본고에서는 고정도 제품을 생산하는 연삭기에 대해 가공물 및 연삭 공구인 연삭 숫돌을 기상에서 측정하기 위한 여러 가지 방법들을 소개하였고 일부는 적응 예를 기술하였다. 소개된 기상 측정장치들은 특히 반복 공정이 필요한 연삭 현장에서 생산성 향상을 위해 유용하게 활용될 수 있을 것으로 생각된다. 그러나 관련 연구가 지속된다면 연삭기의 작업조건 자동 설정, 연삭 상태 진단 등, 연삭기의 지능화에도 적극적으로 응용될 수 있을 것으로 기대된다.

A reduced machining time and increased accuracy for the sculptured surface are very important when producing complicated parts. The step-size and tool-path interval are essential components in high speed and high resolution machining. If they are small, the machining time will increase, whereas if they are large, rough surfaces will be caused. In particular, the machining time, which is key in high speed machining, is affected by the tool-path interval more than the step-size. The conventional method for calculating the tool=path interval is to select a small parametric increment of a small increment based on the curvature of the surface. However, this approach also has limitations. The first is that the tool-path interval can not be calculated precisely. The second is that a separate tool-path interval needs to be calculated in each of the three cases. The third is that the conversion from Cartesian domain to parametric domain or vice versa must be necessary. Accordingly, the current study proposes a new tool-path interval algorithm that do not involve a curvature and that is not necessary for any conversion and a variable step-size algorithm for NURBS.

In this paper, a method to apply the simulated annealing method to three dimensional layout design problem which has multiple constraint conditions and evaluation criteria, was suggested. A program to support three dimensional layout design was developed according to the suggested method. This program was applied to the layout design of the wireless unmaned ocean space submergible boat. The layout result was improved 19.0% for the result of layout design expert. By this, it was verified that the suggested method has validity in supporting three dimensional layout design problem.

Fatigue strength of the welding structure is governed by the residual stress at the weldment toe and static tensile overloads were known as relieving the residual stresses. In this study, static tensile overloads were applied to the welding structures which caused the relief of residual stresses. The amount of residual stress relief was found as proportional to the change of fatigue limit at the given conditions. Based on the fact of the proportionality between the change of fatigue limit and that of residual stress, simple measurement technique is proposed. Modified stress-life curves base on proposed technique gave good agreement with test results.

Three dimensional, elastic-plastic finite element(FE) analyses for circumferential through-wall cracked pipes under combined tension and bending are performed using actual tensile data of stainless steel, for two purposes. The first one is to validate the recently-proposed enhanced reference stress (ERS) method to estimate the J-integral and COD for circumferential through-wall cracked pipes under combined tension and bending. The second one is to compare those results with the GE/EPRI estimations. The FE results of the J-integral and the COD, resulting from six cases of proportional and non-proportional combined tension and bending, compare very well with those estimated from the proposed method. Excellent agreements of the proposed method with the detailed FE results provide sufficient confidence in the use of the proposed method to the Leak-Before-Break(LBB) analysis of through-wall cracked pipes under combined tension and bending.

In this study, a failure mode analysis of CNC machining center is described. First, the system is classified through subsystems into components using part lists and drawings. The component failure rate and failure mode analysis are performed to identify the weak components of a machining center with reliability database. The failure probabilistic function of mechanical part is analyzed by Weibull distribution. The Kolmogorov-Smirnov test is also used to verify the goodness of fit.

This paper proposes a precision displacement measuring method of detecting fringe movement of interferograms with a nanometric resolution. It is well known that the laser interferometer plays a useful and essential role in scientific and industrial application, but they have such error sources as an unequal gain of detectors, imbalanced beams, and lack of quadrature. These error sources degrade the accuracy of the interferometer. However, the fringe movement of interferograms has little relation with these error sources. In order to investigate performance of the proposed method. analysis and simulation were executed over random noise and wavefront distorion. Results of the simulation show that the proposed method is robust against these errors. Experiment was implemented to verify this method.

An error analysis is very important for a precision machine to estimate its performances. This study proposes a new parallel device, cubic parallel manipulator. Errors of the proposed cubic parallel manipulator include upper and down universal joint errors, due to the directional changes in the forces in the links, and actuation errors. An error analysis is presented based on an error model formed through the relation between the universal joint errors of the cubic parallel manipulator and the end effector accuracy. The analysis shows that the method can be used in predicting the accuracy of other cubic parallel devices.

This paper presents modeling of an inductive micro position sensing system and its analysis. The parameters affected the system response are excitation frequency, turn ratio, input position, air-gap size, load resistance, and geometric dimensions. To analyze the system, we try to establish a modeling based on an equivalent magnetic circuit with permeances. The model is verified by the experimental results from 1 kHz to 20 kHz. The magnetic circuit model is well fitted to the experimental data except a little error due to LC resonance in the large turn-ratio system. Modeling enables us to theoretically approach the response characteristics. Based on the magnetic circuit model, system parameters can be selected in such a way to obtain the required characteristics such as high sensitivity, good linearity, or small size.

This paper addresses an analytical approach to the mechanical error analysis of gear train and tolerance design and manufacture of gear train in restricted space considering motor driving torque, driving system inertia, motor acceleration, motor rotor inertia and friction torque. The gear train is designed to have optimum gear ratio in restricted space and each gear is manufactured to have the lowest weight and each gear tooth is heat-treated to have robustness. Based on the small difference between the mechanical error analysis and measurement, gear train design with optimum gear ratio and restricted space and robustness is proposed.

Forming pressure of the rupture disc has been analyzed theoretically and verified by experiments. Final shape of the rupture disc after forming process is assumed to be hemi-ellipsoid for small height of the rupture disc. The predicted forming pressures are in good agreement with those by experiment. A new simple model has been proposed to predict the burst pressure of the rupture disc. Experimental results show that the proposed model of burst pressure describes the bursting characteristics of the rupture disc very well.

It is necessary to develop a new metal cutting technology which does not use cutting fluid, since cutting fluid can have undesirable effect on workers's health and working environment. For this to be possible, it is necessary to replace the conventional method of using cutting fluid, whose basic functions are removing chip and heat, and providing lubrication between tool and chip. In this work, cooled air is utilized in order to replace cutting fluid. Experiments were carried out while cutting workpiece with HSS flat endmill under a variety of supply conditions for cooled air. Also the performance characteristics of the air cooling system. which was built for the experiments, were carefully analyzed. For the reliable operation of air cooling system. moisture contained in the cooled air had to be removed before being supplied to the workpiece and tools. It was found that depending on the amount of its flow rate the temperature of cooled air changes at the time of injection from the nozzle. The flow rate of cooled air also plays an important role in removing the accumulated chip on the workpiece. After comparing the flank wear for the three cases of using cooled air, cutting fluid, and pure dry technique, it was demonstrated that the level of flank wear was similar for the cases of cooled air and cutting fluid. The pure dry technique, however, showed higher level of flank wear than cooled air.

Currently, potentiometric method has been employed to measure fuel amount for automobile. However, potentiometer could be malfunctioned or damaged due to the additives or dirt in fuel because a variable electric resistor is immersed in fuel. Therefore, a device employing strain sensor is designed and tested to verify the possibility as an alternative of the conventional fuel sender. Existing fuel tank has irregular cross section. Therefore, buoyancy is not increased linearly as fuel amount is increased. We design a floater that can compensate the irregular cross section of fuel tank and make buoyancy to increase linearly with increasing fuel amount. New fuel sender, comprising of strain gages on circular membrane, the above commented floater and the cover to prevent the disturbance due to sudden acceleration and deceleration, is designed and tested to replace current fuel sender. On the other hand, we are developing strain sensor that has strain gage deposited directly on the circular membrane with cantilever beam.

An automatic design system for a hydraulic gate has been developed to cut down the time for the design calculation and to optimize its design. It is oriented to the radial gate which is the simplest, most reliable, least expensive and most widely used hydraulic gate. This system is composed of data input, strength computation and result display modules with databases of the properties of components and materials. In this development, the existing intricate design procedure has been changed to the straightforward procedure without assumption of weight. With this code, the design time of the radial gate could be reduced below one thirtieth in comparison with manual work and the optimum design could be accomplished easily.

This paper suggests another system for a cutting force measuring tool in a milling process. Generally, tool dynamometer is taken into account for the most appropriate cutting force measuring tool in the analysis of cutting mechanism. However, high price and limited space make it difficult to be in-situ system for controllable milling process. Although an alternative method using AC current of servo-motor has been suggested, it is unsuitable for cutting force control because of small upper frequency limit and noise. The cutting force measuring system is composed of two load cells placed between the moving table bracket and the nut flange part of ballscrew. It has many advantages such as low cost and wide range measurement than tool dynamometer because of the built-in moving table and the low cost load cell. The static and dynamic model of the measuring system using imbeded load cell is introduced. Various Experiments are carried out to validate both models. By comparing the cutting forces from a series of end milling experiments on the tool dynamometer and the system developed in this paper, the accuracy of the cutting force measuring system is verified. Upper frequency limit is measured by the experiment of dynamic characteristics.

A heat dissipation technology using flow resonant phenomenon is a kind of new concept in heat transfer area. A vibration exciter is needed to generate an air turbulence which has the natural shedding frequency of a heat system. A mechanical vibrating device for the air flow oscillation is introduced, which is driven by a moving coil actuator. An analytical dynamic model for this mechanical vibration exciter is presented and its validity is verified by the comparison with experimental data. Values of some unko주 system parameters in the analytic model are estimated through the system identification approach. based on this mathematical model, a high bandwidth vibration exciter is designed using feedback control. During the experimental verification phased, it turns out the high frequency modal resonant characteristics of vibrating plate are the major barrier against obtaining a high bandwidth vibration exciter.

In this paper, Automatic Dynamic Balancer(ADB) was simulated and investigated to use at the high speed rotating chuck for the friction welding. In the limited computer simulations and experiments that have been presently carried out, several conclusions have been found. Above critical speed of the rotating system, ADB can balance the rotating disk. Therefore, it can be predicted that ADB can make an uniform flash during the friction welding.

Recently Moire and PMP(Phase Measuring Profilometry) are adopted as a practical methodology for non-contact 3-D measurement of free surface. These methods extract the 3-D informations from the images of the object projected with stripe-pattern light. This paper presents a simple projector generating stripe-pattern light using expensive polygon mirror. In this projector, slit-beam is generated with a Laser diode and a rod lens and the laser diode is switched on/off synchronizing with the rotation of the polygon mirror. So its structure is very simple and light-weighted compared to the existent projection methods using several lenses and it is also easy to change the pitch and the phase of the stripe pattern. Experimental results show that the intensity profile of the stripe pattern can be approximated with sinusoidal curve by reducing the pitch of the stripe pattern.

Composite materials consists of two or more different material layers. The usefulness of clad metal rods forms the possibilities of combination of properties of different metals. Copper clad aluminum composite materials are being used for economic and structural purpose. In this study, composite billet consists of commercially pure copper and aluminum(A6061) and experimental conditions consist of the combinations of clad thickness, extrusion ratio, and semi-cone angle of die. In order to investigate the influence of these parameters on the hot direct extrudability of the copper clad aluminum composite material rods, the experimental study have been performed with various extrusion temperatures, extrusion ratios, semi-cone angles of die, and composition rate of Cu:Al.

An upper bound elemental technique(UBET) has been carried out to predict the forming load, the deformation pattern and the extrude length of the lateral extrusion of a spider for the automotive universal joint. For the upper bound analysis, a kinematically admissible velocity field(KAVF) is proposed. From the proposed velocity field, the upper bound load, the deformation pattern and the average length of the extruded billets are determined by minimizing the total energy consumption rate which is a function of unknown velocities at each element. Experiments are carried out with antimony-lead billets at room temperature using the rectangular shape punch. The theoretical prediction of the forming load, the deformation pattern and the extruded length are good in agreement with the experimental results.

Much research efforts have been made on the equal-channel angular pressing(ECAP)that produces ultra-fine grain size materials. Recently many materials have been tested for ECAP process, and in this paper pure-Zirconium is considered due to its applicability to nuclear reactors. Among many process parameters of ECAP, frictional effects on the deformation behavior of materials and on the stress distribution of die have been investigated. The finite element method has been employed in order to investigate this issue, and experiments have also been made to verify the numerical results.