited in a dry state, preserving the functional activity of proteins. Stem cells were cultured on each protein patterned sample at$37^{\circ}C$ for 1day. -
In order to promptly cope with the various requirements of consumers, the environment of product development is being globalized in manufacturing industrials. For this reason, it is necessary to build up an efficient collaborative system for communication between remote area designers. Specially, while Internet and information technologies were merged with the manufacturing or business process, the research for collaborative system has become an important issue. Therefore, we propose a Web-based Engineering Collaboration Framework using SPS(SharePoint Portal Server) which is an enterprise business solution that integrates information from various system into one solution through single sign-on and enterprise application integration capabilities, with flexible deployment options and management tool. Through a Web-based Engineering Collaboration Framework, designers can share knowledge assets and have a remote conference with others via web.
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The primary role of MRP(Material Requirement Planning) is to make a production plan so that we have an exact quantity of right materials on needed time at right place. But the ignorance on capacity constraints makes some problems whenever production schedule is established. To increase the performance of MRP system, a novel approach which is based on new input data structure is suggested. The new input data structure includes all the information about Material BOM, Routing and resource data so that we can easily examine the usage of resources and generate higher performance production plans.
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The worker who is responsible for Airless Pump maintenance have a high possibility to suffer from WMSDs, because a height of Airless Pump workbench is too low. In this paper, I'm going to introduce a research about 1) analysis of working environment through a interview with an actual field worker, 2) Ergonomic simulation modeling of an Ariless Pump worker to suggest a advanced working environment and a working instructions. I have used a DELMIA S/W as a tool for ergonomic simulation and performed a posture & activity to analyze a RULA methodology. Applying the Digital Human Simulation to analyze working posture would be helpful to preventing WMSDs.
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Today, the need for more flexible and adaptive production system and integrated management of their manufacturing information and facilities is ever increasing to cope with competitive and ever-changing global market environments and complexity of new control systems. This paper presents the whole system architecture and the technological characteristics of for each individual system layer which are able to flexibly integrate and manage high-speed and high-precision machining systems. It is investigated that monitoring and integrated management of the control systems can be realized with consideration of detailed information of various CNCs, and the management function may be easily constructed and extended using components of the manufacturing execution layer.
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This article deals the development of Agile and Intelligent Manufacturing System(AIM) for the assembly automation of a tiny ultrasonic actuator used in camera phones and PDAs. The system consists of multi-vision modules, end-effectors, a standard base frame, dispensers, jigs and modular manipulators. Subsystems are a vision system, a force control system and a virtual reality system. Experimental results show that the assembly process for the small components in the various IT applications can be realized by the AIM system.
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This paper introduces a methodology for construction of ontology-based product knowledge Map. For CPC(Collaborative Product Commerce) environment, engineering application of ontology has been studied . However, there are no generic and comprehensive methodologies for ontology construction yet because of such problems: dependency on experience of ontologist and domain experts and insufficiency of detail stages or rules. To solve those problems, we propose a methodology to construct ontology from engineering documents in semi-automatic. We use middle-out strategy and term's axioms, sub-definitions, to build ontology map. 5-turple ontology structure, semantic network and First order logic (FOL) are used for ontology definition in this study.
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Many data mining techniques have been proved useful in revealing important patterns from large data sets. Especially, data mining techniques play an important role in a customer data analysis in a financial industry and an electronic commerce. Also, there are many data mining related research papers in a semiconductor industry and an automotive industry. In addition, data mining techniques are applied to the bioinformatics area. To satisfy customers' various requirements, each industry should develop new processes with more accurate production criteria. Also, they spend more money to guarantee their products' quality. In this manner, we apply data mining techniques to the production-related data such as a test data, a field claim data, and POP (point of production) data in the automotive parts industry. Data collection and transformation techniques should be applied to enhance the analysis results. Also, we classify various types of manufacturing processes and proposed an analysis scheme according to the type of manufacturing process. As a result, we could find inter- or intra-process relationships and critical features to monitor the current status of the each process. Finally, it helps an industry to raise their profit and reduce their failure cost.
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Design data, information, and knowledge have complex associations with each other. Systems related with the management of the data, information, and knowledge are various, and the representations are numerous. Therefore it is difficult to construct a knowledge based design system with a full association knowledge for supporting the design tasks. In this research, OWL based ontology model for an excavator design is developed for the representation of the relationships. Also an ontology model is used to develop the knowledge based excavator design system.
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Many manufacturing companies manage their production-related data for quality management and production management. Nevertheless, production related-data should be closely related to each other Stored data is mainly used to monitor their process and products' error. In this paper, we provide an enterprise-wide production data model for decision support system and product automation. Process data, quality-related data, and test data are integrated to identify the process inter or intra dependency, the yield forecasting, and the trend of process status. In addition, it helps the manufacturing decision support system to decide critical manufacturing problems.
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The participants in collaborative environment want to get the right documents which are intended to find. In general search system, it searches documents which contain only the keywords. For searching different word-expressions for the same meaning, we perform mapping before searching. Our mapping logic consists of three steps. First, the character matching is the mapping of two terminologies that have identical character strings. Second, the definition comparing is the method that compares two terminologies' definitions. Third, the similarity checking pairs terminologies which were not mapped by two prior steps. In this paper, we propose Engineering Information Search System based on ontology mapping.
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In this paper, the CAE Service System for Collaborative Engineering Environment with web services and Multi-frontal Method has been investigated and developed. The enabling technologies such as SOAP and .NET Framework play great roles in the development of integrated distributed application software. In addition to the distribution of analysis modules, numerical solution process itself is again divided into parallel processes using Multi-frontal Method for computational efficiency. We believe that the proposed approach for the analysis can be extended to the entire product development process for sharing and utilizing common product data in the distributed engineering environment.
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In this paper, we performed the customization of CAE analysis in the process of product development and verification. The purpose of customized analysis is to implement collaboration framework of inter-corporate, inter-division for knowledge process based on product development. Customized analysis methodology using ANSYS Workbench API is presented for the web-based and workbench-based application. Cellular phone was selected as a CAD model, and template based process of analysis is conducted. By using this system, customized analysis is suitable to site or user oriented specific analysis and for user who has little experience on CAE analysis.
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Over the past decade, changes in product development processes and increased consumer demands have dramatically influenced engineering working practices and targets. The information technology revolution has made its appearance concurrent to this relentless escalation in product engineering requirement. It has offered hopes for improved productivity despite these increasing demands. The wide availability of personal computing power, virtually inexhaustible sources of information and an abundance of computerized engineering tools have created great expectations. CAPP (Computer Aided Process Planning) Expert system and database were developed using VB.NET and Microsoft SQL 2000 Server.
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Nowadays, the increasing global competition forces manufacturing enterprises to apply new technologies method of their products. To save time and cost in assembly process and to increase the quality of products, it is very important to choose an optimal assembly system. We propose a methodology that generates an optimal assembly system by using the Digital manufacturing.
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High speed milling process is emerging as an important fabrication process benefits include the ability to fabricate micro and meso-scale parts out of a greater range of materials and with more varied geometry. It also enables the creation of micro and meso-scale molds for injection molding. Factors affecting surface roughness have not been studied in depth for this process. A series of experiments has been conducted in order to begin to characterize the factors affecting surface roughness and determine the range of attainable surface roughness values for the high speed milling process. It has previously been shown that run-out creates a greater problem for the dimensional accuracy of pans created by high speed milling process. And run-out also has a more significant effect on the surface quality of milled parts. The surface roughness traces reveal large peak to valley variations. This run-out is generated by spindle dynamics and tool geometry. In order to investigate the relationship between tool alignment errors and surface roughness the scallop generating mechanism in the ball-end milling with tool alignement errors has been studied and simulated. The results indicate that tool alignment errors have no significant effects ell the dimension of scallops in for flat planes.
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This paper present a design experience of supervisory control system platform for agile and intelligent manufacturing(AIM). Embodied integrated environment that can do in place that do work direction, analysis command file generation, achievement using Petrinet-type Graphical Language(PGL) in proposed Supervisory Control System. Also, embodying whole system software in Modular done form, did to have extensity to fit in developer's requirement.
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The assembly of camera lens modules fur the mobile phone has not been automated so far. They are still assembled manually because of high precision of all parts and hard-to-recognize lens by vision camera. In addition, the very short life cycle of the camera phone lens requires flexible and intelligent automation. This study proposes a fast and accurate identification system of the parts by distributing the camera for 4 degree of freedom assembly robot system. Single or multi-cameras can be installed according to the part's image capture and processing mode. It has an agile structure which enables adaptation with the minimal job change. The framework is proposed and the experimental result is shown to prove the effectiveness.
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Development of Rule-Based Knowledge Representation Supporting Tool for Design Digital Moister SystemRecently we started a development of the digital meister expert system for the product design supporting in manufacturing industry. Knowledge representation is of major importance in digital moister expert system. This rule-based expert system-knowledges are designed for a certain type of knowledge representation such as rules or logic. The way in which a rule-based expert system represents knowledge affects the development, efficiency, speed, and maintenance. Eventually, this digital moister system is used to the engineer in manufacturing industry for the process control, production management and system management. In this paper, we propose the digital moister system knowledge representation method for product design supporting in manufacturing industry and we present introduction and contents of rule-based knowledge representation supporting tool.
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A knowledge-based system with CAD is widely used to implement a designer's know-how and a routine calculation within a system. An engineer needs to change several design parameters in an early design stage. However it is not easy to change the design parameters when it needs to update an existing model and data. In this paper, a module has been proposed to make it easy to change the design parameter so that the engineer can easily update and change the design model. Also a flexible interface of the module can easily add or extract the design knowledge.
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V-belt pulleys play a key role in driving cooling pump, oil pump, air-conditioner and so on by using an engine power. Precision deep drawing is one of the main processes for manufacturing the pulleys. Operation variables of the deep drawing equipment, called the setup parameter, must be re-determined whenever the specifications of pulley to be produced are changed. The defect rates during a setup of equipment and the working hours needed for the setup are almost dependent on workers' know-how. This study designs the program for easily determining setup conditions in pulley manufacturing process.
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Many companies in mechanical engineering fields have accumulated information of design and manufacturing. The Enterprise Resource Planning (ERP) and Product Data Management (PDM) systems help information gathering and data managing. However, these systems are not flexible to support suitable functionality for specific product because these systems deal with entire enterprise resources. To cope with this issue, a web-based design support system was constructed for the design process of automotive steel pulley. This system provided 1) search service for part design with key word and clustering map, and 2) estimation service of maximum stress. These services reduced design time by reducing iterative jobs with Computer Aided Design (CAD) and Computer Aided Engineering (CAE) for stress analysis, and by enhancing search for existing data of steel pulley.
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The purpose of this work is to investigate the effect of work load on heart rate variability (HRV) which is widely used marker of the autonomic nervous system activity. Average heart rate, rating of perceived exertion, and the power spectrum of heart rate variability were investigated in seven healthy males during exercise at various work loads. The subjects were divided into two groups according to the average heart rate during exercise, group 1 with lower heart rate and group 2 with higher heart rate. HF component showed decrease followed by increase with workload. Accordingly, the LF/HF ratio showed increase followed by decrease with workload. The peak in LF/HF ratio of group 1 was at the lower workload than that of group 2.
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The purpose of this study is to experimentally analyze swing motion with soft golf clubs and compare with that with normal golf clubs. Soft golf is newly devised recreational sport based on golf but focus on the playability for the elderly. The subject fur the experiment performed swing motion using a normal golf club and a soft golf club in turn. The swing motion of the subjects was tracked using an opto-electric three-dimensional motion analysis system. The results were compared against those obtained with a normal golf club. The range of motion was analyzed along with top head speed for two cases. It was found that higher club head speed could be achieved with reduced range of motion at lumbar joint using soft golf club when compared against the swing using regular club. The lower range of motion fur lumbar bending means reduced risk of injury at the joint. So, it is projected that we can reduce the risk of injury with soft golf while maintaining the club head speed.
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Pressure-induced decubitus is a serious disease among the elderly people. Interface pressure occluding vascular perfusion is known to be a cause of decubitus. Therefore, it is essential to quantify the relationship between vascular perfusion and interface pressure among the elderly people. Nine elderly normal people (
$57.8{\pm}5.6\;years,\;63.3{\pm}7.0kg,\;1.68{\pm}0.05m$ ) were participated. Pressure was applied on the ischial tuberosity in the sitting posture from 0mmHg to 135mmHg as capillary vascular perfusion was recorded. The average interface pressure to occlude vascular perfusion under the ischial tuberosity is 120mmHg. Vascular perfusion values at the capillary occlusion is often lower than 60% of the vascular perfusion at 15mmHg. Higher sampling number is required to have more accurate results. -
The length of root canal has to be measured to cure root canal. Several apex locators were developed to measure the length of root canal. And they were verified by X-ray or micrometer method. But these methods do not consider the non-linear bends of pulp and have
${\pm}0.5mm$ error which is large to measure the length of root canal. The purpose of this study is the research of new method to measure the length of root canal and verifying the apex locator using Micro-CT. The length of root canal of 6 teeth were measured with the apex locator. When the apex locator reads 0.5, 0.6, 0.7, 0.5, 0.9, 1.0mm, the teeth with the file fixed were photographed. The average lengths of root canal of 6 teeth measured by Micro-CT were 0.488, 0.589, 0.680, 0.775, 0.897, 0.992mm. -
Some researchers proposed positive effects of whole body vibration (WBV) on osteoporotic trabecular bones of animals. In the present study, the correlation between the improvement of morphological characteristics and the effect of WBV was investigated and analyzed in OVX rats. The rats were randomly assigned to 5 groups: control, sham, WBV 17Hz, WBV 30Hz and WBV 45Hz. The WBV groups were exercised on a vibration platform (magnitude
$1mm_{peak-peak}$ , frequency : 17Hz, 30Hz and 45Hz, 30 minutes/day for 5 days/week). The 4th lumbar on rats was scanned by In-vivo Micro-CT at the week 0(iust before WBV) and the week 8(after WBV). Structural parameters of the 4th lumbar, based on two dimensional (2D) scan image data, were investigated and analyzed. The quantitative decrement rate of trabecular bone on WBV groups with 30Hz and 45Hz were lower than control and sham groups. The results showed the positive effect of WBV on osteoporotic bones of OVX rats. -
The choice of suitable hip implant is one of important factors in total hip replacement (THR). In clinical view points, improper adaptation of hip implant might cause abnormal stress distribution to the bone, which can shorten the lifespan of replaced hip implant. Currently, interest in custom-designed hip implants has increased as studies reveals the importance of geometric shape of patient's femur in modeling and designing custom hip implants. In this study, we have developed the custom-designed hip implant models with various sizes in hip implant, and the stress distribution in the bone was analyzed using Finite Elements methods. It was found that minimizing the gap between implant stem and femoral cavity is crucial to minimize stress concentration in the bone.
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In case of ultrashort laser ablation of metals, the transfer of energy from the electronic system causing strong absorption of laser light to the lattice needs relaxation times of the order of some picoseconds. Under the above theoretical background, nickel was ablated using femtosecond, picosecond and nanosecond laser. As a result, nickel ablation by picosecond laser and femtosecond laser, which are called ultrashort laser, has similar machinability because of relaxation time of metals, whereas nanosecond Nd:YAG laser has lower absorption, higher thermalization effect in comparison with ultrashort laser.
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We will provide the ultra-precise material processing technique with a femtosecond pulse laser system.
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Although there are many numerical models to simulate fs laser ablation of metals, no model can analyze the ablation phenomena over a wide range of fluence. In this work, a numerical code for simulating the fs laser ablation phenomena of metals has been developed. The two temperature model is employed to predict the ablation rate and the crater shape of metals using phase explosion mechanism in the relatively high fluence regime. Also, the ultrashort thermoelastic model is used for the low fluence regime to account for spallation of the sample by high strain rate. It has been demonstrated that the thermoelastic stress generated within the sample can exceed the yield stress of the material even near the threshold fluence. Numerical computation results are compared with the experiment for Cu and Ni and show good agreement. Discussions are made on the hydrodynamic model considering phase change and hydrodynamic flow.
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High-aspect-ratio(max. 12.5) microchannels with excellent surface quality and good shape uniformity have been realized utilizing laser-induced etching technique. Etch width and depth variations depend largely upon process variables such as laser power and etchant concentration. Etchant concentration in association with viscosity also influence on the cross-sectional profile of the channels. The optimum process conditions for the fabrication of high-aspect-ratio microchannels applicable to micro thermal devices are demonstrated.
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This research is on a laser soldering using the micro solder-balls used in flip chip packaging process. A laser source used in laser soldering is Nd:YAG laser(250W and 60W). Solder-balls of 100, 300,
$500{\mu}m$ size are used in experiments. The laser head to deliver a laser beam and the nozzle to transfer solder-balls are manufactured to bump solder-balls. After soldering solder-balls the shear test is carried out to determine the wetting at the interface between the surface and a solder-balls With the results of solder bumping tests a laminated molding is accomplished for manufacturing the three dimensional molding. -
In the electronic, medical, aerospace and automobile industries, many products and parts are manufactured by joining. Recently, as these get smaller, micro joining is becoming more and more important. In this study, micro wire-to-micro wire parallel joining was performed using single mode fiber laser. Maximum power of the fiber laser is 100 W. The CCD(Charge- Coupled Device, CCD) camera to observe the specimen was made up. The objective was applied to micro joining system to make a small spot size of laser beam. In order to control the target position, micro-multi-axis-stage was set up. This paper presents results for the single mode fiber laser joining of micro wires.
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In precision laser microfabrication, focusing is essential to acquire good machining precision and uniform machining quality. If it does not perform, laser machining cannot be realized. So, confocal scanning method with high depth resolution is used for focus detection technique. This paper is concerned with a procedure for design, analysis and performance test of an autofocus fine actuating stage, which is composed of flexure-hinge type lever mechanism and piezoelectric actuator. Through series of analytical design, the stage is simplified as a rigid bodies(lever and main body) and springs(flexure hinges). The simplified model was applied to determine the dimension of flexure hinges and lever. After structural analysis confirmed design requirement, an actual stage was made and verified through an experiment on the static and dynamic characteristics(maximum stroke and 1st natural frequency). The fabricated stage was satisfied with the design requirement.
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Usually nanosecond pulsing laser ablation of metal is under thermal effect. Many studies of the theoretical analysis and modeling to predict a result of laser ablation of metal are suggested on the basis of the photothermal mechanism. In this paper, we investigate the etching depth and laser fluence of laser ablation of copper films. We proposed the simplified SSB Model(Srinivasan-Smrtic-Babudp model) to study the photothermal effect of nanosecond pulsing laser ablation of copper thin metal. The experimental results were obtained by using the 355nm DPSS
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Two-photon absorption coefficient of a series of dyes in polymer thin films was determined by measuring the femtosecond laser ablation threshold. The threshold value of polymeric thin films decreased gradually when the dopant increased. The two-photon absorption coefficient of the dye molecules dispersed in the polymer film was estimated by using the theoretical relationship between the ablation threshold of the blended polymeric thin films and the dye concentration. The relative values of two-photon absorption cross-section are in good agreement with those measured in solution. On the other hand, the absolute values are smaller than the latter.
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We have investigated the behavior of the ultrafast laser ablation of chromium films (200nm) on the silicon and pyrex-glass(corning 7740) substrate with respect to the laser fluence and the number of laser pulses. In addition, several experiments about ITO thin film were carried out with femto-second Ti:Sapphire laser (150fs). Finally, we introduce the ablation characteristic in accordance with materials of thin film and substrate.