High precision machining technology has become one of the important parts in the development of a precision machine. Such a machine requires high speed on a large workspace as well as high precision positioning. For machining systems having a long stroke with ultra precision, a dual-stage system including a global stage (coarse stage) and a micro stage (fine stage) is designed in this paper. Though linear motors have a long stroke and high precision feed drivers, they have some limitations for submicron positioning. Piezo-actuators with high precision also have severe disadvantage for the travel range, and the stroke is limited to a few microns. In the milling experiments, the positional accuracy has been readily achieved within 0.2 micron over the typical 20 mm stroke, and the path error over 2 micron was reduced within 0.2 micron. Therefore, this technique can be applied to develop high precision positioning and machining in the micro manufacturing and machining system.

Recently, application of ceramics has increased gradually due to excellent mechanical properties. Si3n4-BN ceramic which is one of ceramics is very hard and has superior resistance against volatile temperature and wear. However, extremely high hardness of the $Si_3N_4-BN$ ceramic makes conventional machining very difficult. Therefore, the use of machinable ceramic has been in a poor because of difficult industrial processes in spite of many advantages. And so new technology being called IED(In-process electrolytic dressing) was introduced to solve this problem. The aim of this study is to determine the machining characteristics in terms of pressurized weight to the workpiece and the influence with h-BN content using IED lapping system. Also, Acoustic Emission (AE) is used for the monitoring of surface characteristics.

Fine blanking is a process of press shearing which makes it possible to produce the thick sheet metal of the finished surface and the close dimensional accuracy over the whole material thickness in the single blanking operation. In this paper, a plate holder of automotive seat recliner is manufactured by FCF(Flow Control Forming) method using the conventional mechanical press instead of the fine blanking press. Main processes for manufacturing of the plate holder by FCF method are embossing, half blanking and trimming processes. Optimal clearance, stripper force and counter force to increase the dimensional accuracy of the plate holder have been investigated by FE-analysis. As a result of FE-analysis, the clearance for both embossing and half blanking processes was -2%t and the forces of stripper and counter were 25ton and 15ton, respectively. After manufacturing the plate holder by FCF method, the measured dimensional characteristics have been compared with the required specifications as the final product. Although the dimensional accuracy of the plate holder manufactured by FCF method was a little inferior to that by fine blanking process, it was satisfactory in a general sense.

Burr generated on plate holder should be removed through additional process, because it has an influence on the function of automotive seat recliner. The process layout to perform simultaneously embossing and half blanking of plate holder has been developed in this study in order to minimize the influence of burr formation. The optimal process condition to satisfy the required dimensional accuracy of plate holder has been determined using Taguchi method and finite element analysis. It has been shown from experimental results that the proposed method is decidedly superior to the previous FCF method from the aspect of sheared surface, roll-over, flatness and burr height.

The line-of-sight(LOS) stabilization system is a precision electro-mechanical gimbals assembly for suppressing vibration due to its environment and tracking the target in a desired direction. This paper describes the design of gimbals system to reject the disturbance and to improve stabilization. The controller consists of a DSP with transducer and actuator interfaces. Unknown parameters of the gimbals are estimated by the signal compression method. The cross-correlation coefficient between the impulse response from the assumed model and the one from model of the gimbals is used to obtain the better estimation. The quasi-impulse response through linear element included in the gimbals could be obtained by the signal compression method. The unknown parameter of the linear element could be estimated as comparing the bode plots for impulse response from gimbals with them from model's response.

This paper describes the development of wearing intelligent shoe system to measure applied forces and moments (ground reaction forces and moments) on the soles of feet during human walking. In order to walk safely, robot must get the intelligent feet with 6-axis force/moment sensors (Fx sensor (x-direction force sensor), Fy sensor, Fz sensor, Mx sensor (Mx : x-direction moment sensor), My sensor, and Mz sensor) and detect the forces and moments data from the sensors. And the feet must be controlled with the data and controllers. While a human is walking, the forces and moments should be measured and analyzed for robot's intelligent feet. Therefore, the wearing intelligent shoe system should be developed. In this paper, four 6-axis farce/moment sensors and two high speed measuring devices were designed and fabricated, and the wearing intelligent shoe system was made using these. The characteristic tests of the wearing intelligent shoe system were performed, and the forces and moments were detected using it.

The displacement sensor using optical pickup head is presented. The measuring principle of optical pickup head in focusing direction is adopted to measure displacement. The preliminary tests were carried out to verify the feasibility of the optical pickup head as a displacement sensor and optical pickup head showed about $8\;{\mu}m$ measuring range and 10nm resolution. The methodology to expand measuring range is proposed and proved its validity. The proposed displacement sensors are applied to AFM(Atomic Force Microscope) probe head to measure the deflection of micro-cantilever.

Since the processes of dismantling are very dangerous, there have been many studies to develop remote operating devices using joystick. In this paper, in order to improve the operability of the dismantling equipment that is usually an excavator, a novel concept of tole-operated device is proposed. Operators who use this device with additional environmental sensing devices can work safely away from the dangerous sites. First, based on the concept design of the remote controller, its workspace is analyzed and the workspace mapping from the device to the excavator is explored. Second, after 7 steps of the excavating processes are defined, the kinematics which deals with the conversion from the 3 dimensional position information of the device to the joint variable information of the backhoe is included in this paper. Lastly, 3D graphical simulation of both remote controller and the backhoe will be shown. This new design of the remote control device tan be easily manufactured and gives the workers very convenient and transparent remote control capability.

This paper presents a new approach of recognizing a 3D object using a single camera, based on the extended convex hull of its silhouette. It aims at minimizing the DB size and simplifying the processes for matching and feature extraction. For this purpose, two concepts are introduced: extended convex hull and measurable region. Extended convex hull consists of convex curved edges as well as convex polygons. Measurable region is the cluster of the viewing vectors of a camera represented as the points on the orientation sphere from which a specific set of surfaces can be measured. A measurable region is represented by the extended convex hull of the silhouette which can be obtained by viewing the object from the center of the measurable region. Each silhouette is represented by a relation graph where a node describes an edge using its type, length, reality, and components. Experimental results are included to show that the proposed algorithm works efficiently even when the objects are overlapped and partially occluded. The time complexity for searching the object model in the database is O(N) where N is the number of silhouette models.

This paper describes the optimization of injection molding conditions to minimize sink marks. Sink marks, which refer to a small depression on the surface opposite a thick wall thickness, are often encounted in injection molded plastic parts. Part geometry, material properties and processing conditions during injection molding can affect the sink mark depth. We designed the runner system which is possible balanced filling to cavities using CAE program $Moldflow^{TM}$ and then obtained optimal processing conditions by Taguchi's Robust Design technique. By actual injection molding using optimized mold and molding conditions, it confirmed that sink mark depth decreased zero compared to 1mm level in the conventional mold and process.

In the fossil power plant, the reliability of the components which consist of the many welded parts depends on the quality of welding. The residual stress is occurred by the heat flux of high temperature during weld process. This decreases the mechanical properties as the strength of fatigue and fracture or causes the stress corrosion cracking and fatigue fracture. Especially, the accidents due to the residual stress occurred at the weld parts of high-temperature and high-pressure pipes and steam headers. Also, the residual stress of the welded part in the recently constructed power plants has been brought into relief as the cause of various accidents. The aim of this study is the measurement of the residual stress using the x-ray diffraction method. The merits of this are more accurate and applicable than other methods. The materials used for the study is P92 steel for the use of high temperature pipe on super critical condition. The variables of tests are the post-weld heat treatment, the surface roughness and the depth from the original surface. The test results were analyzed by the distributed characteristics of the full width at half maximum intensity (FWHM) in x-ray diffraction intensity curve and by the relation of hardness with FWHM.

The effect of nitrogen gas pressure in arc ion plating on surface properties of the TiN-coated high speed steel(SKH51) is presented in this paper. The surface roughness, micro-particle, micro-hardness, coated thickness, atomic distribution of TiN, and adhesion strength are measured fur various nitrogen gas pressures. It has been shown that the nitrogen gas pressure has a considerable effect on the surface roughness, adhesion strength, atomic distribution of TiN, and surface deposition of TiN of the high speed steels but that it has little influence on the micro-hardness and coated thickness.

The microstructural effects on the ultrasonic nonlinearity were investigated in isothermally degraded ferritic 2.25Cr-1Mo steel and low cycle fatigued copper. The variation in ultrasonic nonlinearity (${\beta}/{\beta}_0$) was interpreted as resulting from microstructural changes supported by the electron microscopy and X-ray diffraction, in addition to the mechanical test (Victor's hardness and ductile-brittle transition temperature). The ultrasonic nonlinearity of 2.25Cr-1Mo steel increased abruptly in the initial 1,000 h of degradation, and then changed little due to the coarsening of carbide and precipitation of stable $M_6C$ carbide during isothermal degradation. The ultrasonic nonlinearity of copper increased with the fatigue cycles due to the evolution of dislocation cell substructure.

Micro electrochemical machining was investigated to machine micro internal features. This method uses a micro disk tool electrode and can easily machine micro features inside of a micro hole, which are very difficult to make by the conventional processes. In order to limit the machining area and localize the electrochemical dissolution, ultra short pulses were used as power source and a micro disk electrode with insulating layer on its surface was used as a tool electrode. By electrochemical process, internal features, such as groove array, were fabricated on the stainless steel plate.