A burr has been defined as undesirable projection of material formed as a result of plastic flow from a cutting or shearing operation. It is unavoidable in all kinds of machining operation. As a result, burr makes troubles on manufacturing process due to deburring cost, quality of products and productivity. In this study, the primary interest is about exit burr. The burr formation mechanism in each type of burr is classified. Data bases are developed to predict burr formation result. In the milling operation, we develop an algorithm to analyze the burr formation mechanism by the geometrical analysis on the multi featured workpiece with multi cutting path. The algorithm includes three steps, i. e., the feature identification, the cutting condition identification, and the analysis on exit burr formation. We can predict which portion of workpiece would have the exit burr in advance so that we can manage to find a way to minimize the exit burr formation in an actual cutting. Also, this algorithm can be implemented in a commercial CAM package so that we can simulate the NC code to review the burr formation in advance.

This paper suggests a methodology fur improving the machining accuracy by compensating for the machining errors based on on-machine measurement process. Probing errors and machine tool errors included in the measurement data were calibrated or compensated to obtain the actual machining errors. Machine tool errors were modeled in forward and backward directions according to the axis movement direction to consider the effects of backlash errors on the measurement data, and model parameters were determined by measuring a cube array artifact. A rectangular workpiece was machined and then measured with a touch probe as a verification experiment. Machining experiments showed that the machining errors were reduced to within the designated tolerance after compensating for the actual machining errors by modifying the original footpath for the next-step machining.

The laser direct writing method has some advantages of being maskless, allowing rapid and inexpensive prototyping in comparison to conventional mask-based photolithography. In general, there are two kinds of laser direct writing methods such as the laser ablation method and the laser polymerization method. The laser polymerization method was studied fur manufacturing waveguide in this paper. It is important to reduce line width for image mode waveguides, so some investigations will be carried out in various conditions of process parameters such as laser power, writing speed, focusing height and optical properties of polymer. Experimentally, the optical waveguide was manufactured trapezoid shape. Through SEM the waveguide was 20 ${\mu}{\textrm}{m}$ width and 7.4 ${\mu}{\textrm}{m}$ height.

Alumium alloys casting are gaining increased acceptance in the automotive and electronic industeries and squeeze casting is the most efficient method of manufacturing such mass produced parts. This study has been investigated the microstructures and mechanical properties of Al-7.0Si-0.4Mg (AC4C) alloy fabricated by squeeze casting process for development of Fuel system Parts (Fuel rail). The microstructure of squeeze casted specimen were composed of eutectic structure Alumimim solid solution and $Mg_2$Si precipitates. The tensile strength of as-solid solution treatment Al-7.0Si-0.4Mg ahoy revealed 298.5MPa. It was found that Al-7.0Si-0.4Mg alloy have good corrosion resistance in electrochemical polarization test.

The traffic accident is the prerequisite of the traffic accident reconstruction. In this study, the traffic accident (forward collision) and traffic accident reconstruction (inverse collision) simulations are conducted to improve the quality and accuracy of the traffic accident reconstruction. The vehicle and tire models are used to simulate the trajectories for the post-impact motion of the vehicles after collision. The impact dynamic model applicable to the forward and inverse collision simulations is also provided. The accuracy of impact analysis for the vehicular collision depends on the accuracy of the coefficients of restitution and friction. The neural network is used to estimate these coefficients. The forward and inverse collision simulations for the multi-collisions are conducted. The new method fur the accident reconstruction is proposed to calculate the pre-impact velocities of the vehicles without using the trial and error process which requires the repeated calculations of the initial velocities until the forward collision simulation satisfies with the accident evidences. This method estimates the pre-impact velocities of the vehicles by analyzing the trajectories of the vehicles. The vehicle slides on a road surface not only under the skidding during an emergency braking but also under the steering. A vehicle over steering or cornering with excessive speed loses the traction and leaves tile yaw marks on the road surface. The new critical speed formula based on the vehicle dynamics is proposed to analyze the yaw marks and shows smaller errors than ones of the existing critical speed formula.

This paper presents a small loading and positioning device using VCM (voice coil motor). The developed device consists of a VCM-based linear actuating system, a capacitance displacement sensor and a cantilever deflection sensing system. The trust force of the VCM proportional to applied current moves the column supported on two pairs of parallel leaf springs. The infinitesimal displacement of moved column is detected by capacitance displacement sensor with a resolution of 0.1nm and a repeatability of 1nm. Also, a micro cantilever with known stiffness (200N/m), which is mounted on the end of the column, is used as a force sensor to detect the load applied to a specimen. After the cantilever contacts with the specimen, the deflection of cantilever and the load applied to the specimen are measured by using an optical lever system which consists of a diode laser, a mirror and a PSD (position sensitive detector). In this paper, an experimental system was constructed and its actuator and sensing parts were tested and calibrated. Also, the constructed system was applied to the indentation experiment and the load-displacement curve of aluminum was obtained. Experimental results showed that the developed device can be applied for performing nano indentation.

Recently, the tole-robot operations to an unstructured environment have been widely researched. The human's interaction with the tole-robot system can be used to improve robot operation and performance for an unknown environment. The exact modeling based on real environment is fundamental and important process for this interaction. In this paper, we propose an extrinsic parameter calibration and data augmentation method that only uses a circular jig in the hand-eye laser virtual environment. Compared to other methods, easier estimation and overlay can be done by this algorithm. Experimental results using synthetic graphic demonstrate the usefulness of the proposed algorithm.

We propose a new technique to design an unmaned integrating control system based-on Windows XP version off-Line Programming System which can simulate a dynamic model of robot manipulator in three dimensions graphics space in this paper. The robot with 4 and 6 axes modeled SM5 and AM1 respectively were adopted as an objective model. Forward kinematics, inverse kinematics and robot dynamics modeling were included in the developed off-line program. The interface between users and the off$.$line programming system in the Windows XP's graphic user interface environment was also studied. The developing language is Microsoft Visual C++. Graphic libraries, OpenGL, by silicon Graphics, Inc. were utilized for three dimensions graphics.

A PID controller integrated with a velocity feedback is designed for fluid power elevator model system in this study. In this case, for outside disturbance load a hydraulic cylinder and a pressure control valve are used. In this method overshoot is reduced and settling time becomes also shorter than the values achieved from the PID controller system only In conclusion a PID controller integrated with a velocity feedback is considered a suitable control method for fluid power elevator system.

To assess tunnel safety, cracks in tunnel lining are measured by inspectors who observe cracks with their eyes. A manual inspection is, however, slow and subjective. This paper, therefore, proposes vision-based inspection system for measuring cracks in the tunnel lining that inspects cracks fast and objective. The system is consisted of an on-vehicle system and a lab system. An on-vehicle system acquires image data with line CCD camera. A lab system extracts crack then inform their thickness, length and orientation by using image processing. To improve accuracy of crack recognition the geometric properties of a crack was applied to image processing. The proposed system were verified with experiments in both laboratory and field environment.

In this study, a dicing machine with vision system was built and an algorithm for automatic alignment was developed for dual camera system. The system had a macro and a micro inspection tool. The algorithm was formulated from geometric relations. When a wafer was put on the cutting stage within certain range, it was inspected by vision system and compared with a standard pattern. The difference between the patterns was analyzed and evaluated. Then, the stage was moved by x, y, $\theta$ axes to compensate these differences. The amount of compensation was calculated from the result of the vision inspection through the automatic alignment algorithm. The stage was moved to the compensated position and was inspected by vision for checking its result again. Accuracy and validity of the algorithm was discussed from these data.

The design methodology of plastic injection molding die has been gradually moved from two-dimensional line drawings to three-dimensional solid models. The 3D design gives many benefits, a few of which are: ease of design change, data associativity from concept design to final assembly. In the paper represented is the implementation of a program which automatically generates 3D mold-bases and cooling-lines, conforming to given geometric constraints. It utilized a commercial CAD software and the related API(application program interface) libraries. We constructed a DB(database) of typical mold-bases assembled from standard parts, from which the geometry (position & dimension) of a mold-base and composed parts can be automatical]y determined by a few key parameters. Also we classified cooling lines into several typical types and constructed a DB, from which the position of cooling lines is automatically determined. The research is expected not only to simplify construction of a 3D mold-base model including cooling lines but also to reduce design efforts, by way of databases and automatized determination of geometric dimensions.

In order to investigate the effect of surface treatment in Aluminium alloy and Titanium alloy which are used to armor material during ballistic impact, a ballistic testing was conducted. Anodizing was used to achieve higher surface hardness of Aluminium alloy and Iron plating in PVD(Physical Vapor Deposition) method was used to achieve higher surface hardness of Titanium alloy. Surface hardness test were conducted using a Micro victor's hardness tester. Ballistic resistance of these materials was measured by protection ballistic limit(V-50), a statical velocity with 50% probability penetration. Fracture behaviors and ballistic tolerance, described by penetration modes, are respectfully observed from the results of V-50 test and Projectile Through Plates (PTP) test at velocities greater than V-50. PTP tests were conducted with 0$^{\circ}$obliquity at room temperature using 5.56mm ball projectile. V-50 tests were conducted with 0$^{\circ}$obliquity at room temperature with projectiles that were able to achieve near or complete penetration during PTP tests. Surface hardness, resistance to penetration. and penetration modes of surface treated alloy laminates are compared to those of surface non-treated alloy laminates. A high speed photography was used to analyze the dynamic perforation phenomena of the test materials.

For the analysis of machined surface topography and machine-tool chatter, the cutting system is considered to be a single degree of freedom system. This paper presents a modeling method of equivalent vibratory system for precision cutting in end-milling using an impact test, an Autoregressive Moving Average (ARMA) mode] and a bisection method It has been shown that the proposed modeling method provides a good identification of the cutting system. The advantages of the proposed method in comparison to the existing method are that it is very easy and accurate.

Mechanical properties of the materials used for transportations and industrial machinery under high strain rate loading conditions such as high impact loading are required to provide appropriate safety assessment to varying dynamically leaded mechanical structures. The Split Hopkinson Pressure Bar(SHPB) technique with a special experimental apparatus can be used to obtain the material behavior under high strain rate ]ending conditions. In this paper, the dynamic deformation behavior of a brass under both high strain rate compressive loading conditions has been determined using the SHPB technique.

In this paper, efficient and accurate contact search algorithm is proposed for the contact problems by the finite element method. A slave node and a maser contact segment is defined using the side of a finite element on the contact surface. The specific goal is to develop techniques of reducing the nonsmoothness of the contact interactions arising from the finite element discretization of the contact surface. Contact detection is accomplished by monitoring the territory of the slave nodes throughout the calculation for possible penetration of a master surface. To establish the validity of the proposed algorithm, some different process and geometries examples were simulated. Efforts are focused on the error rate that is based on the penetrated area through the simulations fur large deformation with contact surface between deformable bodies. A proposed algorithm offers improvements in contact detection from the simulation results.

In this paper, a two-dimensional multibody DADS model of a moving walk is developed to improve the ride quality of a moving walk system. The proposed DADS model is able to estimate the longitudinal acceleration of moving walk system, which is the more sensitive and important than other accelerations. To show the validity of the developed model, the longitudinal accelerations of pallet obtained from the computer simulations are compared to the experimental data in frequency domain. Then, the factorial design technique is applied to determine the main design factor and to improve the ride quality. The change of the spring compression in the lower part of the tension generating system improved the ride quality of the moving walk system.

In this paper, the tube forming by radial-forward extrusion is analyzed by numerical simulation and experiments. The paper discusses the effects of process variables such as gap height, relative gap width and die corner radius on tube forming. The influence of deformation patterns of flange in radial extrusion on forward extrusion for tube forming is investigated and summarized in terms of the maximum forming force and hardness variations along the extrusion path. Furthermore the external defects are shown experimentally during the forming operation. Based on finite element analysis in conjunction with experimental test in Al alloy, analysis is performed for important parameter combination in order to reduce forming defects. Eventually, the process parameters for safe forming are suggested in order to reduce the forming defects.

An optimal control approach to robust control design is proposed in this study for rigid robotic systems under the unknown load and the other uncertainties. The uncertainties are quadratically bounded for some positive definite matrix. Iterative method to find the matrix is shown. Simulations are made for a weight-lifting operation of a two-link manipulator and the robust control performance of robotic systems by the proposed algorithm is remarkable.

In this paper, investigated are the machining characteristics such as material removal rate and machining time with respect to discharge area and capacitance in micro electrical discharge machining (MEDM). As discharge area determined by the electrode size and capacitance change, the optimal feedrate to allow the minimum machining time changes. The smaller discharge area is, the lower MRR becomes because of the area effect. As the capacitance increases, MRR also increases. However there is the limit capacitance beyond which the MRR does not increase anymore. As the discharge area increases, the limit capacitance also increases.

As mechanical components are miniaturized, the demand on micro die and mold is increasing. Micro mechanical components usually have high hardness and good conductivity. So micro electrical discharge machining (MEDM) is an effective way to machine those components. In micro cavity fabrication using MEDM, it is observed that the bottom surface of cavity is distorted. Electric charges tend to be concentrated at the sharp edge. At the center of the bottom surface, debris can not be drawn off easily. These two phenomena make the bottom surface of the electrode and workpiece distort. As machining depth increases, the distorted shape of electrode approaches hemisphere. This process is affected by capacitance and the size of electrode. By using a smaller electrode than the desired cavity size and appropriate tool movement, bottom shape distortion can be prevented.

The bone fracture healing is simulated by using one of the complex system rules, named cellular automata method. It is assumed that each cell has property of Bone, Cartilage or Fibrous connective tissue. Nine local rules are adopted to change the property of each cell against the mechanical stimulus, which consists of the strain energy density, and the existence of bone in the surroundings. Two dimensional sheep metatarsal model is considered and the bone fracture healing is simulated. The simulation results agree well with those obtained by using fuzzy logic model and experimental data. The cellular automata method found to be one of the simulation methods to express the bone fracture healing. The cellular automata method is expected to be effective in representing biological phenomenon.

Many people are exposed to accidents by vehicles or sports. The most frequent injuries by these accidents is concerned with a knee joint. The three-dimensional surface model of a knee is needed for dynamic analysis of knee motion and knee reconstruction. three-dimensional motion data of a knee joint were obtained using X-ray and precise magnetic sensors. The surface data of a femur and a tibia were obtained using cross-sectional pictures by CT. The three-dimensional surface models of a femur and a tibia were made by the method of optimal triangular patch. Using obtained motion data, we simulated the motion of three-dimensional knee joint model.