• Transactions of Materials Processing
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• v.15 no.9 s.90
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• pp.673-678
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• 2006

Demands for micro parts have increased with recent advances in IT and machinery industries. However, the present technology loaves much to be desired to effectively produce parts with the volume of $1mm^{3}$ and less by mechanical method in large quantities. This paper provides a method for efficient quantity production of complete micro 3D structure using micro end-milling cutting process. The possibility has proven via manufacturing experiment of a multistage micro complex gear structure of $500{\mu}m$ in length, $500{\mu}m$ in maximum external diameter and a volume of $1mm^{3}$ and less.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2014.10a
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• pp.893-899
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• 2014

X-band antenna has been widely used to effectively transmit the high resolution image data from the observation satellite to the ground station. To achieve above mission, X-band antenna is mainly composed of the 2-axis gimbal system using stepping motors and gears. However, the micro-vibration induced by the stepping motor actuation and the imperfect gear teeth alignment during this on-orbit operation is the main source of image quality degradation. In this paper, X-band antenna combined with a blade gear for micro-vibration isolation was suggested and investigated. The structural safety of the blade gear with low rotational stiffness was confirmed by structure analysis based on the derived torque budget. The isolation performance of the X-band antenna with the blade gear was verified through micro-vibration measurement test using the dedicated micro-vibration measurement device proposed in this study.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.25 no.5
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• pp.313-320
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• 2015

A 2-axis gimbal-type X-band antenna has been widely used to effectively transmit the high resolution image data from the observation satellite to the desired ground station. However, a discontinuous stepper motor activation for rotating the pointing mechanism in azimuth and elevation directions induces undesirable micro-vibration disturbances which can result in the image quality degradation of a high-resolution observation satellite. To enhance the image quality of the observation satellite, attenuating the micro-vibration induced by an activation of the stepper motor for rotational movements of the antenna is important task. In this study, we proposed a low-rotational-stiffness blade gear applied to the output shaft of the stepper motor to obtain the micro-vibration isolation performance. The design of the blade gear was performed through the structure analysis such that this gear is satisfied with the margin of safety rule under the derived torque budget. In addition, the micro-vibration isolation performance of the blade gear was verified through the micro-vibration measurement test using the dedicated micro-vibration measurement device proposed in this study.

• Journal of the Korean Society for Heat Treatment
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• v.27 no.4
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• pp.191-201
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• 2014

The gear was made of SNC815 case-carburized, quench hardened and tempered steel. The gears were failed far earlier than the expected service life used in the industrial site. Causes of the failed gear were analyzed by microstructure observation. By the SEM and micro structure examinations, the damaged surfaces had been weared and failed by fatigue. Through microscope observation on the damaged surface, it was found that the cause of failure was determined by external overloading and the initial stage of the damage was closely related to complex contact fatigue failure. The overload and contact fatigue contributed to the early failure cause.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.11a
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• pp.507-508
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• 2010

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.4 no.4
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• pp.7-13
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• 2005

In the case of fabricating micro pole structures such as column, square-pole and gear shaft by the micro end-milling process, it can be useful in the fields of industry, for example, micro parts, electrode for electrical discharge machining and micro mold for injection molding. In this study, machining factors and the process were analyzed. Machining experiments of various micro pole configurations were performed. Analysis of the change and effect of the cutting force according to the machining conditions was carried out. An analytical study of the deformation of the micro pole caused cutting conditions and cutting force through the finite element method and ANSYS program was carried out. As a result, this research presented a method of fabricating the column pole of below $100{\mu}m$ diameter with high aspect ratio by using micro end-milling process, and based on that, a method of fabricating a variety of applicable structures. Also the minimum size of the pole capable of fabricating through theory and experiment were demonstrated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.589-592
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• 2003

In the machining process of micros shape by using high-precision machining system and micro end-mill, it is important for machining characters of tools to be grasped in order to stably use tools of micro end-mill. In this study. we carried out an analytical experiment of basic machining features by using end-mill tools for the purpose of damage prevention and manufacture of high quality when the tools of micro end-mill are used. This experiment used a micro machining system with high precision and a variety of end-mill tools commercialized from tens to hundreds microns in diameter. To establish an optimal machining condition without tool damage, cutting force was analyzed according to the changes of tool diameter and cutting conditions such as cutting speed. feed rate, depth of cut. And an examination was performed for the shape and surface illumination of machining surface according to the changes of machining conditions. Based on these micro machining conditions, micro square pillar, cylinder shaft. thin wall with high aspect ratio, and micro 3-D structures such as micro gear and fan were manufactured.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.39 no.4
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• pp.371-378
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• 2015

Range extenders, which are power generation systems driven by small engines, extend the driving distance and time of electric vehicles (EVs) through continuous charging of batteries. The currently used range extenders with gasoline engines pose limitations with regard to the realization of high-power compact systems, owing to their complex structure and low energy density. In contrast, micro gas turbine (MGT) range extenders (MGT power packs) possess high power and low weight, and can therefore be significantly reduced in size despite increase in speed. In this study, an MGT power pack for the range extenders of EVs was developed using a turbo-prop micro turbine, an alternator for passenger vehicles and electric batteries. The operating characteristics of the MGT power pack were measured through a series of experiments conducted under electrical no-load and load conditions. Their power generation performance and efficiency were measured under various electrical loads and power transmission gear ratios. From the results, electrical load was found to have no influence on power generation performance. The maximum electrical power output was 0.8 kW at a core turbine speed of 150 krpm, and the application of 3:1 reduction gear to the turbine output shaft increased the power to 1.5 kW by 88%. This implies that the test results demonstrated stable power generation performance of the MGT power pack regardless of vehicle load changes, thus revealing its feasibility for use with the range extenders of EVs.

• Journal of the Institute of Electronics Engineers of Korea SC
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• v.40 no.6
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• pp.87-94
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• 2003

This paper presents results of the development of the turbo generator system with structure which is HSG(High Speed Generator) installed directly to gas-turbine engine. Turbo generator with a high speed motor-generator directly has many advantages aspects of weight, size, lubrication system and complexity of the system compared of conventional turbo generator system with a gear box. But because of direct high speed operation of the high speed generator, we have to need stable high speed motor driving algorithm for perfect engine ignition when engine start. Also we have to need the design of the Power conditioning unit(PCU) for converting high speed AC output power to conventional AC power or needed DC power.