This investigation is the result of the structural analysis by finite element method for optimal design of the cross beam with circular holes of the electric car-body. in order to install the air pipe and electric wire pipe that correspond signal between electric machines for the control system and to reduce the weight of the electric car-body, several circular areas from a cross beam should be taken off. What we want to perform is the optimal design of a cross beam with circular holes to posses equal stress in comparison with no hole cross beam. first, no hole cross beam as basic modal be chosen, executing the analysis, reviewing the distribution of stress and displacement at each location. several parameter should be adopted from the cross beam geometry like the location and shape of the hole to affect the maximum stress and displacement. So the analysis was executed by finite element analysis for finding optimal design parameter to the change of the location and shape of the circular hole. finally, the optimal design of the cross beam with circular holes was obtained and the maximum equivalent stress was compared with no hole cross beam at each location.

Microcellular foaming is being researched as a method of maintaining and improving the mechanical characteristics of plastics as well as saving the material costs. This can not only improve the mechanical properties including impact strength of plastic by producing cells with the size of few ${\mu}$m diameters within the plastic, but also can save the material cost of plastic products with the general volumetric expansion of 2 to 10 times. But quite a long time is required for the gas to be absorbed in the plastic. Therefore consistent research should be done to reduce the saturation time of gas into the plastic and this paper provides the method of water microcellular foaming process as one of the methods using the high diffusivity of water. In addition, we can improve impact property of foamed plastic by using this method.

In spite of the advance of 3D solid modeling technology, there are some distinct areas where 2D CAD S/W are still dominant, and more competent comparing with 3D CAD S/W. For example, in the manufacturing of 2D-shaped electrical parts, most related manufacturing tools have 2D geometric features by nature, and 3D solid models applied to these parts have substantial overheads. Nevertheless, most 2D CAD S/W have no topological inquiry services because they have no such information on their geometrical database inherently. Thus, it is needed to extract such information from 2D CAD database for developing more advanced application such as automated drafting/design S/W. In this paper, the extraction of topological information from 2D CAD has been performed in general way using concept of B-rep. A general extraction algorithm, data structure and meta file format for 2D topological object have been developed and successfully applied to the development of the automated lead frame die design system in Samsung Aerospace. it is also possible to provide a flexible, powerful topology-oriented functionality on any common 2D CAD S/W.

In order to establish the design technique of the robust current controller in d.c series wound motor driver system, this paper proposes a method of the compensated Bang-Bang current control using d.c series wound motor driver system under the improperly variable load to get minimum time for the torque control. The compensated Bang-Bang current controller structure is simpler than that of PID plus Bang-Bang controller. This paper shows that a general 16 bits microprocessor is efficiently used to implement such an algorithm. The calculation time of software is extremely small when compared with that of conventional PID plus Bang-Bang controller. Both nonlinear operating characteristics of digital switching elements and describing function methods are used for the analysis and synthesis. Real-time implementation of the compensated Bang-Bang current controller is achieved. The concept of design strategy of the control and the PWM waveform generation algorithms are presented in this paper.

The scale of dendritic structure of a cast preform plays a key role in determining the mechanical properties of cast/forged products. In this study, casting experiments are carried out to reduce dendrite arm spacing (DAS) to smaller than 20 ${\mu}$m by increasing cooling rate of the mold and then to spheriodize dendritic structures by addition of alloying elements such as Zr and Ti-B. From the casting experiments, appropriate casting conditions for producing the cast preform of a motorcycle connecting rod are obtained. To obtain fine microstructures of the cast preform, mold temperature must set to be low whilst cooling rate being high. When cooling rate is 10 $^{\circ}C$/s, the size of DAS is 17.4 ${\mu}$m. And the degree of spheriodization of a grain in the cast preform is described by aspect ratio, which is defined as the ratio of major and minor radii of an elliptical grain. When 0.5% Zr and 0.24 % Ti+B are added to the molten aluminum alloy, the best aspect-ratio 0.75 is obtained. After forging the cast preform of a motorcycle connecting rod, the microstructure and mechanical properties of the cast preform are compared with those of the cast/forged product. Cast/forged products are superior in microstructure and in mechanical properties such as ultimate strength, elongation, and hardness.

In this paper, a practical method for design and machining of cycloid gear was investigated. Based on the proposed method, a systematic program was developed for automatically designing the tooth profiles of epicycloid and hypocycloid gears for the case fo one difference between the number of teeth of cycloid gear and the number coordinates of tooth profiles and pressure angles. The error analysis between cycloid curve and Biarc curve was performed to show the effective method of equidistant partitioning of cycloid curve so that efficient method of Biarc curve fitting was also proposed for the partitioned curve.

Three dimensional CAD data viewer helps a user to view and use many different types of CAD data without having costly programs that produced them loaded on their computers. A viewer for standard data formats such as STEP and IGES is more useful since most of the CAD systems provide translators for them. We developed a 3D CAD viewer for STEP AP203 solid and assembly data. In addition to the standard shading and assembly tree display, functions for 3D markups and measurement of distance and angles were implemented.

In milling, cutting tool ins directly attached to spindle and this tells that spindle can provide very useful information on the cutting tool condition such as wear or breakage. Since spindle is rotating at a high speed, measuring spindle velocity using a noncontacting measurement system gives the best information which can be obtained. Due to the force applied to spindle through cutting tool, velocity of spindle changes. And any change in cutting tool condition affects cutting force and consequently spindle vibration. With the intent of continuously monitoring cutting tool condition in intermittent machining operations in a benign manner, a noncontacting velocity measurement system using a laser Doppler velocimeter was assembled to measure spindle torsional vibration. Spindle vibration was measured and analysis of it in the frequency domain yielded a measure which corresponded to amount of cutting tool wear in milling.

The influence of surface preparation methods after plasma cutting on the quality of weld zone was investigated. For comparison, three types of welded specimens were prepared by machining (WM), plasma cutting with light regrinding (WPG) and without regrinding (WP), by using three kinds of materials, carbon steel (SM45C), stainless steel (STS304) and aluminum alloy (A6061-T6). Nondestructive examination, hardness test, microstructure examination, and fracture toughness test were performed. The results showed that there was no appreciable reduction in hardness or fracture toughness in WP specimens. But a little difference in heat affected zone size was observed.

In order to remain competitive, a manufacturing company needs to maintain the optimal condition of its manufacturing system. Machine tools as an important element of a manufacturing system consist of complex mechanical as well as electronic components. Therefore, diagnosing the troubles of machine tools is a tricky process which requires a lot of experience and knowledge. Since providing machine tool users with necessary services at the right time is very difficult and expensive, a remote diagnosis system is to be regarded as a good alternative, with which users can diagnose and fix the machine troubles. This paper presents a framework for a remote machine tools diagnosis system by combining the world wide web technology and backward reasoning expert system.

In order to execute the major role as the high density large capacity data storage device, which is one of the major characteristics of DVD(Digital Versatile Disk), there must be a method to effectively absorb the external impact or internal vibration. The DVD which has been developed until now tries to control two different types of vibrations, using only one absorber. But this goes against the independence Axiom of Axiomatic Approach which makes the design to be coupled. And in fat most of the malfunctions occurring during DVD data input/output is due to impact or vibration. Therefore in this paper, the vibration absorption system and operation reliability of DVD will be evaluated with the Axiomatic Approach and plans and feasibility to design an improved vibration absorption system will be provided also based on the Axiomatic Approach.

The compression behavior of semi-solid materials in studied from a viewpoint of yield criteria and analysis methods. To describe the behavior of materials in semi-solid state, several theories have been proposed by extending the concept of plasticity of porous compressible materials. in the present work, the upper-bound method and the finite element method are used to model the simple compression process using yield criteria of Kuhn and Doraivelu. Segregation between solid and liquid which cause defect of product is analysed for Sn-15%Pb alloy is compared with the experimental result of Charreyron et al..

A kinematically admissible velocity field is derived to analyze the forming load and the extruded length in the extrusion/forging process of trochoidally headed bars from round billets. The forming load and the extruded length are obtained by minimizing the total energy-consumption rate. Experiments are carried out with lead billets at room temperature using trochoidally shaped punches. The theoretical predictions of forming load and extruded length are in good agreement with the experimental results.

The flywheel energy storage system using superconducting magnetic bearings is a device to store electrical energy as rotatioal kinetic energy by motor and to convert it to electrical energy by generator when it is necessary. The rotordynamic analysis should be performed with an adequate analytical model and equations of motion to identify the stable driving condition and the dynamic behavior. The critical speed and the unbalance response of superconducting magnetic bearings-flywheel system are studied in this paper. The analytical results show that the system has one forward whirling mode and two backward whirling models below 500rpm. The maximum displacement 0.75mm is detected at the first forward mode (385rpm)through unbalance response analysis. The analytical results are compared with the experimental result by the spin-down test. The experimental result shows that the maximum displacement is 0.7mm at 370rpm.

A new KAVF(kinematically-admissible velocity field) is proposed to determine the forming load, the average extruded length and the flow pattern is the extrusion/forging process of polygonal headed bars. Experiments are carried out with lead billets at room temperature using regular polygonal shaped punches. The theoretical predictions of the forming load and the average extruded length are in good agreement with the experimental results.

Track rubber parts has heat built-up as long as dynamic loading is applied from running tracked vehicles. Durability is required for rubber part to sustain the heat accumulation and heat exchange between rubber-metal assembly and environmental air and ground. For this research, the track assembly was divided into four parts i.e., bottom track shoe, upper track pad, pin busing and metal structure. Three rubber parts and metal structure were modelled and analyzed with MARC package program to obtain time-temperature data which was induced form mechanical work of tracked vehicles. heat accumulation data was obtained from special experiments under the room temperature of 25$^{\circ}C\;and\;35^{\circ}C$ to simulate the actual environmental conditions. From this research, it is cleared that the environmental temperature does not affect to the heat accumulation speed in rubber parts. Also, the heat built-up mechanism was clarified from the thermo-mechanical work based on numerical analysis and experiments.

A new forming technology has been developed to fabricate near-net shape components by using aluminum alloys with globular microstructure. The estimations of filling characteristic in the forging simulation with arbitrarily shaped dies of SSM are calculated by finite element method with proposed algorithm. The proposed model and various boundary conditions for arbitrarily shaped die are investigated with the coupling calculation between the liquid phase flow and the solid phase deformation. The simulation processes with arbitrarily shaped dies are performed on the isothermal conditions and axisymmetric problems. To analyze the forging process simulation with SSM, new stress-strain relationship for semi-solid behaviour is described, and forging the liquid flow. Furthermore, For the purpose of getting net shape of SSM, it is important to be obtain a solid fraction in forging process with arbitrarily shaped dies. To produce a automotive part which have good mechanical properties, the filling pattern in accordance with die velocity and solid fraction distribution has to be estimated for arbitrarily shaped die.

A constitutive model was proposed to study the effects of fiber waviness on the elastic properties of unidirectional composite materials. The predictions showed that the degree of fiber waviness significantly affected the elastic properties of composite materials. A special fabrication technique was developed for thic composite materials with various fiber waviness ratios. Tensile, compressive and flexural tests were conducted to obtain the elastic properties of composite materials with fiber waviness experimentally. The experimental result were in good agreement with the predictions.

G code has to be made after changing the drawing information to DXF file, the converting file. When the information is changed, the converted file had the unnecessary time of rapid feed during working and the large DATA capacity. It need for arranging the information ordered irregularly. This CAM program based AutoCAD can be decreased uncomfortableness in contrast to use of each system. Also it can be increased productivity by arranging information. And it can be used easily for the beginner of the minor enterprises. its program can be decreased system error between others by using one system and increased work efficiency by using DCL.

The modern trends of optical storage devices can be characterized by high density in information recording, and high bandwidth in data input/output processing rate. These make servo engineers to face with a new barrier on control system design in much more difficult way. The first step to attack this barrier will be through a systematic modeling for the dynamic characteristics of optical storage drive. in this paper, an analytical dynamic model for an optical storage drive based on FEM is drived, and compared with experimental results. Through this comparison, a practical dynamic model on the focusing and tracking motion of optical storage drive is proposed for the initiation of real control system design problem.

Based on the cable-extension transducers, a new technique for two dimensional position measurement is developed in this paper. This new technique includes the use of two such transducers and the planar position is determined through triangulation. This paper also presents uncertainty analysis results for establishing sensor design specifications. An actual prototyped sensor system is built and its accuracy is verified through h\both experiments with coordinate measurement machines and its application to the real-time control of a high load wheeled mobile robot. This new type of position sensor can be easily used in a wide variety of automation applications in industry for two dimensional position measurements with high accuracy over a relatively large range, and it is both cast effective and robust against hostile environments.

An overhead crane system consists of trolley, girder, rope, object, trolley motor, girder motor, and hoist motor. An analytic model which derived from the modelling of the overhead crane system is nonlinear model which includes the swing and the twist angle of the object. this model consists of the equation of motion for motors and object. If the swing angle and the acceleration of Z for the object are small, this model becomes a simple nonlinear model which doesn't include the swing and the twist angle of the object. From the results of computer simulation, the characteristics of an actual overhead crane system could be predicted by the simple nonlinear model.

3D linear and circular interpolations are a basic part for the machining of complex shapes. Until now, because of the absence of appropriate algorithms for the generation of 3D lines and circles, a full accomplishment for available machine tool resolution is difficult. this paper presents new algorithms for 3D linear and circular interpolation in the reference pulse technique. In 3D space, the line or circle is not expressed as an implicit function, it is only defined as the intersection of two surfaces. A 3D line is defined as the intersection of two planes, and a 3D circle is defined as the intersection of a plane and the surface of a sphere. Based on these concepts, interpolation algorithms are designed to follow intersection curves in 3D space, and a real-time 3D linear and circular interpolator was developed in software using a PC. The algorithm implemented in a PC showed promising results in interpolation error and speed performance. It is expected that it can be applied to the next generation computerized numerical control systems for the machining of 3D lines, circles and some other complex shapes.

To automate the polishing process, a polishing robot with two axes which is attached to a machining center with three axes has been developed by our previous research. This automatic polishing robot is able to keep the polishing tool normal to the curved surface of die and is able to maintain a constant pneumatic pressure. Therefore, in the case of a curved surface die, the surface roughness to be polished by the system with five axes is improved superior than the surface by a three-axis machining center. However, because the polishing robot was big and heavy, a polishing workspace was limited and then it was difficult to attach the robot to machining center. In this study, the smaller and lighter polishing robot than the previous has been designed to improve defects due to the magnitude and weight of the robot. And the sliding mode control ins applied to polishing robot to improve the tracking performance. To obtain switching parameters of sliding mode control, the signal compression method is used. Code separation program to separate the date for a three-axis machining center and a two-axis polishing robot from a five-axis NC data is improved for users to check conveniently the separated trajectory and to handle many data by using the graphic user interface. To evaluate the polishing performance of the developed robot, the polishing experiment for shadow mask was carried out. The result shows the automatic polishing robot has a good trajectory tracking performance and obtains a good polished workpiece efficiently under recommended polishing conditions.

In the continuous cutting process such as turning operation, chip control is thought very important to achieve the unmanned manufacturing system. The prediction of chip breakage under the given conditions is a substantial element for chip control. In this paper, a systematic approach to know the chip breaking region is represented under the concept of equivalent parameters. to Verify the suggested model, cutting experiments are executed with a commercial type and two other type chip breakers which have modified chip breaker parameters such as land width, groove width and nose radius. predicted chip breaking regions using the 3D cutting model agrees with those obtained from the experiments.