An Experiment was carried out to find the scheme far minimization of burr formation on inclined exit surface in drilling. Several drills with different geometry are used for drilling the workpiece with inclined exit surface. Step drills are specified with step angle and step size. The influence of the inclination angle of exit surface on burr formation was observed, which enables to analyze the burr formation mechanism on inclined exit surface. Along the edge on the inclined exit surface, burrs are formed by the bending deflection to feed direction and also burrs are formed in exit direction of cutting edge. To minimize the burr formed in feed direction, the corner angle which is formed by the inclination angle and step angle must be large enough not to be bent to burr. By decreasing step angle of drill and decreasing the distance between two axes of two holes, burr formation at the intersecting holes can be minimized. Burr formation mechanisms are analyzed according to the drill geometries and cutting conditions. Several schemes far burr minimization on inclined exit surface were proposed.

Fitting process carried out in automobile transmission assembly line is classified into three classes; heat fitting, press fitting, and their combined fitting. Heat fitting is a method that heats gear to a suitable range under the tempering temperature and squeezes it toward the outer diameter of shaft. Its stress depends on the yield strength of gear. Press fitting is a method that generally squeezes gear toward that of shaft at room temperature by press. Another method heats warmly gear and safely squeezes it toward that of shaft. Warm shrink fitting process for automobile transmission part is now gradually increased, but the parts (shaft/gear) assembled by this process produced dimensional changes of gear profile in both radial and circumferential directions. So that it may cause noise and vibration between gears. In order to solve these problems, we need an analysis of warm shrink fitting process, in which design parameters are involved; contact pressure according to fitting interference between outer diameter of shaft and inner diameter of gear, fitting temperature, and profile tolerance of gear. In this study, an closed form equation to predict contact pressure and fitting load was proposed in order to develop optimization technique of warm shrink fitting process and verified its reliability through the experimental results measured in the field and FEM, that is, thermal-structural coupled field analysis. Actual loads measured in the field have a good agreement with the results obtained by theoretical and finite element analysis and also the expanded amounts of the gear profile in both radial and circumferential directions are within the limit tolerances used in the field.

Sandwich structures, which are composed of a thick core between two faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Accordingly, the usage of sandwich structure is very widely applied to the aircraft, the automobile and marine industry, etc., because of these advantages. In this paper, we have investigated the buckling protection of an inner structure plate and the useful corrugated configuration for contact, and the fabrication method of the inner structure plate for large area using the continuous molding process. Also, we have guaranteed the accuracy of the molding process through the micro corrugated mold fabrication and secured the accuracy and analyzed aspect properties of the inner structure plate fabricated for a large area using the partial mold process. We have compared molding simulation according to the aspect thickness of the corrugated configuration with the molding experiment results.

The lead frame manufactured by stamping process plays an important role in connecting semiconductor to PCB board. As a result of the miniaturization of semiconductor, its corresponding lead frame punch has been narrow. In case of the punch with high slenderness ratio such as lead frame punch, the punch can be broken suddenly due to buckling. To prevent the fracture of lead frame punch, some manufacturers have experientially attached stiffeners to weak parts of punch. The purpose of this study, therefore, is to suggest the guideline far design of stiffened punch. The optimal position and the number of stiffeners to be attached to punch are investigated by elastic buckling analysis. The elastic buckling analysis consists of the eigenvalue buckling analysis and nonlinear buckling analysis. The critical buckling load of elastic buckling analysis is compared with that of buckling test. Finally, the guideline far attaching stiffeners is suggested through analysis of cross section of lead frame punch such as moment of inertia and eccentricity.

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting fores caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together far cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.

The synthesis of optimal controllers for multivariable systems usually requires an accurate linear model of the plant dynamics. Real systems, however, contain nonlinearities and high-order dynamics that may be difficult to model using conventional techniques. This paper presents a novel loaming method for the synthesis of LQR controllers that doesn't require explicit modeling of the plant dynamics. This method utilizes the sign of Jacobian and gradient descent techniques to iteratively reduce the LQR objective function. It becomes easier and more convenient because it is relatively very easy to get the sign of Jacobian instead of its Jacobian. Simulations involving an overhead crane and a hydrofoil catamaran show that the proposed LQR-LC algorithm improves controller performance, even when the Jacobian information is estimated from input-output data.

In this paper a adaptive backstepping control scheme is proposed for control of a do motor driving a one-link manipulator. Fuzzy logic systems are used to approximate the unknown nonlinear function including the parametric uncertainty and disturbance throughout the entire electromechanical system. A compensation controller is also proposed to estimate the bound of approximation error. Thus the asymptotic stability of the closed-loop control system can be obtained. Numerical simulations are included to show the effectiveness of the proposed controller.

We discuss two possibilities of using femtosecond pulse lasers as a new interferometric light source for enhanced precision surface-profile metrology. First, a train of ultra-fast laser pulses yields repeated low temporal coherence, which allows unequal-path scanning interferometry, which is not feasible with white light. Second, the high spatial coherence of femtosecond pulse lasers enables large-sized optics to be tested in nonsymmetric configurations with relatively small-sized reference surfaces. These two advantages are verified experimentally using Fizeau and Twyman-Green type scanning interferometers.

A hybrid focus method with multiple laser slits is newly proposed for the measurement of surface morphology with depth discontinuity, and it is based on the integration of DFB and DFF. Rough depth information is estimated through calibration tables which are constructed by DFD with multiple laser slits, and then DFF is applied to only each specific depth range using the rough depth information resulting from DFD. The proposed hybrid method gives more accurate results than DFD and DFF, and faster measurement than DFF in the vicinity of depth discontinuity Its performance is verified through experiments of calibration blocks with sharp depth discontinuity.

This paper addresses the methodology development far the automated machining setup planning system using case-based reasoning(CBR). The case-based reasoning is used to develop a setup planning system. which consists of part input and representation module, case retrieval module, and case adaptation module. We present new approaches in the part input and representation module and the case retrieval module focusing on the similarity index determination. An illustrative example is included to demonstrate the proposed method.

Cold expansion method is used to protect a fatigue fracture from fastener hole in the structure and aerospace industry. Cold expansion is that an oversized tapered mandrel goes through the hole and produces a compressive residual stress as well as plastic deformation around the hole. Here, mandrel shapes are one of the factors which are influenced on the residual stress distribution by cold expansion method. This paper, according to mandrel shapes (diameter of mandrel, length of mandrel and length of taper), we are performed a finite element analysis of residual stress distribution by cold expansion method. From this study, it has been found that diameter of mandrel and length of taper are an important factor which was generated a low compressive residual stress surround of fastener hole by cold expansion method.

Surface deflections have a great effect on the external appearance of automobiles. Usually, they are occurred on large flat panels containing sudden shape changes and of very small size about $\pm$30$\sim$300$\mu$m. Since the current numerical method is not sufficient for predicting these defects, the correction of these defects still depends on trial and error, which requires a great deal of time and expense. Consequently, developing the numerical method to predict and prevent these defects is very important far improving cosmetic surface qualities. In this study, an evaluation system that can analyze surface deflections using numerical simulation and a visualization system are reported. To calculate the surface deflections numerically, robust algorithms and simulation methodologies are suggested and to visualize them quantitatively, the curvature variation algorithm is proposed. To verify the developed systems, the experimental die of the handle portion of exterior door is analyzed. The results showed that the experimental and simulational visualization are in good agreement. Compensation methods to correct the surface deflections are also tested. The evaluation system proposed in this paper could be used to predict and minimize the occurrence of surface deflections in die manufacturing.

Hydraulic excavators have been popular devices in construction fields because of their multi-workings and economic efficiency. The mathematical models of excavators have many nonlinearities because of opening characteristics and dead zone of main control valve(MCV), oil temperature variation, etc. The objective of this paper is to develop a simulator for hydraulic excavator using AMESim. Components and their circuits are expressed graphically. Also, parameters and nonlinear characteristics are considered in a text style. From the simulation results, fixed spring stiffness of MCV can not obtain the satisfactory accuracy of spool displacement under whole P-Q diagrams. Closed loop type MCV containing a proportional gain, is proposed in this paper that can reduce displacement error. The ability of closed loop MCV is verified through comparing with normal type MCV using AMESim simulator. The excavator simulator can be used to forecast the attachment behaviors when components, mechanical attachments and hydraulic circuits change, or other control algorithms are applied. The simulator could be a kind of development platform for new excavators.

This paper is concerned with the weight reduction of front side member of a vehicle considering the application of high strength steel sheet. The influence of steel sheet grade and thickness on the energy absorption, impact load and deformed shape of front side member is investigated by using reverse engineering and FE-analysis. The reverse engineering is applied to obtain 3D model of front side member from B.I.W for the FE simulation. FE analysis is carried out with commercial crash analysis SW PAM-CRASH. The crashworthiness of front side member is considerably improved with steel sheet strength and thickness increase. From the result of this study the weight reduction in automotive parts for the improvement of the fuel efficiency can be easily achieved with replacing high strength steel without deterioration of crashworthiness.

The purpose of this study is to improve the machining of free-formed NURBS surfaces using newly defined G-codes which can directly deal with shapes defined from CAD/CAM programs on a surface basis and specialize in rough and finish cut. To this purpose, a NURBS surface interpolation system is proposed in this paper. The proposed interpolation system includes online tool-path planning, real-time interpolation and feedrate regulation considering an effective machining method and minimum machining time all suitable for unit NURBS surface machining. The corresponding algorithms are simultaneously executed in an online manner. The proposed NURBS surface interpolation system is integrated and implemented with a PC-based 3-axis CNC milling system. A graphic user interface (GUI) and a 3D tool-path viewer which interprets the G-codes for NURBS surfaces and displays whole tool-paths are also developed and included in our real-time control system. The proposed system is evaluated through actual machining in terms of size of NC data, machining time, regulation of feedrate and cutting force focused on finish cut in comparison with the existing method.

The cooling capacity of a micro-heat pipe is mainly governed by the magnitude of capillary pressure induced in the wick structure. For microchannel wicks, a higher capillary pressure is achievable for narrower and deeper channels. In this study, a metallic micro-heat pipe adopting high-aspect-ratio microchannel wicks is fabricated. Micromachining of high-aspect-ratio microchannels is done using the laser-induced wet etching technique in which a focused laser beam irradiates the workpiece placed in a liquid etchant along a desired channel pattern. Because of the direct writing characteristic of the laser-induced wet etching method, no mask is necessary and the fabrication procedure is relatively simple. Deep microchannels of an aspect ratio close to 10 can be readily fabricated with little heat damage of the workpiece. The laser-induced wet etching process for the fabrication of high-aspect-ratio microchannels in 0.5mm thick stainless steel foil is presented in detail. The shape and size variations of microchannels with respect to the process variables, such as laser power, scanning speed, number of scans, and etchant concentration are closely examined. Also, the fabrication of a flat micro-heat pipe based on the high-aspect-ratio microchannels is demonstrated.

Pyramid shape of micro pattern is applied to the light guide panel (LGP) to enhance the uniformity of the brightness of the LCD. The micro pyramids are molded in intaglio on the surface of the LGP. The size of each pyramid is 5$\mu$m $\times$ 5$\mu$m on bottom and the height is about 3.5$\mu$m. The pyramids are distributed on the LGP surface randomly to be sparser where the light comes in and denser at the opposite side as a result of a simulation using lightools$^{TM}$ Based on this design, a silicon pattern master and a nickel stamper are fabricated by MEMS process and electro plating process. Intaglio micro pyramids are fabricated on the 6' of silicon wafer from the anisotropic etching using KOH and the process time, temperature of the KOH solution, etc are optimized to obtain precise shape of the pattern. A Wi stamper is fabricated from this pattern master by electro plating process and the embossed pyramid patterns turns out to be well defined on the stamper. Adopting this stamper to the mold base with two cavities, 1.8' and 3.6' LGPs are injection molded.

Recently the electrostatic 2-axis MEMS stages have been fabricated f3r the purpose of an application to PSD (Probe-based Storage Device). However, all of the components (platform, comb electrodes, springs, anchors, etc.) in those stages are placed in-plane so that they have low areal efficiencies such as a few percentage, which is undesirable as data storage devices. In this paper, we present a novel structure of an electrostatic 2-axis MEMS stage that is characterized by having a large areal efficiency of about 25%. For obtaining large area efficiency, the actuator part consisting of mainly comb electrodes and springs is placed right below the platform. The structure and operational principle of the MEMS stage are described, followed by a design and analysis, the fabrication and measurement results. Experimental results show that the driving ranges of the fabricated stage along the x and y axis were 27$\mu$m, 38$\mu$m at the supplied voltages of 65V, 70V, respectively and the natural frequencies along x and y axis were 180Hz, 310Hz, respectively. The total size of the stage is about 5.9$\times$6.8mm$^2$ and the platform size is about 2.7$\times$3.6mm$^2$.

A new approach which combines implicit surface scheme and recursive subdivision method is suggested in order to fill the holes with complex shapes in the polygon model. In the method, a base surface is constructed by creating smooth implicit surface from the points selected in the neighborhood of holes. In order to assure C$^1$ continuity between the newly generated surface and the original polygon model, offset points of same number as the selected points are used as the augmented constraint conditions in the calculation of implicit surface. In this paper the well-known recursive subdivision method is used in order to generate the triangular net with good quality using the hole boundary curve and generated base implicit surface. An efficient anisotropic smoothing algorithm is introduced to eliminate the unwanted noise data and improve the quality of polygon model. The effectiveness and validity of the proposed method are demonstrated by performing numerical experiments for the various types of holes and polygon model.

In this paper a new approach which combines implicit surface scheme and NURBS surface interpolation method is proposed in order to generate a complete surface model from unorganized point cloud data. In the method a base surface was generated by creating smooth implicit surface from the input point cloud data through which the actual surface would pass. The implicit surface was defined by a combination of shape functions including quadratic polynomial function, cubic polynomial functions and radial basis function using adaptive domain decomposition method. In this paper voxel data which can be extracted easily from the base implicit surface were used in order to generate rectangular net with good quality using the normal projection and smoothing scheme. After generating the interior points and tangential vectors in each rectangular region considering the required accuracy, the NURBS surface were constructed by interpolating the rectangular array of points using boundary tangential vectors which assure C$^1$ continuity between rectangular patches. The validity and effectiveness of this new approach was demonstrated by performing numerical experiments for the various types of point cloud data.