• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.5
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• pp.590-597
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• 1985

A recursive geometric adaptive control method to compensate for machining straightness error in the finished surface due to tool deflection and guideway error generated by end milling process is developed. The relationship between the tool deflection and the feedrate is modeled by a modified Taylor's tool life equation. Without a priori knowledge on the variations off cutting parameters, time varying parameters are then estimated by an exponentially windowed recursive least squares method with only post-process measurements of the straightness error. The location error is controlled by shifting the milling bed in the direction perpendicular to the finished surface and adding a certain amount of feedrate with respect to the tool deflection model before cutting. The waviness error is compensated by adjusting the feedrate during machining. Experimental results show that location error is controlled within a range of fixturing error of the bed on the guideway and that about 60% reduction in the waviness error can be achieved within a few steps of parameter adaption under wide operating ranges of cutting conditions even if the parameters do not converge to fixed values.

• Structural Engineering and Mechanics
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• v.58 no.6
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• pp.949-966
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• 2016

The second order analysis taking place due to non-linear behavior of the structures under the mechanical and geometric factors through implementing exact and approximate methods is an indispensible issue in the analysis of such structures. Among the exact methods is the slope-deflection method that due to its simplicity and efficiency of its relationships has always been in consideration. By solving the differential equations of the modified slope-deflection method in which the effect of axial compressive force is considered, the stiffness matrix including trigonometric entries would be obtained. The complexity of computations with trigonometric functions causes replacement with their Maclaurin expansion. In most cases only the first two terms of this expansion are used but to obtain more accurate results, more elements are needed. In this paper, the effect of utilizing higher order terms of Maclaurin expansion on reducing the number of required elements and attaining more rapid convergence with less error is investigated for the Bernoulli beam with various boundary conditions. The results indicate that when using only one element along the beam length, utilizing higher order terms in Maclaurin expansion would reduce the relative error in determining the critical buckling load and kinematic parameters in the second order analysis.

• International Journal of Automotive Technology
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• v.8 no.1
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• pp.75-82
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• 2007

This paper presents practical work on the reduction of gear whine noise. In order to identify the source of the gear whine noise, transfer paths are searched and analyzed by operational deflection shape analysis and experimental modal analysis. It was found that gear whine noise has an air-borne noise path instead of structure-borne noise path. The main sources of air-borne noise were the two global modes caused by the resonance of an axle system. These modes created a vibro-acoustic noise problem. Vibro-acoustic noise can be reduced by controlling the vibration of the noise source. The vibration of noise source is controlled by the modification of structure to avoid the resonance or to reduce the excitation force. In the study, the excitation force of the axle system is attenuated by changing the tooth profile of the hypoid gear. The modification of the tooth profile yields a reduction of transmission error, which is correlated to the gear whine noise. Finally, whine noise is reduced by 10 dBA.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.7
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• pp.112-119
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• 2001

In modern manufacturing, many products that have geometrically complicated features, including three-dimensional sculptured surfaces, are being designed and produced to meet various sophisticated functional specifications. The cutting force is required not only for the design of machine and cutting tools, but also for the determination of the cutting conditions for the various machining operations. The ball-end mill is deflected by the cutting force and, the tool deflection is one of the main reasons of the machining errors on a free-form surface. Hence, The cutting force generated in the ball-end milling is the most important property of the machining. The purpose of this study is to find the characteristics of the cutting force in inclined plane and the resultant machining errors in the ball-end milling process. Although the depth of cut is constant in the inclined plane, the cutting force area varies due to the hemisphere of the ball-end mill.

• Journal of Mechanical Science and Technology
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• v.18 no.4
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• pp.622-629
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• 2004

In this paper, effects of elastic energy of magnetostrictive film on the deflection of a cantilevered film-substrate system are investigated. The total energy including the elastic energy of magnetostrictive film is formulated. And it is minimized to give the curvatures and the position of neutral axis of the cantilevered system. To discuss the effects of the elastic energy of film in a measured system, three magnetostrictive unimorph cantilevers and a bimorph cantilever reported elsewhere are reviewed. It is shown that the assumption, since the thickness of film is much smaller than that of substrate the film elastic energy is negligible, can cause considerable error in evaluating magnetostrictive coefficients. Not the ratio of thicknesses but elastic energies between film and substrate is also shown to play important role in making decision whether the assumption is valid or not.

• Proceedings of the KSME Conference
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• 2004.04a
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• pp.132-137
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• 2004

In this work, effects of hyper-elastic rubber material properties on the indentation load-deflection curve and subindenter deformation are first examined via [mite element (FE) analyses. An optimal data acquisition spot is selected, which features maximum strain energy density and negligible frictional effect. We then contrive two normalized functions. which map an indentation load vs. deflection curve into a strain energy density vs. first invariant curve. From the strain energy density vs. first invariant curve, we can extract the rubber material properties. This new spherical indentation approach produces the rubber material properties in a manner more effective than the common uniaxial tensile/compression tests. The indentation approach successfully measures the rubber material properties and the corresponding nominal stress.strain curve with an average error less than 3%.

• Journal of Mechanical Science and Technology
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• v.17 no.3
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• pp.321-328
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• 2003

The elongation of contact length on the line of action is considered with particular reference for roll forming of gears, and for dynamic behavior of the tooth in meshing. However there is no paper that discuss the elongation of contact length in the load meshing of gears. Based on our investigation, the contact length on the line of action elongates more than the kinematically calculated value. In rolling, as the tool approaches the workpiece, the center distance of the gears decreases by a small amount. But, the elongation of contact length is sensitive. Therefore, the contact point on the line of action is difficult to be determined, which complicates the tooth analysis. In this study, the exact relation between the elongation of contact length and the tooth space over the recess or before the approach are revealed by experiments and kinematic theory. This analytical result applies not only for rolling, but also for the single flank meshing which is done under constant center distance.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.6
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• pp.816-825
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• 2004

In this work, effects of hyper-elastic rubber material properties on the indentation load-deflection curve and subindenter deformation are examined via finite element (FE) analyses. An optimal location for data analysis is selected, which features maximum strain energy density and negligible frictional effect. We then contrive two normalized functions, which map an indentation load vs. deflection curve into a strain energy density vs. first invariant curve. From the strain energy density vs. first invariant curve, we can extract the rubber material properties. This new spherical indentation approach produces the rubber material properties in a manner more effective than the common uniaxial tensile/com-pression tests. The indentation approach successfully measures the rubber material properties and the corresponding nominal stress-strain curve with an average error less than 3%.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.1
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• pp.15-22
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• 2002

This paper introduces a compensating system for machining error, which is resulted from chucking with separated jaws. In machining the chucked cylindrical workpiece, the deterioration of machining accuracy, such as out-of-roundness is inevitable due to the variation of the radial compliance of the chuck workpiece system which is caused by the position of jaws with respect to the direction of the applied force. To compensate the chucking compliance induced error, firstly roundness profile of workpiece due to chucking compliance after machining needs to be predicted. Then using this predicted profile, the compensated tool feed trajectory can be generated. And by synchronizing the cutting tool feed system with workpiece rotation, the chucking compliance induced error can be compensated. To satisfy the condition that the cutting tool feed system must provide high speed and high position accuracy, brushless linear DC motor is used. In this study, firstly through the force-deflection experiment in workpiece chucked lathe, the variation of radial compliance of chuck workpiece system is obtained. Secondly using the mathematical equation and cutting experiment result, the predicted profile of workpiece and its compensation tool trajectory are generated. Thirdly the configuration of compensation system using linear motor is introduced, and to improve the system performance, PID controller is designed. Finally the tracking performance of system is examined by experiment. Through the real cutting experiment, roundness is significantly improved.

• Structural Engineering and Mechanics
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• v.85 no.5
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• pp.635-644
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• 2023

The design of honeycomb sandwich structures is often challenging because these structures can be tailored from a variety of possible cores and face sheets configurations, therefore, the design of sandwich structures is characterized as a time-consuming and complex task. A data-driven computational approach that integrates the analytical method and Artificial Neural Network (ANN) is developed by the authors to rapidly predict the design of sandwich structures for a targeted maximum structural deflection. The elaborated ANN reverse design approach is applied to obtain the thickness of the sandwich core, the thickness of the laminated face sheets, and safety factors for composite sandwich structure. The required data for building ANN model were obtained using the governing equations of sandwich components in conjunction with the Monte Carlo Method. Then, the functional relationship between the input and output features was created using the neural network Backpropagation (BP) algorithm. The input variables were the dimensions of the sandwich structure, the applied load, the core density, and the maximum deflection, which was the reverse input given by the designer. The outstanding performance of reverse ANN model revealed through a low value of mean square error (MSE) together with the coefficient of determination (R2) close to the unity. Furthermore, the output of the model was in good agreement with the analytical solution with a maximum error 4.7%. The combination of reverse concept and ANN may provide a potentially novel approach in designing of sandwich structures. The main added value of this study is the elaboration of a reverse ANN model, which provides a low computational technique as well as savestime in the design or redesign of sandwich structures compared to analytical and finite element approaches.