The potential for growth and the future impact of Rapid Prototyping that it will have on the product development cycle are enormous. Since making tools, precedes making parts, Rapid Tooling becomes widely used in automobile, aerospace, electronic, and other industries. In this study, master models formed by Rapid Prototyping of Stereolithography have been applied for vacuum casting to obtain silicone patterns which have transformed into epoxy models. The epoxy models have been measured to check dimension errors, and tested their functions. These checking and measurement have provided information on plastic injection possibilities and data for die design, Temporary die making with the materials of Aluminum/Epoxy and powder injection metal (PIM) has also been discussed in terms of hardness, surface roughness, and SEM microstructures.

This paper proposes a method to generate the velocity trajectory which guarantees user specified contour errors at corners for high speed and high precision motion control of CNC machines. The relation among the desired trajectory, system bandwidth and corner contour error are derived. Experiments show that the corner contour error specified by users can be guaranteed with the proposed velocity trajectory.

In the automobile development, press tool design and manufacturing are very difficult and need high cost experienced workers. Therefore, we concerned ourselves in the cost down and easy manufacturing. In this research, we have developed a tool for LH/RH of the front fender, which had difficulty in forming. We have carried out the drawing analysis by Pam-stamp and CATIA modeling. Finally, we get the optimal design parameter. As a result of try out, we found out the optimal width and margin at the center line for tool design. Also, in order to get good results we have to intaglio margin in the part of the wheel house and utilize double bead on every side except corner.

Previous researches and experiments have already verified that the primary noise source of high pressure tandem axial thpe piston pump is fluid-borne noise from the process of oil distribution between the kidney-shaped port and valve plate. So, many researchers have improved pressure gradients and reduced sound levels by applying pre-compression and pre-decompression metering grooves to valve plate. In practice however, the sound level of th high pressure tandem axial type piston pump is still undesirable. This paper testified the effect of pumping phase of the piston on vibration and noise of th high pressure tandem axial type piston pump on the best of theoretical research in $this^(1)$. Therefore considering the pumping phase of the piston when assembling the tandem axial type piston pump, it is possible to reduce 1.5~2[dB]of sound level.

Electrical damages to critical parts in rotation machinery have caused may machinery failures and hours of costly downtime. The problem of shaft currents generated in non-electrical machines have puzzled both users and manufacturers of these machines. The main solution for preventing electro- magnetic type damage is to demagnetize all of the machinery parts, however this is costly and time consuming. Therefore a thorough investigation into the causes and physical characteristics of electro- magnetic shaft currents is needed. In this paper, the self excitation theory was developed for a simple model, and axial flux Faraday disk machine surrounded by a long solenoid. Experimental tests were conducted to investigate the physical characteristics on an electromagnetic self excitation rig. The theory showed that the directions of both the shaft rotation and the coil turns should e identical if self excitation is to occur. From the tests, the electromagnetic type shaft current had both AC and DC components occurred at all vibration frequencies. This could point to the way to detect small instabilities or natural frequency locations by monitoring shaft currents.

Cutting force characteristics is closely related with tool wear on the end milling. And it is found that the tool wear can be properly obtained by observation through the tool-maker's microscope when STS 304 is cut using an end mill. The relationship between the tool wear and the cutting force is established based on data obtained from a series of experiments. A cutting force model can be derived from basic cutting force model using parasitic force components of this tool wear. The results of th simulation using the cutting force model proposed in this paper were verified experimentally and a good agreement was partly obtained. The proposed model is capable of predicting increased cutting force due to tool wear.

High precision internal plunge grinding is difficult because of the decrease in the quill stiffness due to the small diameter of wheel. In this paper, the characteristics of internal plunge grinding were investigated. Grinding experiments were performed at various grinding conditions with vitrified bonded CBN wheels. The grinding period was assumed to be consisted of rough grinding and fine grinding. The classification of grinding was determined int terms of the normal grinding forces and actual depth of cut. The experimental results indicate that the higher depth of cut and infeed speed result in the longer rough grinding time. The maximum normal grinding force was nearly equal to the static force and it decreases exponentially as the grinding continues.

An efficient automatic inspection system for Floating Seal is developed, The proposed system consists of a high resolution line scan camera, microcomputer, and PLC (Programmable Logic Controller). In order to perform rapid inspection, The ROI (Region of Interest) is extracted from the original image. There are types of defects; shape defects and surface defects. Each features of defects are captured by edge detect, segmentation, morphological operation, and threshold analysis. PLC controller is used to synchronize the whole system and store the inspection results temporarily to reduce the overhead of microcomputer. As a result, the system is being utilized successfully in a teal inspection line.

In this study, Cu ferrite was machined with cermet tool to clarify the machinability. The main conclusions obtained were as follows. The tool wear becomes the smallest at the cutting speed of 90m/min with the depth of cut of 0.2mm. The surface roughness becomes larger with increasing the cutting speed and the chamfer angle. The tool with the chamfer angle of $15{\circ}$ shows the best performance. The surface roughness increases almost proportionally with the increase of the chip size. The tool wear decreases with increasing feed in the depth of cut not more than 0.2mm.

The improvement of the water level control is important since it will prevent the steam generator trip so that improve the reliability and credibility of operation system. In this paper, the closed loop system identification is performed which can be used for the system monitoring and prediction of the system response. The model also can be used for the prediction control. Irving model is used as a steam generator model. The plant is an open loop unstable and non-minimum phase system. Fuzzy controller stabilize the system and the stable controller stabilize the system and the stable closed loop system is identified using neural networks. The obtained neural network model is validated using the untrained input and output. The results of computer simulation show the obtained Neural Network model represents the closed loop system well.

This study is concentrated on the development of real-time estimation model and vision control method as well as the experimental test. The proposed method permits a kind of adaptability not otherwise available in that the relationship between the camera-space location of manipulable visual cues and the vector of manipulator joint coordinates is estimate in real time. This is done based on a estimation model ta\hat generalizes known manipulator kinematics to accommodate unknown relative camera position and orientation as well as uncertainty of manipulator. This vision control method is roboust and reliable, which overcomes the difficulties of the conventional research such as precise calibration of the vision sensor, exact kinematic modeling of the manipulator, and correct knowledge of position and orientation of CCD camera with respect to the manipulator base. Finally, evidence of the ability of real-time vision control method for manipulator's position control is provided by performing the thin-rod placement in space with 2 cues test model which is completed without a prior knowledge of camera or manipulator positions. This feature opens the door to a range of applications of manipulation, including a mobile manipulator with stationary cameras tracking and providing information for control of the manipulator event.

A four-degree-of-freedom non-linear model with time varying mesh stiffness has been developed for the dynamic analysis of spur gear trains. The model includes a spur gear pair, two shafts, two inertias representing load and prime mover. In the model, developed several factors such as time varying mesh stiffness and damping, separation of teeth, teeth collision, various gear errors and profile modifications have been considered. Two computer programs are developed to calculate stiffness of a gear pair and transmission error and the dynamic analysis of modeled system using time integration method. Dynamic tooth and mesh forces, dynamic factors are calculated. Numerical examples have been given, which shows the time varying mesh stiffness ha a significant effect upon the dynamic tooth force and torsional vibrations.

The objective of this research is to develop an effective inspection planning strategy for sculpture surfaces in OMM(On-Machine Measurement) process. As a first step, effective measuring point locations are determined to obtain optimum results for given sampling numbers. Two measuring point selection methods are suggested in this study based on newly proposed CAD/CAM/CAI integration concept: (1) by the prediction of cutting errors, (2) by considering cutter contact points to avoid the measurement errors caused by cusps. As a next step, the TSP(Traveling Salesman Problem)algorithm is applied to minimize the probe moving distance. Appropriate simulations and experiments are performed to verify the proposed inspection planning strategy in this study, and the results are analyzed.

This paper gives an overview of the various approaches to designing statistical pattern recognition scheme based on Bayes discrimination rule and the artificial neural networks for rotating machine condition classification. Concerning to Bayes discrimination rule, this paper contains the linear discrimination rule applied to classification into several multivariate normal distributions with common covariance matrices, the quadratic discrimination rule under different covariance matrices. Also we discribes k-nearest neighbor method to directly estimate a posterior probability of each class. Five features are extracted in time domain vibration signals. Employing these five features, statistical pattern classifier and neural networks have been established to detect defects on rotating machine. Four different cases of rotation machine were observed. The effects of k number and neural networks structures on monitoring performance have also been investigated. For the comparison of diagnosis performance of these two method, their recognition success rates are calculated form the test data. The result of experiment which classifies the rotating machine conditions using each method presents that the neural networks shows the highest recognition rate.

The paper presents the modeling and optimal control for the reduction of transverse vibration of simply supported beam under a moving mass. The equations of motion are derived by using assumed mode method. The coriolis and centripetal accelerations are accommodated in the equations of motion to account for the dynamic effect of the traveling mass. In order to reduce the transverse vibration of the beam, an optimal controller with full state feedback is designed based on the linearized equations of motion. The optimal actuator locations are determined with the evaluation of an optimal cost functional defined by the worst initial condition with the trade-off of controlled mode performance. Numerical simulations are performed with respect to various velocities and different traveling masses. Even if the velocity of the traveling mass reaches to the critical speed which can cause the resonance of the beam, the controller with two piezoelectric actuators shows the excellent performance under severe time-varying disturbances of the system.

We introduce the algorithms of 2-D and 3-D position estimation using 2-D vision sensors. The sensors used in this research issue red laser slit light to the body. So, it is very convenient to obtain the coordinates of corner point or edge in sensor coordinate. Since the measured points are normally not fixed in the body coordinate, the additional conditions, that corner lines or edges are straight and fixed in the body coordinate, are used to find out the position and orientation of the body. In the case of 2-D motional body, we can find the solution analytically. But in the case of 3-D motional body, linearization technique and least mean squares method are used because of hard nonlinearity.

The shape of surface micro-crack is very irregular due to nonhomogeneous microstructure but is very important in respect to qualitative estimation of fatigue life. Fractal geomety can quantify the shape of surface mciro-crack. Fractal dimension is measured for surface micro-cracks with coast line and box counting method and estimates cycle ration in Al 2024-T3. The average fractal dimension $D_{favg}$ of surface micro-cracks has 3-parameter weibull distribution and location parameter is nearly constant but shape parameter decreases as cycle ration increases. The fractal dimension by coast line method is measured for individual surface micro-crack but the fractal dimension by box countin method is measured for all the surface micro-cracks under sampling area. Therefore, This paper shows fractal dimension $D_{fb}$ can predict cycle ratio $N/N_f$ more convenient than fractal dimension $D_{favg}$.

The weld quality of $CO_2$ arc welding is closely related to the arc stability. As the characteristics of the arc are excessively complex and nonlinear, it is not easy to make the arc model as mathematical form and to control the arc state to be stabilized. This paper was aimed to estimate the arc stability and to control for stabilizing the arc state in short circuit metal transfer mode of $CO_2$ arc welding. For these purposes, the behaviors of arc stability was investigated at different welding conditions using Mita's arc stability index, and the fuzzy control algorithm which uses the arc stability index as control imput and the arc voltage as control output was developed. In the control of the arc stability, the experiments of two cases were performed; the case of setting an initial welding voltage arbitrarily, the case of the step change in workpiece shape. Obtained results were as follows; Mita's arc stability index was able to be estimated qualitatively in the case of using the inverter type welding power source and the control performance for stabilizing the arc status was excellent in the case of existing step change disturbance.

This paper describes the calibration method and the calculation equations of expanded uncertainty for a precision electric force measuring device. The calibration of the electric force measuring device is performed three times (0 ${\circ}$(first time), $120{\circ}$(second time), $240{\circ}$(third time)) at each calibration point. It is usually selected ten points from zero load to rated load of the electric force measuring device. The expanded uncertainty is calculated by combining A type standard uncertainty and B type standard uncertainty. The calibration method and the calculation equations of expanded uncertainty can be widely used in the calibration of the precision electric force measuring device.

It is investigated that internal defect of planetary gear which consists of two gears with different number of teeth on both side. The internal defect, central burst, begin to form at the place of adiabatic shear band which usually has maximum ductile fracture value during the forming operation, forward and backward extrusion. It makes the plastic forming of planetary gear difficult. The prediction of defect to minimize the cost to produce the planetary gear. The finite element simulation code DEFORM is applied to analyze the defects. In the analysis, the toothed gears are assumed as axisymmetric cylinders whose diameters are equal to those of pitch circles of the each gears. Experiments were carried out with the SCM415 alloy steel as billet material and AIDA 630-ton knuckle-joint press. The calculated results and experimental inspections are compared to design a die and blank without defects and the results are useful to predict the internal defect.

This paper describes the effect of the stylus tip size on the shape error in surface topography measurement. To analyze the distortional effect of an actual surface geometry origination from the finite stylus size, the surface is modeled as a sinusoid and the stylus tip as a circle. The magnitude of this distortion is defined as the ration of standard deviation, and this is expressed as an analytic function of the stylus tip radius and the geometrical parameter of a sinusoid. In this paper, the spectrum analysis of the profile is applied to investigate the distortional effect due to the mechanical filtering of the stylus in the frequency domain. and, the cumulative power spectrum is proposed to assess the shape error of measured data according to the various stylus tip sizes. From these results, a new method to select proper stylus tip radius is proposed.

In this paper, we present an ultrasonic sensor based path planning method using fuzzy logic for obstacle avoidance of an intelligent vehicle in unknown environments. Generally, Robot navigation in unknown terrains is a very complex task difficult to control because of the great amount of imprecise and ambiguous sensor information that has to be considered. In this case, fuzzy logic can satisfactorily deal with such information in quite efficient manner. In this study, we propose two fuzzy logic controller which is composed of steering controller and velocity controller respectively. Our object is to develop a fuzzy controller that can enable a mobile robot to navigate from a start point to a goal point without collisions, in the least possible travel time. The ability and effectiveness for the proposed algorithm will be demonstrated by simulation and expeiment.

Electronic speckle contouring(ESC) is the optical method for measuring shape by using fringe-projection techniques in electronic speckle pattern interferometry. It has the advantage of being non-contacting and can also give a field view of the surface under investigation. Fringes in ESC represent the difference in depth along the view direction between the master wavefront and the test component. The contour maps of three-dimensional diffuse objects are obtained by small shifts of optical fiber carrying the dual-object-beams and 4-frame phase shift. We proposed the contouring method by shifting the collimated illumination beams through optical fiber in order to obtain the contour fringe patterns. And also, we performed addition of incremental addition of images and experiments based on it. we obtained both quantitative increment without decorrelation effect and qualitative improvement by reducing the noise of contour fringes.

In this study, chip-tool friction and shear characteristics of cold drawn free machining steels in turning were assessed. To do this, a newly developed equivalent oblique cutting model was adopted. And for comparison with those of free machining steels, chip-tool friction and shear characteristics of conventional carbon steels were also investigated. The Pb-S free machining steel shows superior machinability to others. In case of the Bi-S free machining steel, the shear stress and the specific friction energy are relatively lower than those of conventional carbon steels, but its shear strain is relatively high, so it does not show any remarkable improvement of machinability.

This paper suggests a numerical method of finding optimal geometric path and minimum-time motion for a manipulator arm. To find the minimum-time motion, the optimal geometric path is searched first, and the minimum-time motion is searched on this optimal path. In the algorithm finding optimal geometric path, the objective function is minimizing the combination of joint velocities, joint-jerks, and actuator forces as well as avoiding several static obstacles, where global search is performed by adjusting the seed points of the obstacle models. In the minimum-time algorithm, the traveling time is expressed by the linear combinations of finite-term quintic B-splines and the coefficients of the splines are obtained by nonlinear programming to minimize the total traveling time subject to the constraints of the velocity-dependent actuator forces. These two search algorithms are basically similar and their convergences are quite stable.

In this research, a power-assisted steering system is modeled as a part of a full vehicle dynamic model. The dynamic model of the steering system incorporates hydraulic and dynamic relations between major parts of a steering system, such as steering column, control valve, rack and pinion gear. Through an experimental setup of the steering system, the steering system model is validated. The steering model is included in a full vehicle dynamic model of a car, where kinematic relations between steering and suspension system are defined, and various simulations are performed to evaluate the performance of steering system in conjunction with overall dynamic performance of the vehicle.

In order to regulate cutting torque in milling, monitoring system should be set to a certain threshold. Radial immersion ratio is an important factor to determine the threshold and should be estimated in process for automatic regulation. In this paper, on-line estimation of the radial immersion ration using spindle motor current in face milling is presented. When a tooth finishes sweeping, a sudden drop of cutting torque occurs. This torque drop is equal to cutting torque acting on a single tooth at the swept angle of cut and can be acquired form cutting torque signals. Average cutting torque per revolution can also be calculate form cutting torque signals. The ratio of cutting torque acting on a single tooth at the swept angle of cut to the average cutting torque per revolution is a function of the swept angle of cut and the number of teeth. Using the magnitude of this ratio, the radial immersion ratio is estimated. Identical algorithm is adopted to estimate the immersion ratio based on the spindle motor current measurement. The experiments performed under different cutting conditions show that the radial immersion ratio can be estimated within 10% error range by the proposed method using spindle motor current.

This paper describes a research work of developing computer-aided design of lead frame, semiconductor, with blanking operation which is very precise for progressive working. Approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. This system has been written in AutoLISP on the AutoCAD using a personal computer and in I-DEAS Drafting Programming Language on the I-DEAS Master Series Drafting with Workstation, HP9000/715(64) and tool kit on the ESPRIT. Transference of data among AutoCAD, I-DEAS Master Series Drafting, and ESPRIT is accomplished by DXF(drawing exchange format) and IGES(initial graphics exchange specification) methods. This system is composed of six modules, which are input and shape treatment, production feasibility check, strip-layout, die-layout, modelling, and post-processor modules. The system can design process planning and Die design considering several factors and generate NC data automatically according to drawings of die-layout module. As forming process of high precision product and die design system using 2-D geometry recognition are integrated with technology of process planning, die design, and CAE analysis, standardization of die part in die design and process planning of high pression product for semiconductor lead frame is possible to set. Results carried out in each module will provide efficiencies to the designer and the manufacturer of lead frame, semiconductor.