• Journal of the Korean Society for Precision Engineering
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• v.28 no.8
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• pp.992-999
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• 2011

The recent power add-on drive wheelchairs (PADWs) provide greater physical activity, are easier to transport, and may be an excellent alternative for the typical manual or electric wheelchairs. The development of in-wheel motor for a PADW is the principal issues. In this paper, design, implementation, and testing of the permanent magnet synchronous motor (PMSM) for a PADW are presented. To design output power and torque of the motor, the equation of motion has been investigated. The design parameters were calculated and the dimension and shape of the motor which was limited by the In-wheel mechanism of the PADW were done by applying FEM and optimal design technique. The prototype of the motor mentioned above was fabricated with precise machining and assembling. Then the motor tested on dynamometer and the measured results of the motor were verified by comparing the design results. The fabricated motor was 80 mm in length with a diameter of 110 mm and small enough to be attached the driving unit of the PADW.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.10
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• pp.195-201
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• 2002

This paper deals with the precision grinding for aspherical surface of optical parts. A parallel grinding method using the spherical wheel was suggested as a new grinding method. In this method, the wheel axis is positioned at a $\pi$/4 from the Z-axis in the direction of the X-axis. An advantage of this grinding method is that the wheel used in grinding achieves its maximum area, reducing wheel wear and improving the accuracy of the ground mirror surface. In addition, a truing by the CG (curve generating) method was proposed. After truing, the shape of spherical wheel transcribed on the carbon is measured by the Form-Talysurf-120L. The error of the form in the spherical wheel which is the value ${\Delta}x$ and $R{^2}{_y}$ inferred from the measured profile data is compensated by the re-truing. Finally, in the aspherical grinding experiment, the WC of the molding die was examined by the parallel grinding method using the resin bonded diamond wheel with a grain size of ＃3000. A form accuracy of 0.16${\mu}m$ P-V and a surface roughness of 0.0067${\mu}m$ Ra have been resulted.

• Transactions of Materials Processing
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• v.18 no.4
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• pp.310-316
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• 2009

Micro lens array(MLA) is widely used in information technology(IT) industry fields for various applications such as a projection display, an optical power regulator, a micro mass spectrometer and for medical appliances. Recently, MLA have been fabricated and developed by using a reflow method having the processes of micro etching, electroplating, micro machining and laser local heating. Laser thermal relaxation method is introduced in marking of microdots on the surface of densified glass. In this paper, we have proposed a new direct fabrication process using UV laser local thermal-expansion(UV-LLTE) and investigated the optimal processing conditions of MLA on the surface of negative photo-resist material. We have also studied the 3D shape of the micro lens obtained by UV laser irradiation and the optimal process conditions. And then, we made chrome mold by electroplating. After that, we made MLA using chrome mold by hot embossing processing. Finally, we have measured the opto-physical properties of micro lens and then have also tested the possibility of MLA applications.

• IE interfaces
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• v.18 no.3
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• pp.247-252
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• 2005

In the automated production environment in the present days, the minimization of manual operation becomes a very important factor in increasing the efficiency of the production system. The exit burr produced through the milling operation on the edge of workpiece usually requires manual deburring process to enhance the level of precision of the resulting product. So far, researchers have developed various methods to understand the formation of exit burr in cutting process. One method to analytically identify the formation of exit burr was to use the geometrical information of CAD and CAM data used in automated machining. This method, in turn, generated the information resulting from the analysis such as burr type, cutting region, and exit angle. Up to now, the geometrical data were restricted to the single feature and single path. In this paper, a method to deal with the complicated geometric features such as line segment, arc, hole, and spline will be presented and validated using the field data. This method also deals with the complex workpiece shape which is a combination of multiple features. As for the cutting path, multiple tool path is analyzed in order to simulate the real cutting process. All this analysis is combined into a Windows based software and real data are used to validate the program in the conclusion.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.15 no.6
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• pp.58-63
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• 2006

FIB equipment can perform sputtering and chemical vapor deposition simultaneously. It is very advantageously used to fabricate a micro structure part having 3D shape because the minimum beam size of ${\Phi}10nm$ and smaller is available. Since general FIB uses very short wavelength and extremely high energy, it can directly make a micro structure less than $1{\mu}m$. As a result, FIB has been probability in manufacturing high performance micro devices and high precision micro structures. Until now, FIB has been commonly used as a very powerful tool in the semiconductor industry. It is mainly used for mask repair, device correction, failure analysis, IC error correction, etc. In this paper FIB-Sputtering and FIB-CVD characteristic analysis were carried out according to $Ga^+$ ion beam current that is very important parameter for minimizing the pattern size and maximizing the yield. Also, for FIB-Sputtering burr caused by redeposition of the substrate characteristic analysis was carried out.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.4
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• pp.120-127
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• 2009

Spindle units of machine tool are very important part in the manufacturing area. Recently high speed machining has become the main issue of metal cutting. To develop high speed machine tools, a lot of studies have been carried out for high speed spindle. Due to increase of the rotational speed of the spindle, there has been renewal of interest in vibration of spindle. This paper concerns the improvement of spindle design using design of experiments. To improve the design of critical speed and weight of spindle, the experiments using central composite method have been carried out. The targets are critical speed and weight of spindle. For optimization of critical speed and weight and optimization of only critical speed by operation of all area search through response optimizer, the result of analysis has improved design of each factor. Finite element analyses are performed by using the commercial codes ARMD, CATIA V5 and ANSYS workbench. From the results, it has been shown that the proposed method is effective for modification of spindle design to improve critical speed and weight.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.9
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• pp.166-171
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• 2002

The objective of this paper is to investigate the effect of clearance and the configuration of die system on burr formation by FEM analysis and experimental tests. Compared with casting, forging and machining, shearing has been known, especially in heavy or mass-production industries, as a very economical and fast way to obtain the desired shape Recently, the shearing process becomes widely used in the small and light electronic component manufacturing industries. When shearing a part of sheet metal, the burr formed on the cutting edge is usually unavoidable. The burr would not only degrade the precision of products but also causes additional cost for the deburring process. In this paper, the influence of shearing parameters such as clearance and configurations of the lower pad (ejector) on burr formation is investigated by using the experimental and numerical approach. From the experimental results, it has been shown that the more narrow clearance gives the smaller burr height and the higher shearing forces. The removal of lower holder also makes the sheared surface integrity and the dimensional accuracy become worse. The FEM results (using DEFORM-2D) show good agreement with the experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.165-173
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• 2003

As the cycling time of new products have become more and more short in recent years, the demand for lowering the cost and reducing the production time becomes stronger. In order for the demand, the rapid prototyping and rapid tooling technology have been used. It has been widely known that RP technology has advantages with fabricating 3-D object having a complicated geometric shape. RP products, however, have a limitation with applying to the real die and mold because soft materials such as resin, paper and wax has been mostly used in RP technology. So in this paper, the RP products have been copied to semi-metallic soft tools using the mixture of metal fillers and epoxy resin. In order to evaluate the effect of the fillers on the characteristics of semi-metallic soft tools, three fillers are used including commercial aluminum powder, cast iron powder recycled by machining chips, and aluminum short fiber made by self-excited vibration technique. Besides, in the case of aluminum powder, the change of characteristics of semi-metallic soft tools is also tested according to the volume fraction of the powder.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.91-94
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• 2005

With increasing demands for large-scale micro-optical components in the field of digital display, the establishment of large-scale fabrication technology fur polymeric patterns has become a priority. The starting point of any polymer replication process is the mold, and the mold often has flat surface. However, It is very hard to replicate large-scale micro patterns using the flat mold, because the cost of large-scale flat mold was very high, and some uniformity and releasing problems were often occurred in large scale flat molding process. In this study, a UV roll imprinting system to overcome the financial and fabrication issues of large-scale pattern replication process was designed and constructed. As a practical example of the system, a lenticular lens with radius of curvature of $223{\mu}m$ and pitch of $280{\mu}m$, which was used to provide wide viewing angle in projection TV, was designed and fabricated. The roll stamper was fabricated using direct machining process of aluminum roll base. Finally, the shape accuracy and uniformity of roll imprinted lenticular lens sheet were measured and analyzed.

• Transactions of Materials Processing
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• v.24 no.2
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• pp.121-129
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• 2015

A net-shape forming of small and complex-shaped metal parts by metal injection molding (MIM) has economic advantages in mass production, especially for STS 316L valve fitting. STS 316L offers excellent corrosion resistance, but it has poor machinability, which is a limitation in using it for a cost-effective production where both forging and machining are employed. Simulation and experimental analysis were performed to develop a MIM STS 316L 90° elbow fitting minimizing trial and error. A Taguchi method was used to determine which input parameter was the most sensitive to possible defects (e.g. sink mark depth) during the injection molding. The final prototype was successfully built. The results indicate that the simulation tool can be used during the design process to minimize trial and error, but the final adjustment of parameters based on field experience is essential.