• Journal of the Korean Society for Precision Engineering
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• v.13 no.2
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• pp.133-145
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• 1996

This paper presents an indirect cutting force measuring system, which uses the current signals from the AC servo drive units of the horizontal machining center, with its applications to the adaptive regulation of the cutting forces in various milling processes and to the on-line monitoring of tool breakage. A typical model for the feed-drive control system of a horizontal machining center is developed to analyze cutting force measurement from the drive motor. The pulsating milling forces can be measured indirectly within the bandwidth of the current feedback control loop of the feed-drive system. It is shown that the indirectly measured cutting force signals can be used in the adaptive controller for cutting force regulation. The whole scheme has been embedded in the commercial machining center and a series of cutting experiments on the face cutting processes are performed. The adaptive controller reveals reliable cutting force regulating capability against the various cutting conditions. It is also shown that the tool breakage in milling can be detected within one spindle revolution by adaptively filtering the current signals. The effect of the cutter run-out has been considered for the reliable on-line detection of tool breakage.

• Journal of the Korean Society for Precision Engineering
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• v.9 no.4
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• pp.22-35
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• 1992

In highly automated machining centers, intelligent sensor fddeback systems are indispensable on order to monitor their operations, to ensure efficient metal removal, and to initate remedial action in the event of accident. In this study, an on-line tool wear detection system for thrning operations is developed, and experimentally evaluated. The system employs multiple sensors and the signals from these sensors are processed using a multichannel autoegressive (AR) series model. The resulting output from the signal processing block is then fed to a previously tranied artificial neural network (multiayered perceptron) to make a final decision on the state of the cutting tool. To learn the necessary input/output mapping for tool wear detection, the weithts and thresholds of the network are adjusted according to the back propagation (BP) method during off-line training. The results of experimental evaluation show that the system works well over a wide range of cutting conditions, and the ability of the system to detect tool wear is improved due to the generalization, fault-tolearant and self-ofganizing properties of the neural network.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.11
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• pp.148-154
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• 2001

Drilling is one of the most important operations in machining industry and usually the most efficient and economical method of cutting a hole in metal. From automobile parts to aircraft components, almost every manufactured product requires that holes are to be drilled for the purpose of assembly, creation of fluid passages, and so on. It is therefore desirable to monitor drill wear and hole quality changes during the hole drilling process. One important aspect in controlling the drilling process is monitoring drill wear status. A drill-wear monitoring system provides information about drill status. With the information, optimum planning for tool change is possible. And drill-wear monitoring system in needed to evaluated drilled hole quality and the wear of drill. Accordingly, this paper deals with an on-line drill wear monitoring system of the detection of tool wear with the computer vision and the area of the drill flank wear is analyzed quantitatively by the system.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.6
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• pp.445-451
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• 2016

The Inconel 718 alloy is a well-known super-heat-resistant alloy and a difficult-to-cut material. Inconel 718 with excellent corrosion and heat resistance is used in harsh environments. However, the heat generated is not released owing to excellent physical properties, making processes (e.g., adhesion and thermal fatigue) difficult. Tool condition monitoring in machining is significant in reducing manufacturing costs. The cutting tool is easily broken and worn because of the material properties of Inconel 718. Therefore, tool management is required to improve tool life and machinability. This study proposes a method of predicting the tool wear with non-contacting sensors (e.g., IR thermometer for measuring the cutting temperature and a microphone for measuring the sound pressure level in machining). The cutting temperature and sound pressure fluctuation according to the tool condition and cutting force are analyzed using experimental data. This experiment verifies the effectiveness of the non-contact measurement signals in tool condition monitoring.

• Journal of Preventive Medicine and Public Health
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• v.32 no.1
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• pp.48-59
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• 1999

Objectives. This study was conducted to evaluate the association between upper extremity musculoskeletal symptoms and Rapid Upper Limb Assessment(RULA) in vehicle assembly line workers. The goal of this study is to show the feasibility of RULA as a checklist for work related musculoskeletal symptoms (WMSDs) in Korean workers. Methods. The total number of 199 people from the department of assembly and 115 people from the department of Quality Control(QC) in automotive plant were subjects for this cross sectional study. A standard symptom questionnaire survey has been used for the individual characteristics, work history, musculosketal symptoms and non-occupational covariates. The data were obtained by applying one-on-one interview for the all subjects. RULA has been applied for ergonomic work posture analysis and the primary ergonomic risk sure was computed by RULA method. Association between upper extremity musculoskeletal symptoms and RULA were assessed by multiple logistic regression analysis. Results. A total of 314 workers was examined. The prevalence of musculoskeletal symptoms by NIOSH case definition was 62.4%. The distribution of musculoskeletal symptoms by the part of the body turned out to be following; back:41.4%, neck: 32.8%, shoulder: 26.4%, arm: 10.5% and hand:29.3%. The relationship of the individual RULA scores were statistically significant for the prevalence of musculoskeletal symptoms. As the result of the multiple logistic regressioin analysis, grand final score (OR=2.250 95% CI: 1.402-3.612) was associated with musculoskeletal symptoms in any part of the body.; upper arm score(OR=1.786 95% CI: 1.036-3.079) and posture score A(OR=1.634 95% CI: 1.016-2.626) in neck; muscel use score(OR=3.076 95% CI:1.782-5.310) and posture score A(OR=1.798 95% CI: 1.072-3.017) in shoulder; upper arm score(OR=1.715 95% CI: 1.083-2.715) and muscel use score(OR=2.057 95% CI:1.303-3.248) in neck & shoulder; muscle use score(OR=10.662 95% CI: 3.180-35.742) in arm; writst/wist score(OR=2.068 95% CI: 1.130-3.786) and muscle use score(OR=2.215 95% CI: 1.284-3.819) in hand & wrist.; muscle use score of trunk (OR=2.601 95% CI: 1.147-5.901) in back. Conclusions. Musculoskeletal symptoms of the extremities were strongly associated with individual RULA body score. These results show that RULA can be used as a useful assessment tool for the evaluation of musculoskeletal loading which is known to contribute to work-related musculoskeletal disorders. RULA also can be used as a screening tool or incorporated into a wider ergonomic assessment of epidemiological, physical, mental, environmental and organizational factors. As shown in this study, complement of the analysis system for the other risk factors and characterizing between the upper limb and back part will be needed for future work.