각광을 받고 있는 광통신 분야의 핵심부품인 페룰은 일본이 전 세계의 95%를 장악하고 있다. 국내에서도 일부 업체에서 양산을 하고 있으나, 핵심 연삭공정에 사용되는 연삭 가공장비는 전량 수입되고 있는 실정이다. 페룰은 0.1∼0.3$\mu\textrm{m}$의 동심도, ${\pm}$ 0.2$\mu\textrm{m}$의 외경치수, 0.1$\mu\textrm{m}$대의 진원도와 원통도, 10nm의 표면 거칠기를 구현해야 세계적 경쟁력을 갖출 수 있는 초미세, 초정밀 기계가공 부품이다.(중략)

산업의 발달과 더불어 초소형, 고정밀 제품에 대한 수요가 증가함에 따라 이를 가공할 수 있는 마이크로 가공기술 및 초정밀 공작기계를 구현할 수 있는 설계기술이 국가 경쟁력을 결정하는 핵심 기술로 인식되기에 이르렀다. 공작기계의 성능은 주축계 설계 및 제작기술, 이송계 설계 및 제작기술, 오차 보상기술, 베드 구조물 설계 및 방진기술, 시스템 종합기술 등에 의해 결정되며, 이중에서도 주축계의 설계 및 제작 기술은 가공정밀도 및 생산기술을 주도하는 핵심기술이라 할 수 있다.(중략)

21세기 초고속 통신시스템 구축의 핵심 부품인 고정밀도의 광페룰(Fig. 1)의 수요는 획기적으로 증가할 것으로 전망된다. 전 세계 광페룰 생산량의 90% 정도를 일본에서 생산하고 있으며, 현재 국내 업체들도 일본산 가공설비를 대부분 도입하여 광페룰을 생산하고 있으나 품질 수준이나 생산량에서 아직 미미한 형편이다. 광페룰의 품질수준은 통신 품질의 향상 욕구에 따라 점점 높은 정밀도와 동심도가 요구되고 있으며 정밀도에 따른 가격의 차는 수배에 달하고 있다.(중략)

This study explains the effects of lubricant and surface treatment on hot forging die life. The mechanical and thermal load, and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause die wear, heat checking and plastic deformation, etc. This study is fur the effects of solid lubricants and surface treatment condition for hot forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatment and lubricant are very important to improve die life for hot forging process. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these effects, experiments are performed for hot ring compression test and heat transfer coefficient in various conditions as like different initial billet temperatures and different loads. The effects of lubricant and surface treatment for hot forging die life are explained by their thermal characteristics. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

In this paper, the warm forging process sequence has been determined to manufacture the warm forged product for the precision bevel gear used as the differential gear unit of a commercial automobile. The preform shape of bevel gear influences the dimensional accuracy and stiffness of final product. So, the design parameters related preform shape such as aspect ratio and chamfer length having an influence the formability of forged product are analyzed. Then the optimal conditions of design parameters have been selected by artificial neural network (ANN). Finally, to verify the optimal preform shape, the experiments of the warm forging of the bevel gear have been executed. The proposed method can give more systematic and economically feasible means for designing preform shape in metal forming process.

The Nd:YAG laser process is known to have high speed and deep penetration capability to become one of the most advanced welding technologies. This paper describes the machining characteristics of SM45C carbon steel welding by use of an Nd:YAG laser. In spite of its good mechanical characteristics, SM45C carbon steel has a high carbon contents and suffers a limitation in the industrial application due to the poor welding properties. The major process parameters studied in the present laser welding experiment were position of focus, travel speed and laser power. Optical microscope and SEM were used to investigate the microstructures of the welded zone. The experimental results showed that penetration depth of the welding process increases with laser power. Both the microstructural investigation and the theoretical calculations indicated that materials undergoes a very high heating and cooling cycle during welding process. It was also found that the austenite nucleation takes place at the initial stage and the completion temperature of austenite transformation is much higher than in the case of the arc welding.

The precision fabrication of glass is increasingly demanded for the latest industrial applications of spherical lenses, micro-optical components, and so on. In many cases, the surface roughness of glass is required to be minute for improving the optical characteristics. In this paper, machining characteristics of SF-5 glass and quarts glass are studied by using the ELID grinding process to get mirror surface and productivity compared with a general lapping process. A rotary type grinder with air spindle was used for the experiments. Mitutoyo surface tester and AFM were also used to measure the grinded surface of glass. As the results of experiments, they showed that the surface roughness (Ra) of SF-5 glass was under 7.8 nm and that of quartz glass was under 3.0 m using the # 8000 grinder. So, the possibility of highly efficient and accurate surface for optical components can be achieved by the ELID grinding process.

Through the previous works, it was found that the laminated grinding wheel is more efficient to generate smoother surface in short time than general grinding wheels. But, if the laminated grinding wheel is easily worn-out, it is impossible to apply this wheel in the real grinding process, because the periodic time for dressing is closely linked to the productivity of the process. So, it is required to investigate the wear of the laminated grinding wheel fer studying the periodic time for dressing. But it is difficult to analyze the dressing period quantitavely. Therefore, in this study, periodic times for dressing of the laminated grinding wheel and general grinding wheel are deduced from the relationship between the wear of grinding wheels and the surface roughness changes according to the number of traverse in cylindrical traverse grinding through experiments. This study shows that there are some differences in the wheel wear mechanisms between the general and laminated grinding wheels. As a result, it is also found that the periodic time for dressing of the laminated grinding wheel is longer than that of the general grinding wheel.

The centerless through-feed grinding is performed by passing the workpiece between the grinding wheel and the regulating wheel. So, the amount of removed material around the leading end, of the workpiece is always more than that around the trailing end until the leading end leaves the grinding wheel. Because of this, there are differences in diameters along the workpiece axis during grinding, and workpiece axis is not parallel to the grinding wheel axis and the contact lines between the workpiece and wheels. Thus the ground workpiece shows tapering error inherently. To eliminate this error, the workpiece axis must be kept to be parallel to the grinding wheel axis. And, the direction of the workpiece axis can be controlled by the work-rest blade. Therefore, the effects of work-rest blade inclination angle on the through-feed centerless ground part are investigated in this study. As a result, it is found that there is a positive inclination angle of the work-rest blade for minimizing the tapering error of a ground workpiece.

Characterization of an ultra precision grinding plate for GMR head manufacturing is performed by measuring frictional forces between the grinding plate and the advanced ceramic Two kinds of methods of producing the precision grinding plates are presented: texturing and micro-channeling. Texturing is effective in terms of production time but micro-channeling excels in quality control. It is found that the frictional coefficient of a precision grinding plate decreases as the impregnation of diamond grain onto the precision-grinding plate progresses, and remains unchanged once the impregnation process is successfully completed, even after 100 revolutions of the precision-grinding plate against the advanced ceramic under 40 N of normal force. Therefore, the measurement of the frictional coefficient can replace costly and time-consuming process of estimating the level of impregnation of diamond grain on the precision-grinding plate, which has been performed by using scanning electron microscope, and be employed as an index to determine the level of impregnation of diamond grain.

This paper develops a control method that is composed of the proportional control algorithm and the learning algorithm based on the recurrent neural networks (RNN) for the position control of a pneumatic rodless cylinder. The proportional control algorithm is suggested for the modeled pneumatic system, which is obtained easily simplifying the system, and the RNN is suggested for the compensation of the modeling errors and uncertainties of the pneumatic system. In the proportional control, two zones are suggested in the phase plane. One is the transient zone for the smooth tracking and the other is the small movement zone for the accurate position control with eliminating the stick-slip phenomenon. The RNN is connected in parallel with the proportional control for the compensation of modeling errors and frictions, compressibilities, and parameter uncertainties in the pneumatic control system. This paper experimentally verifies the feasibility of the proposed control algorithm for such pneumatic systems.

In the field of precision manufacturing demanding high positioning performance, the mechanical friction in positioning device deteriorates the quality of the product and increases the cost of production for positioning devices. Therefore, we propose a contract-free linear actuator using active magnetic bearing. The structure and operating principle of the proposed system are explained, and the magnetic forces are analyzed by magnetic circuit theory to design magnetic bearings and linear actuator. With the derived equation of motion, the stability is identified. Experimental results are presented to show the feasibility.

A precision displacement measurement system of 3-DOF micro motions is proposed in this paper. The measurement system is composed of two diode lasers, two quadratic PSDs, two beam splitters and a sphere whose surface is highly reflective. In this measurement system, the sphere reflector is mounted on the platform of positioning devices whose 3-DOF translational motions are to be measured, and the sensitive areas of two PSDs are oriented toward the center point of the sphere reflector. Each laser beam emitted from two diode laser sources is reflected at the surface of sphere and arrives at two PSDs. Each PSD serves as a 2-dimensional sensor, providing the information on the 3-dimensional position of the sphere. In this paper, we model the relationship between the outputs of two PSDs and 3-DOF translational motions of the sphere mounted on the object. Based on a deduced measurement model, we perform measurement simulation and evaluate the performance of the proposed measurement system: linearity, sensitivity, and measurement error. The simulation results show that the proposed measurement system can be valid means of precision displacement measurement of 3-dimensional micro motions.

This paper describes the development of a 6-axis robot's finger force/moment sensor, which measures forces Fx, Fy, Fz, and moments Mx, My, Mz simultaneously, for stably grasping an unknown object. In order to safely grasp an unknown object using the robot's gripper, it should measure the force in the gripping direction and the force in the gravity direction, and perform the force control using the measured forces. Thus, the robot's gripper should be composed of 6-axis robot's finger force/moment sensor that can measure forces Fx, Fy, Fz, and moments Mx, My, Mz simultaneously. In this paper, the 6-axis robot's finger force/moment sensor for measuring forces Fx, Fy, Fz, and moments Mx, My, Mz simultaneously was newly modeled using several parallel-plate beams, designed, and fabricated. The characteristic test of made sensor was performed. and the result shows that interference errors of the developed sensor are less than 3%. Also, Robot's gripper with the 6-axis robot's finger force/moment sensor for the characteristic test of force control was manufactured, and the characteristic test for grasping an unknown object was performed using it. The fabricated gripper could grasp an unknown object stably. Thus, the developed 6-axis robot's finger force/moment sensor may be used for robot's gripper.

The aligning between the punch and die governs no only the burr formation characteristics but also the life time of the punch and die in the sheet metal blanking process. There are many ways to adjust the two elements in the general punching systems but in the case of micro punch system, the punch size is reduced to a few tenth of micrometer range and the general aligning methods are almost impossible to apply. The image processing is the most widely used method in micro punch aligning, but in order to apply the method, it needs quite a large space for visionary system to approach the punch-die aligning zone. In this paper, the new punch-die aligning method with using the total capacitance between the punch and die hole is proposed. In this method, the tip surface of the punch tool locates at the same plane of the die surface and the capacitance variation between the two elements are measured. When the center of the two elements are coincided, the capacitance is minimized, but when the align is changed to any direction, the capacitance between the two elements increase. In order to verify the feasibility of this method, the aligning and punching tests was performed.

A novel three degrees of freedom sensing method utilizing binary grid pattern image and vision camera is presented. The binary grid pattern image is designed by Pseudo-Random Binary Arrays and referenced to encode in-plane position of a moving stage of the contact-free planar actuator. First, the yaw motion of the stage is detected using fast image processing and then the other planar positions, x and y, are decoded with a sequence of images. This method can be applied to the system that needs feedback of in-plane position, with advantages of a good accuracy and high resolution comparable with the encoder, a relatively compact structure, no friction, and a low cost. In this paper, all the procedures of the above sensing mechanism are described in detail, including simulation and experiment results.

Continuously variable damper can yield diverse damping forces for a single damping velocity. It is widely used in the semi-active suspension system since, with right control logics, it can enhance ride comfort compared to the passive damper while not degrading driving safety. A key to the successful design of the continuously variable damper is the knowledge of its complex and nonlinear characteristics. In this paper, research has been done for analyzing characteristics of the continuously variable damper. Various damper components have been investigated and their effects upon the force-velocity characteristics of the damper have been examined. The effects of the damper characteristics change upon ride comfort and driving safety have also been investigated by numerical simulations.

A critical issue in area-based stereo matching lies in selecting a fixed rectangular window size. Previous stereo methods doesn't deal effectively with occluding boundary due to inevitable window-based problems, and so give inaccurate and noisy matching results in areas with steep disparity variations. In this paper, a variable window approach is presented to estimate accurate, detailed and smooth disparities for three-dimensional structure reconstruction. It makes the smoothing of depth discontinuity reduced by evaluating corresponding correlation values and intensity gradient-based similarity in the three-dimensional disparity space. In addition, it investigates maximum connected match candidate points and then devise the novel arbitrarily shaped variable window representative of a same disparity to treat with disparity variations of various structure shapes. We demonstrate the performance of the proposed variable window method with synthetic images, and show how our results improve on those of closely related techniques for accuracy, robustness, matching density and computing speed.

An effective die-polishing robot system is developed. ATC (Automatic Tool Change), tool posture angle control, and robot program for polishing application are developed and integrated into a robotic system that consists of a robot, pneumatic grinding tool, and grinding abrasives (papers and special films). ATC is specifically designed to exchange whole grinding tool set for complete unmanned operation. A tool posture angle control system is developed for the tools to maintain a specified skew angle rather than right angle on the surface for best finishing results. A PC and the robot controller control ATC and tool posture angle. Also, there have been more considerations on enhancing the performance of the system. Elastic material is inserted between the grinding pad and the holder for better grinding contact. Robot path data are generated automatically from the NC data of previous machining process.

We propose a new technique far real-tine controller design of a autonomous cruise mobile robot with three drive wheels. The proposed control scheme uses a Caussian function as a unit function in the fuzzy neural network. and a back propagation algorithm to train the fuzzy neural network controller in the framework of the specialized learning architecture. It is proposed a learning controller consisting of two neural network-fuzzy based on independent reasoning and a connection net with fixed weights to simply the neural networks-foray. The control performance of the proposed controller is illustrated by performing the computer simulation for trajectory tracking of the speed and azimuth of a autonomous cruise mobile robot driven by three independent wheels.

The back beam for a automotive bumper was roll formed to improve performance, reduce weight and save cost. For the back beams produced by conventional stamping and roll forming, the crashworthiness analyses were carried out by numerical simulation and real impact test. The characteristic properties and applicability of the roll formed back beam are discussed from the results of the analyses.

In this study, stress analysis using Boundary Element Method (BEM) was carried to investigate stress distribution in the brazing joint between a Hardmetal and a HSS. The two models were proposed to analyze the stress singularity in the interfaces of the brazing joint. The material type, thickness of the filler metal and the length of the vertical brazing adhesive are considered in the BEM analysis. As results, the peak point of the stress is founded to be in the lower interface of the brazed joint. It should be noted that the maximum stress of the peak point is being affected by the thickness and length of the brazing joint.

In this study we performed optimal design for the vehicle mechanical component which satisfies both a sufficient stiffness and a lightweight using topology optimization technique. The FEA for the initial model before optimal design is performed by ABAQUS/Standard. And, we suggest optimization model using the topology optimal design program Altair Optisturuct 3.6. The FEA of optimal design is performed under the same condition as the initial model. We performed the FEA fur the topology optimal design model and verified the validity of the present method.

This paper proposes an efficient mechanism design system of multi-stage gear drives including not only parallel shaft gears but also non-parallel gears such as bevel and worm gear drives. The system automatically generates three dimensional structures of specification-adjusted mechanisms, and shows the sorted list of the mechanisms according to the evaluation result by using a fuzzy expert system. The list can be used as reliable candidates of the spatial mechanism structures of multi-stage gear drives. Thus, it is expected that the system can increase the efficiency of design and cut off the expenses of preliminary design considerably.

The energy release rate for an interface crack in pseudo-isotropic dissimilar materials was obtained by the eigenfunction expansion method using the two-term William's type complex stress function. The complex stress function for pseudo-isotropic materials must be different from that for anisotropic materials. The energy release rate for an interface crack in pseudo-isotropic dissimilar materials was analyzed numerically by RWCIM. The results obtained were verified by comparing the other worker's results and discussed.

Sensitivity analysis of suspension elements of an articulated bogie for light railway vehicles is presented. The ride, stability and safety are used as dynamic performance indices. Suspension elements of 10 and a conicity of wheel are used as design variables. To analyze sensitivity of design variables. the railway vehicle dynamics analysis program AGEM is used. The results show that the secondary suspension elements have a strong effect on ride and the primary suspension elements have a moderate effect on ride. Conicity of wheel has a strong effect on the stability. The safety is not effected by all the design variables.

In this paper, a two-dimensional electroelastic analysis is performed on a piezoelectric material with an open crack. The approach of Lekhnitskii's complex potential functions is used in the derivation and Bueckner's weight function theory is extended to piezoelectric materials. The stress intensity factors and the electric displacement intensity factor are calculated by the weight function theory.

Twin screw extruders are the heart of the polymer processing industry. They are used at some stage in nearly all polymer processing operations. This paper is concerned with the basic elements of the extruder design. The proper design of the geometry of the extruder screw is of crucial importance to the proper functioning of the extruder. If the material transport instabilities occur as a result of improper screw geometry, even the most sophisticated computerized control system cannot solve the problem. For this purpose, a characteristic design on the screw flights shape of the closely intermeshing co-rotating twin screw extruder. This paper presents design parameters of double flighted screw and triple flighted screw elements, and characteristics of various screw channel area versus screw diameter ratio, K value, in the barrel of screw extruder.

In order to make a deep and precise micro-hole, electrode wear and clearance between the electrode and the workpiece are important parameters using micro-electrical discharge machining. In this study, experiments were carried out to show the characteristics of electrode wear and radial clearance with respect to the depth of machined hole. Electrode wear varied with respect to the depth of hole. With deeper machined hole, bigger clearance was observed. Also it was found that the diameter of electrode influences machining characteristics of deep holes.

Recently, the world are preparing for new revolution, called as If (Information Technology), NT (Nano-Technology), and BT (Bio-Technology). NT can be applied to various fields such as semiconductor-micro technology. Ultra precision processing is required for NT in the field of mechanical engineering. Recently, together with radical advancement of electronic and photonics industry, necessity of ultra precision processing is on the increase for the manufacture of various kernel parts. Therefore, in this paper, stability of ultra precision cutting unit is investigated, this unit is the kernel unit in ultra precision processing machine. According to alteration of shape and material about hinge, stability investigation is performed. In this paper, hinge shapes of micro stage in UPCU(Ultra Precision Cutting Unit) are designed as two types, where, hinge shapes are composed of round and rectangularity. Elasticity and strength are analyzed about micro stage, according to hinge shapes, by FE analysis. Micro stage in ultra precision processing machine has to keep hinge shape under cutting condition with 3-component force (cutting component, axial component, radial component) and to reduce modification against cutting force. Then we investigated its elasticity and its strength against these conditions. Material of micro stage is generally used to duralumin with small thermal deformation. But, stability of micro stage is investigated, according to elasticity and strength due to various materials, by FE analysis. Where, Used materials are composed of aluminum of low strength and cooper of medium strength and spring steel of high strength. Through this stability investigation, trial and error is reduced in design and manufacture, at the same time, we are accumulated foundation data for unit control.