Metal stamping is widely used in the mass-production process of the automobile. During the stamping process, air may be trapped between the draw die and the panel and/or between the punch and the panel. Air pocket rapidly not only increases forming load in the final stage, but also deforms the product just formed by compressive air inside the air pocket in knockout process. To prevent these problems air bent holes are drilled in the die to exhaust the trapped air but all processes associated with air bent holes are performed by empirical know-how of workers in the field due to lack of researches. Therefore this study developed an automated design system for predicting the shape and position, and volume of air pocket on the draw die by using the AutoLISP language under AutoCAD circumstance. The system is able to display the shape of air pocket occurred in the draw die and to calculate automatically its volume by strokes. So it makes a stepping stone to calculate theoretical size of an air bent hole and numbers according to it by predicting and analyzing the position and volume of air pocket. Results obtained from the system enable the designers or manufacturers of the stamping die to be more efficient in this field.

For the precision measurement of industrial products, the location of holes inside the products, if they exist, are often selected as feature points. The measurement of hole location would be performed by vision and laser-vision sensor. However, the usage of those sensors is limited in case of big change of light intensity and reflective shiny surface of the products. In order to overcome the difficulties, we have developed a hole displacement measuring device using contact-type displacement sensors (LVDTs). The developed measurement device attached to a robot measures small displacement of a hole by allowing its X-Y movement due to the contact forces between the hole and its own circular cone. The developed device consists of three plates which are connected in series for its own function. The first plate is used for the attachment to an industrial robot with ball-bush joints and springs. The second and third plates allow X-Y direction as LM guides. The bottom of the third plate is designed that various circular cones can be easily attached according to the shape of the hole. The developed system was implemented for its effectiveness that its measurement accuracy is less than 0.05㎜.

White light scanning interferometry has gotten a firm position in 3D surface profile measuring field. Recently, the LCD industry gave a chance for this technology to enter into real industry fields. It is known that white-light phase￢shifting algorithm give a best resolution compare to other algorithms, but there are some problems to be resolved. One of them is 300㎚ jump in height profile, called bat-wing effect. The main reason of this problem is an ambiguity of phase￢peak detection algorithm, and some solution has been proposed, but it didn't work perfectly. In this paper, I will show the cases when these effects are occurred, and these height discrepancies will be almost disappeared when broad-band illuminators are used.

The flame image observation and analysis has been investigated for combustion monitoring and management of the pulverized coal firing for thermal power plant, especially for lower nitrogen oxide generation and safer operation. We aimed at obtaining the relationship between burner flame image information and emissions of nitrogen oxide and unburned carbon in furnace utilizing the flame image processing methods, by which we quantitatively determine the conditions of combustion on the individual burners. Its feasibility test was undertaken with Samchonpo thermal power plant #4 unit which has 24 burners, through which the system was observed to be effective for evaluating the combustion conditions and continuous monitoring to prevent future loss of ignition.

There are being a lot of studies for achievement of high speed Dehydration, high-strength and Lightweight of washing machine in the latest washing machine business. It is essential that strength of mechanical press-joining (MPJ) for spin drum is improved to attain that target. MPJ of spin drum is composed of seaming and caulking process. Because Seaming process of MPJ has various design factors such as thickness, bending radius, seaming width, caulking press width and the dynamic factor such as multistage plastic working, elastic recovery, residual stress, the optimum conditions can't be easily determined. Using a design of experiment (DOE) based on the FEM (Finite Element Method), which has several advantages such as less computing, high accuracy performance and usefulness, this study was performed investigating the interaction effect between the various design factor as well as the main effect of the each design factor during drum MPJ and proposed optimum condition using center composition method among response surface derived from regression equation of simulation-based DOE.

Recently, there have been several instances that the nuclear power plants were shut down due to the mechanical faults in the main transformer of the plants. These mechanical faults are primarily originated from the electromagnetically induced mechanical vibrations. Magnetostriction is identified to be the main cause of the mechanical vibration after analyzing the vibration data of the main transformers in nuclear power plants. In this study, we derived a mathematical model of the magnetostriction based on the Jiles-Atherton hysteresis model. The validity of the model is checked by matching the simulations with the experimental observations. The magnetostriction model used in this study will be the first step toward developing a design tool for the transformers that have minimal mechanical vibrations and are robust to mechanical faults.