• Tribology and Lubricants
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• v.34 no.6
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• pp.325-331
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• 2018

Automobiles and systems requiring high gear ratios and high power densities generally use worm gears. In particular, as worm gears have a small volume and self-locking function, home appliances such as refrigerators and washers consist of worm gears. We can classify worm gears into cylindrical worms and rectangular worms. According to the AGMA standard, there are four types of cylindrical worms, ZA, ZN, ZK and ZI, depending on the machining of the worm shaft. It is preferable to use a ZI-type worm shaft, which is a combination of a worm wheel having an involute helical tooth surface and a conjugate tooth surface. However, in many cases, industries mostly use ZK, ZN, and ZA worm shafts because of the ease of processing. This paper presents numerical approaches to produce ZI and ZA worm surfaces and worm wheel. For the analysis of the transmission error of a worm gear system, this study (1) generates surface profile functions of ZI profile worm gear and worm shaft based on the common rack theory, (2) adopts the Newton-Raphson method for the analysis of the gear surface contact condition, and (3) presents and compares the corresponding transmission errors of ZI and ZA worm gears.

• Transactions of the KSME C: Technology and Education
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• v.3 no.4
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• pp.265-271
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• 2015

The bonding process should be achieved in vacuum environment to avoid air bubble. In this study, we studied about pressure uniformity that became an issue in thermo compression bonding usually. Uniform press is realized by the method that use air spring and metal form spring. The concept of uniform press using air spring is removed except pressing direction in the press processing so angle between the vector of pressure surface and the pressure axis is parallel automatically. Air spring compensate the errors of machining and assembly. Metal form compensate the thermal deformation and flatness error.

• Publications of The Korean Astronomical Society
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• v.32 no.1
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• pp.359-361
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• 2017

We report our research on aluminum mirror optics for future infrared astronomical satellites. For space infrared missions, cooling the whole instrument is crucial to suppress the infrared background and detector noise. In this aspect, aluminum is appropriate for cryogenic optics, because the same material can be used for the whole structure of the instrument including optical components thanks to its excellent machinability, which helps to mitigate optical misalignment at low temperatures. We have fabricated aluminum mirrors with ultra-precision machining and measured the wave front errors (WFEs) of the mirrors with a Fizeau interferometer. Based on the power spectral densities of the WFEs, we confirmed that the surface accuracy of all the mirrors satisfied the requirements for the SPICA Coronagraph Instrument. We then integrated the mirrors into an optical system, and examined the image quality of the system with an optical laser. As a result, the total WFE is estimated to be 33 nm (rms) from the Strehl ratio. This is consistent with the WFEs estimated from the measurement of the individual mirrors.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.1
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• pp.156-161
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• 1992

In this research a monitoring system for turning using NC information and the current of feed motor as a monitoring signal was developed. The overall system consists of modules such as learning process, NC data transmission, generation of forecast information, signal acquisition, monitoring and post process. In the learning process, the reference data and the cutting force equation necessary for monitoring are obtained from the accumulated monitoring results. In the generation of forecast information, the information of forecasted cutting forces is acquired from the cutting force equation and NC program and appended to each NC block as a monitor code. Reliability of monitoring is improved by using the monitor code in the real-time monitoring. Monitoring module is divided into two parts : the off-line monitoring where errors of NC program are checked and the on-line monitoring where the level of motor current is monitored during cutting operations. If the actual current level exceeds the limit value provided by the monitor code in the level monitoring, it is recognized as abnormal. In the event of abnormal status, the post processor sends the emergency stop signal to NC controller to stop the operation. Actual experiments have shown that the developed monitoring system works well.

• Journal of the Korea Computer Graphics Society
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• v.16 no.2
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• pp.9-17
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• 2010

Minkowski sum of two polyedra is an operation to compute the sum of all pairs of points contained in the polyhedra. It has been a very useful tool to solve many geometric problems arising in the areas of robotics, NC machining, solid modeling, and so on. However, very few algorithms have been proposed to compute Minkowski sum of polyhedra, because computing Minkowski sum boundaries is susceptible to roundoff errors. We propose an algorithm to robustly compute the Minkowski sum boundaries by employing the controlled linear perturbation scheme to prevent numerically ambiguous and degenerate cases from occurring. According to our experiments, our algorithm computes the Minkowski sum boundaries with the precision of $10^{-14}$ by perturbing the vertices of the input polyhedra up to $10^{-10}$.

• The Journal of Advanced Prosthodontics
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• v.10 no.4
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• pp.321-327
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• 2018

PURPOSE. The purpose of this study was to compare the cutting method and the lamination method to investigate whether the CAD data of the proposed inlay shape are machined correctly. MATERIALS AND METHODS. The Mesial-Occlusal shape of the inlay was modeled by changing the stereolithography (STL). Each group used SLS (metal powder) or SLA (photocurable resin) in the additive method, and wax or zirconia in the subtractive method (n=10 per group, total n=40). Three-dimensional (3D) analysis program (Geomagic Control X inspection software; 3D systems) was used for the alignment and analysis. The root mean square (RMS) in the 2D plane state was measured within $50{\mu}m$ radius of eight comparison measuring points (CMP). Differences were analyzed using one-way analysis of variance and post-hoc Tukey's test were used (${\alpha}=.05$). RESULTS. There was a significant difference in RMS only in SLA and SLS of 2D section (P<.05). In CMP mean, CMP 4 ($-5.3{\pm}46.7{\mu}m$) had a value closest to 0, while CMP 6 ($20.1{\pm}42.4{\mu}m$) and CMP 1 ($-89.2{\pm}61.4{\mu}m$) had the greatest positive value and the greatest negative value, respectively. CONCLUSION. Since the errors obtained from the study do not exceed the clinically acceptable values, the lamination method and the cutting method can be used clinically.

• Journal of Industrial Convergence
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• v.17 no.4
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• pp.9-14
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• 2019

This paper presents several problems that can occur in the development of the ultra-compact LED package of less than 1.0mm and introduces the solution to them. In the existing mold structure, since the upper and lower core parts are integrated, various errors have occurred due to the roughness of EDM in the small model, which is a limiting factor in further reducing the mold size. As a countermeasure, the prefabricated model was presented in an earlier study to overcome the obstacles to the development of a ultra-compact LED package. In this paper, several problems have been found during the fabrication of prototypes as a starting work to produce the results for the presented model. The types are suggested and the solutions are discussed. And by changing the existing 2-row structure to 3-row structure in the same size lead frame, the aspect of efficient production is considered. The experimental procedure verifies the proposed solution and conducts a test to produce a prototype to confirm that a good product can be produced.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.2
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• pp.145-149
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• 2017

One of the challenges facing precision manufacturers is the increasing feature complexity of tight tolerance parts. All engineering drawings must account for the size, form, orientation, and location of all features to ensure manufacturability, measurability, and design intent. Geometric controls per ASME Y14.5 are typically applied to specify dimensional tolerances on engineering drawings and define size, form, orientation, and location of features. Many engineering drawings lack the necessary geometric dimensioning and tolerancing to allow for timely and accurate inspection and verification. Plus-minus tolerancing is typically ambiguous and requires extra time by engineering, programming, machining, and inspection functions to debate and agree on a single conclusion. Complex geometry can result in long inspection and verification times and put even the most sophisticated measurement equipment and processes to the test. In addition, design, manufacturing and quality engineers are often frustrated by communication errors over these features. However, an approach called profile tolerancing offers optimal definition of design intent by explicitly defining uniform boundaries around the physical geometry. It is an efficient and effective method for measurement and quality control. There are several advantages for product designers who use position and profile tolerancing instead of linear dimensioning. When design intent is conveyed unambiguously, manufacturers don't have to field multiple question from suppliers as they design and build a process for manufacturing and inspection. Profile tolerancing, when it is applied correctly, provides manufacturing and inspection functions with unambiguously defined tolerancing. Those data are manufacturable and measurable. Customers can see cost and lead time reductions with parts that consistently meet the design intent. Components can function properly-eliminating costly rework, redesign, and missed market opportunities. However a supplier that is poised to embrace profile tolerancing will no doubt run into resistance from those who would prefer the way things have always been done. It is not just internal naysayers, but also suppliers that might fight the change. In addition, the investment for suppliers can be steep in terms of training, equipment, and software.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.132-141
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• 2013

Robotic Drilling Systems(RDSs) set the standard for the factory automation systems in aerospace manufacturing. With the benefits of cost effective drilling and predictive maintenance, RDSs can provide greater flexibility in the manufacturing process. The system can be easily adopted to manage very complex and time-consuming processes, such as automated fastening hole drilling processes of large aircraft sections, where it would be difficult accomplished by workers following teaching or conventional guided methods. However, in order to build an RDS based on a CAD model, the precise calibration of the Tool Center Point(TCP) must be performed in order to define the relationships between the fastening-hole target and the End Effector(EEF). Based on the kinematics principle, the robot manipulator requires a new method to correct the 3D errors between the CAD model of the reference coordinate system and the actual measurements. The system can be called as a successful system if following conditions can be met; a. seamless integration of the industrial robot controller and the IO Level communication, b. performing pre-defined drilling procedures automatically. This study focuses on implementing a new technology called iGPS into the fastening-hole-drilling process, which is a critical process in aircraft manufacturing. The proposed system exhibits better than 100-micron 3D accuracy under the predefined working space. Based on the proposed EEF fastening-hole machining process, the corresponding processes and programs are developed, and its feasibility is studied.

• Journal of Institute of Control, Robotics and Systems
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• v.6 no.1
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• pp.73-80
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• 2000

The stewart platform manipulator proposed by stewart is the parallel manipulator which is composed of several independent actuators connecting the upper plate with the base plate and capable of executing a six degree of freedom motion. The manipulator has a structure of a closed loop form, and provides better load-to-weight ratio and ratio and rigidity than a serial manipulator with an open loop form. Moreover, the manipulator has high positional accuracy because position errors of actuators are not additive. Because of these advantages, this manipulator is widely used in many engineering applications such as a driving simulator, a tool of machining center, a force/torque sensor and so on. When this Stewart platform manipulator is controlled in joint space, it is difficult to design a controller using an analytic method due to nonhnearity and unknown parameters of actuators. Therefore, a PID controller is often used because of easiness in applications. To find the PID control gain, a trial-and-error method is generally used. This method is time-consuming, and does not guarantee a optimal gain. Thus, this paper proposes a GA-PID controller which selects an optimal PID control gain using genetic algorithms. And this proposed controller is evaluated experimentally and shows acceptable performance.