Machining accuracy is affected by quasi-static errors of machining center. Since machine errors have a direct influence upon both the surface finish and geometric shape of the finished workpiece, it is very important to measure the machine errors and to compensate these errors. The laser measurement method for identifying geometric errors of machine tool has the disadvantages such as high cost, long calibration time and usage of volumetric error synthesis model. Accordingly, this paper deals with analysis of the geometric errors of a machine tool using ball bar test without using complicated error synthesis model. Statistical analysis method was adopted in this paper for deriving geometric errors using hemispherical helix ball bar test. As a result of experiment, geometric errors of the vertical machining center are compensated by 88%.

Optical disk system aiming at fast data transfer rate and high-density recording requires the improvement in performance of the pickup head. Especially, the pickup actuator needs better linearity and stability. So, a lever actuator for optical disk is proposed. In this paper, the role of lever and its structure are discussed and the flexure hinge is introduced to enhance the precise movement. Using the Newoton's method, the motion of equation for the lever actuator is obtained. The results are compared with the analysis results by the FEM (Finite Element Method) for the vibration and the magnetic field. Consequently, the lever actuator has the 2"d system characteristics in 3-axis moving directions and superior stability for the external vibration.tion.

Vehicle dynamics control systems are. complex and non-linear, so they have difficulties in developing a controller for the anti-lock braking systems and the auto-traction systems. Currently the fuzzy-logic technique to estimate the absolute vehicle speed is good results in normal conditions. But the estimation error in severe braking is discontented. In this paper, we estimate the absolute vehicle speed by using the wheel speed data from standard 50-tooth anti-lock braking system wheel speed sensors. Radial symmetric basis function of the neural network model is proposed to implement and estimate the absolute vehicle speed, and principal component analysis on input data is used. Ten algorithms are verified experimentally to estimate the absolute vehicle speed and one of those is perfectly shown to estimate the vehicle speed with a 4% error during a braking maneuver.

Grinding temperature between a grinding wheel and a workpiece surface, rising rapidly during a machining operation, has bad effects on a surface integrity such as the burning, the residual stress and the crack. In this study, the temperature distribution was obtained briefly by the finite element method and the grinding temperature of a workpiece varying with the grinding condition was measured experimentally. For obtaining the grinding temperature, a thermocouple method was applied. Three thermocouples were inserted in a surface of each workpiece. Changed grinding conditions were the depth of cuts, the feedrate, the dry and wet grinding, the up and down grinding and the number of pieces.

Since cross-feed directional cutting force which is normal to machined surface directly influences the machined surface of the workpiece and total force loaded in cutter, it is necessary to estimate this force to control the roughness of the machined surface and total force in cutter. However, there have been difficulties in using the current existing in a stationary motor for cutting state prediction because of some unpredictable behavior of the current. Empirical approach was conducted to resolve the problem. As a result, we showed that the current and its unpredictable behavior are related to the infinitesimal rotation of the motor. Subsequently, the relationship between the current and the cutting force was identified with the error less than 50%. And, the estimation results of the two machine tools with different characteristics were compared to each other to confirm the validity of the presented estimation method and the characteristics of current of the stationary feed motor.

Recently tube hydroforming has been widely applied to the automotive industries due to its several advantages over conventional methods. In this paper, attention is paid to comparison of an implicit and an explicit finite element method widely used for numerical simulation of a hydroforming process. For an explicit FEM, a huge amount of computational time is required because of the very small time increment to solve a quasi-static problem. Hence, when an explicit FEM is used fDr a hydroforming process, it is general to convert the real problem to a virtual problem with a different processing time and mass density by appropriate scaling factor. However it is difficult to figure out how large the scaling should be adopted enough to ignore the dynamic effects and maintain the desired accuracy. In this paper, the comparison of the results obtained from both methods focus on the accuracy of the predicted geometrical shape and the stress with various scaling factors which are applied to analyze hydroforming process of an automobile lower arm.

There is an intensifying demand fur linear motors in vast range of industry applications such as in factory automation and semi-conductor manufacturing equipment due to their high positioning accuracy, high static stiffness, high thrust and excellent dynamic characteristics. This paper presents an iron core type linear motor for machine tool whose rated thrust is up to 6000N. For electromagnetic field and dynamic analysis, finite element method (FEM) is implemented to predict motor performance. Various design parameters are considered to reduce thrust ripple and to improve dynamic performance with the least sacrifice of effective thrust. Experimental results on thrust and static stiffness are also followed to confirmed the validity of the analysis.

Ceramics are being increasingly used in industry due to their outstanding physical and chemical properties. But these materials are difficult to machine by traditional machining processes, because they are hard and brittle. Recently, as one of various alternative processes, laser-beam machining is widely used in the cutting of ceramics. Although the use of lasers presents a number of advantages over other methods, one of the problems associated with this process is the uncertain formation of cracks that result from the thermal stresses. This paper presents a Bayesian probabilistic modeling of crack formation over thin alumina plates during laser cutting.

Some materials exhibit a rising K-R curve, while the K-R curve for other materials is flat. The shape of the K-R curve depends on material behavior and, to a lesser extent, on the configuration of the cracked structure. The K-R curve for an ideally brittle material is flat because the surface energy is an invariant material property. However, the K-R curve can take on a variety of shapes when nonlinear material behavior accompanies fracture. Five different hot-rolled thin plates are tested to investigate K-R curve behavior. A special experimental apparatus is used to prevent specimens from buckling.

A need fer stable and comfortable cabins in the high-speed passenger ships has increased. For active control of the motion of the ship cabin, a few control algorithms have been applied to the three dimensional real models in the vibration basin. Experimental results show that the feedforward neural network with a linear feedback controller is one of the promising control algorithms for this active control.

In most machining companies, operators decide the cutting condition, a pair of spindle speed (5) and table federate (F) by experience and subjective judgment. As cutting conditions are determined by operators' experience and ability, inconsistent cutting conditions are given in same operating conditions. The objective of this study is to develop the cutting condition decision system which utilizes shop data and predicts tool life by neural network and eventually leads to the optimal cutting condition. The production time per piece is considered for an optimization object. We will discuss the process of an optimal cutting condition decision by neural network. By this process, a series of shop data is stored. And neural network is constructed for prediction of tool life and the optimal cutting condition is recommended from a cutting condition decision system using the stored shop data. The results show that the developed system is rational in searching the optimal cutting conditions on job operations.

The use of ceramic inserts in hot extrusion dies offers significant technical and economic advantages over other forms of manufacture. In this paper, process simulation and stress analysis are thus combined during the design, and a data exchange program has been developed that enables optimal design of the dies taking into account the elastic deflections generated in shrink fitting the die inserts and that caused by the stresses generated in the process. The shrink fit analysis has been performed that enables optimal design of the dies taking into account the elastic deflections which generated in shrink fitting the die inserts and that caused by the stresses generated in the process and by using DEFORM software for process analysis. This data can be processed as load input data for a finite element die-stress analysis. Process simulation and stress analysis are thus combined during the die design. The stress analysis of the dies is used to determine the stress conditions on the ceramic insert by considering contact and interference effects under both mechanical and thermal loads. The results are compared with the experimental ones for verification.

We use a compound-cam twin arm structure and random tool access method to achieve a faster ATC (Automatic Tool Changer) system for the accurate position and rotation control of a tool magazine and an exchange am. Based on the data obtained from various sensors, it is possible to follow the sequence of commands in each control step for an exchange arm. However, it is not so easy to reduce the exchange time of the system because of the slow responses of the sensors and execution mode delays of PLC (Programmable Logic Controller) scan time. In this paper, we propose a new programmed limit-switch position control method to obtain the shortest possible delays for the random tool access method and compound-cam twin arm structure. With some experimental results, we have achieved below 0.9sec tool exchange time with the proposed method.

In this paper, we propose a hierarchical motion controller with stand-alone vision system to enhance the flexibility of the robot soccer system. In addition, we simplified the model of dynamic environments of the robot using petri-net and simple state diagram. Based on the proposed model, we designed the robot soccer system with velocity and position controller that includes 4-level hierarchically structured controller. Some experimental results using the stand-alone vision system from host system show improvement of the controller performance by reducing processing time of vision algorithm.

This study describes a method of finding an optimal path of a soccer robot by using a concentric circle method with different radii of rotation. Comparing with conventional algorithms which try to find the shortest path length, the variable concentric circle method find the shortest moving time. The radius fur the shortest moving time for a given ball location depends on the relative location between a shooting robot and a ball. Practically it is difficult to find an analytical solution due to many unknowns. Assuming a radius of rotation within a possible range, total path moving time can be calculated by adding the times needed for straight path and circular path. Among these times the shortest time is obtained. In this paper, a graphical solution is presented such that the game ground is divided into 3 regions with a minimum, medium, and maximum radius of rotation.

A new position correction method using four fiducials as reference points was developed and examined. It was aimed to calibrate nonlinear deformation by numerous error sources. A correlation for correction was derived from the geometric relationship between four fiducials and chip position. Compared with three points method, it exhibited more accurate correction, especially for inner area of a quadrilateral composed of four fiducial points. Its accuracy was found to be increased as fiducials moves outwardly within a printed circuit board (PCB) and/or as they form more rectangle-like shape As for arbitrarily nonlinear deformation, this method can be applied using more than five fiducials. In this case, local-area calibration is carried out by sectioning a board area into several rectangular are as.

The design of hydraulic & control system has been developed for the disc spinning machine. The hydraulic system has been designed in the overall system including the vertical & horizontal slide fur spinning works which are controlled by hydraulic servo valves in right & left side, and the clamping slide for holding & pressing blank material in center during spinning process. Based on the design concept of this hydraulic system, model test experiments for hydraulic servo control system is tested to conform confidence and applying possibility. The control system is introduced with the fuzzy-sliding mode controller for the hydraulic force control reacting force as a disturbance, because a fuzzy controller does not require an accurate mathematical model for the generation of nonlinear factors in the actual nonlinear plant with unknown disturbances and a sliding controller has the robustness & stability in mathematical control algorithm. We conform that the fuzzy-sliding mode controller has a good performance in force control for the plant with a strong disturbance. Also, we observe that a steady state error of the fuzzy-sliding mode controller can be reduced better than those of an another controllers.

The objective of this paper is to investigate the effect of clearance and the configuration of die system on burr formation by FEM analysis and experimental tests. Compared with casting, forging and machining, shearing has been known, especially in heavy or mass-production industries, as a very economical and fast way to obtain the desired shape Recently, the shearing process becomes widely used in the small and light electronic component manufacturing industries. When shearing a part of sheet metal, the burr formed on the cutting edge is usually unavoidable. The burr would not only degrade the precision of products but also causes additional cost for the deburring process. In this paper, the influence of shearing parameters such as clearance and configurations of the lower pad (ejector) on burr formation is investigated by using the experimental and numerical approach. From the experimental results, it has been shown that the more narrow clearance gives the smaller burr height and the higher shearing forces. The removal of lower holder also makes the sheared surface integrity and the dimensional accuracy become worse. The FEM results (using DEFORM-2D) show good agreement with the experimental results.

One of the ever-increasing demands on the performances of heterodyne interferometers is to improve the measurement resolution, of which current state -of-the-art reaches the region of sub-nanometers. So far, the demand has been met by increasing the clock speed that drives the electronics involved fur the phase measurement of the Doppler shift, but its further advance is being hampered by the technological limit of modem electronics. To cope with the problem, in this investigation, we propose a new scheme of phase -measuring electronics that reduces the measurement resolution without further increase in clock speed. Our scheme adopts a super-heterodyne technique that lowers the original beat frequency to a level of 1 MHz by mixing it with a stable reference signal generated from a special phase- locked-loop. The technique enables us to measure the phase of Doppler shift with a resolution of 1.58 nanometer at a sampling rate of 1 MHz. To avoid the undesirable decrease in the maximum measurable speed caused by the lowered beat frequency, a special form of frequency up-down counting technique is combined with the super-heterodyning. This allows performing required phase unwrapping simply by using programmable digital gates without 2n ambiguities up to the maximum velocity guaranteed by the original beat frequency.

Solid state deformation of PZT is effective for the micron scale displacement. Inch-worm gets large linear displacement by incrementally summing displacements of PZT actuators. Dynamic stiffness of inch-worm is generally low compared to its driving condition due to the small size and light weight of inch-worm. Mechanical vibration induced by low stiffness may degenerate the motion accuracy of the inch-worm. In this paper, dynamic characteristics of the inch-worm are modeled by using the frequency domain curve fitting based on the experimental frequency response function. SMC (sliding mode control) is examined for motion control of the inch-worm. Simulation and experimental results show that the inch-worm with SMC scheme is feasible for the precise displacement device.

As industry is developed, the faster transportation of freight train is demanded. The optimum design of a structure requires the determination of economical member size and shape of a structure which will satisfy the design conditions and the functions. In this study, it is attempted to minimize the dead weight of bogie frame. From the numerical results in the shape and size optimization of the bogie frame, it is known that the weight can be reduced up to 17.45% with the displacement, stress, first natural frequency and critical buckling-load constraints. The first natural frequency and the critical buckling load of the optimized model is larger than that of the lowest design value. Stress and displacement conditions are also satisfied within the design conditions. From the results, the optimal model is stable and useful for the improvement of railway carriages.