A worm screw is widely used in a geared motor unit for motion conversion from rotation to linear. For mass production of a high quality worm, the current rolling process is substituted with the milling process. Since the milling process enables the integration of all operations of worm manufacturing on a CNC(Computer Numerical Control) lathe, productivity can be remarkably improved. In this study, the tooling system for side milling on a CNC lathe to improve machinability is developed. However, the cutting tool-workpiece interference is important factors to be considered for producing high quality worms. For adaptability of various worms machining, the tool-workpiece interference simulation system based on a tool-tip trajectory model is developed. The developed simulation system is verified through several kinds of worms and experimental results.

Recently, focused ion beam (FIB) applications have been investigated for the modification of VLSI circuit, the MEMS processing, and the localized ion doping. A multi aperture FIB system has been introduced as the demands of FIB applications for high speed and large area processing increase. A liquid metal ion source has problems, a large angular divergence and a metal contamination into a substrate. In this study, a gas ion source was introduced to replace a liquid metal ion source. The gas ion source generated inductively coupled plasma (ICP) in a quartz tube (diameter: 45 ㎜). Ar gas fed into the quartz was ionized by a 2 turned radio frequency antenna. The Ar ions were extracted by 2 extraction grids. The maximum extraction voltage was 10 ㎸. A numerical simulation was used to optimize the design of extraction grids and to predict an ion trajectory. As a result, the maximum ion current density was 38 ㎃/㎠ and the spread of ion energy was 1.6 % for the extraction voltage.

PC-TEMs (Polycarbonate Track-Etched membranes) were micro-drilled for biomedical applications by ultrafast pulsed laser. The ablation and damage characteristics were studied on PE-TEMs by assuming porous thin membranes. The experiments were conducted in the range of 2.02 J/㎠ and 8.07J/㎠. The ablation threshold and damage threshold were found to be 2.56J/㎠ and 1.14J/㎠, respectively. While a conical shaped drilled holes was made in lower fluence region, straight shaped holes were drilled in higher fluence region. Nanoholes made the membrane as porous material and ablation characteristics for both bulk and thin film membranes were compared.

This paper presents design and control of a quarter-vehicle magneto-rheological (MR) suspension system for ECS (electronic control suspension). In order to achieve this goal, MR shock absorber is designed and manufactured based on the optimized damping force levels and mechanical dimensions required for a commercial mid-sized passenger vehicle. After experimentally evaluating dynamic characteristics of the manufactured MR shock absorber, the quarter-vehicle MR suspension system consisting of sprung mass, spring, tire and the MR shock absorber is constructed in order to investigate the ride comfort and driving stability. After deriving the equations of the motion for the proposed quarter-vehicle MR suspension system, the skyhook controller is then implemented for the realization of quarter-vehicle MR suspension system. In order to present control performance of MR shock absorber for ECS, ride comfort and driving stability characteristics such as vertical acceleration of sprung mass and tire deflection are experimentally evaluated under various road conditions and presented in both time and frequency domain.

Mobile harbor which is a novel concept of ocean transportation to bring the containers from the cargo ship waiting on the ocean away is being focused now. To provide the mobile harbor with the stable loading/unloading condition, it is necessary to develop the oscillation mitigation technologies such as anti-rolling system. Anti-rolling system using AMD(Active Mass Driving) has merits that it can handle the disturbances more actively and mitigate the rolling oscillation faster than other type anti-rolling system. However, rack-and-pinion type AMD has problems such as big friction noise from gears and motor, wear and tear, and continuous maintenance. In this paper, novel anti-rolling system using Maglev type AMD for mobile harbor is suggested in order to resolve the problems caused by the friction. This novel anti-rolling system doesn’t make any friction because it supports the moving mass by using magnetic levitation force and moves it by using propulsion force from the linear motor. The demo system of the novel anti-rolling system using maglev type AMD has been developed in order to investigate its feasibility. This paper presents the procedures and results of development of this demo system.

Hydraulic excavator is one of the most widely used heavy machines in construction sites including dismantling. In the dismantling sites, the excavators equipped with crusher or breaker carry out dangerous operations, so drivers are always exposed to unexpected danger. For safety operation, remote control of the hydraulic excavator has been studied using proportional control valve, which requires an appropriate motion control of its bucket tip. In this case, kinematics and dynamics analysis have to be preceded through modeling of excavator. However, it is difficult to acquire reasonable results from the analysis due to insufficient information of physical parameters such as mass of each links and locations of mass centers, etc. This study deals with the trajectory control of bucket tip, which is based on experimental estimation of cylinder output force. The estimated forces are fed into the control of each cylinder in order to compensate gravitational and frictional effects in the cylinders. The control was applied to horizontal trajectories that are for flattening work.

Terrain recognition ability is crucial to the performance of legged robots in an outdoor environment. For instance, a robot will not easily walk and it will tumble or deviate from its path if there is no information on whether the walking surface is flat, rugged, tough, and slippery. In this study, the ground surface recognition ability of robots is discussed, and to enable walking robots to recognize the surface state and changes, a central moment method was used. The values of the sensor signals (load cell) of robots while walking were detected in the supported section and were analyzed according to signal variance, skewness, and kurtosis. Based on the results of such analysis, the surface state was detected and classified.

In recent years, hot-stamped components are more increasingly used in the automotive industry in order to reduce weight and to improve the strength of vehicles. In hot stamping process, blank is hot formed and press hardened in a tool. However, in hot stamping without cooling channel, temperature of the tool increases gradually in mass production thus cannot meet the critical cooling rate to obtain high strength over 1500 ㎫. Warpage occurs in the hot stamped component due to non-uniform stress state caused by unbalanced cooling. Therefore, tools should be uniformly as well as rapidly cooled down by the coolant which flows through cooling channel. In this paper, optimal design method of cooling channel to obtain uniform and high strength of the component is proposed. Optimized cooling channel is applied to the hot press Vbending process. As a result of measuring strength, hardness and microstructure of the hot formed parts, it is known that the design methodology of cooling channel is effective to the hot stamping process.

Inkjet printhead may have a lot of nozzles to increase productivity as a manufacturing tool. So, the uniformity of jetting performance among a lot of nozzles has been one of the key issues in inkjet technology. In this study, we investigated the cross-talk effect which should be reduced for uniform jetting performance among a lot of nozzles. Due to the cross-talk, the jetting performance of a nozzle can be affected when neighboring nozzles are firing. For experimental study, we used commercial inkjet head SE-128 from Dimatix. To understand the cross-talk effect of SE-128 head, we measured the change in jetting speed of a nozzle when neighboring nozzles are jetting. The measured jetting speed was compared to the case of one nozzle jetting. Also, we used laser vibrometer to measure change in pressure wave due to cross-talk. As a result of the cross-talk, the jetting speed can become faster or sometimes slower depending on firing nozzle location. If the all nozzle are jetting, the jetting speed of a nozzle became slower because the pressure wave for jetting is reduced.

The dental high-speed air turbine handpiece is one of the most popular devices that have been widely used as the main means of cutting tooth structure and restorative material in dentistry. In consideration of usage and marketability of the dental handpiece, it is obviously worthy of investigating it. The goal of this paper is to establish the relationship between the air turbine speed and the supply route inside the handpiece. To do this, the Computational Fluid Dynamics (CFD) tool, Fine^TM/Turbo is used and the optimal supply route position is suggested from the simulation results. In addition, as an attempt for domestic product, the reverse engineering process of a high speed dental handpiece by 3D X-Ray CT equipment and wire cutting is presented for the Mark II model in NSK. In doing so, the 3D modeling of the handpiece parts is carried out with CATIA V5, and the interference between parts is examined. Finally, the result of performance test for the prototype produced in this research is presented.

High stiffness frame design for a spine manipulation device was developed in this research. For the safety of a spinal manipulation, high stiffness of the device is required. A finite element (FE) model of the device frame is created and validated by measured vibration data. Parameters are suggested for high stiffness design of the frame. Based on the Taguchi design of experiment (DOE), a practical set of design parameter values is suggested.

Under extreme test or operation condition, refrigerator endures complicated stresses state and thermal bowing deformation arises on the sidewall. Shelf rails designed in the inner case provide increased surface area to permit expansion without bowing, and also increase structural rigidity to resist bowing. In this study, we designed six different shelf patterns of refrigerator model and studied the bead on refrigerator deformation using finite element method (FEM). Analysis result shows that increasing the numbers of beads properly in refrigerator is more helpful to reduce thermal bowing deformation. In addition, the beads would decrease stress on refrigerator sidewall. However, vertical beads have no effect to reduce thermal deformation of the bowing.

In this paper, pole-changing induction motor has been studied. To control the speed of the induction motor, many various methods can be used. Compared to the other speed control method, pole changing method is simple, cost effective, and reliable. From this research, pole changing induction motor with 2 and 4 pole windings are analyzed and designed, of which rated torque is about 2Nm. A real induction motor is also fabricated and some experiment has been performed showing that the analysis and experiment results are similar.

Steam reformer was organized with steam reforming process and CO removing process. The steam reforming process needed high temperature, 600~900 ℃, for catalytic-reaction which was extract of hydrogen from steam and hydrocarbon. The effects of the evaporator configuration on its heat transfer characteristics were investigated both experimentally and numerically to pursue the miniaturization. In this study, three configurations were considered where the different structures were tested; empty, embossing and mesh filled. For the comparison of heat transfer performance of shape evaporator disk, numerical analysis using SC-Tetra code and experiment were carried out. In case of reformer system design, it should be considered heat transfer rate, differential pressure and fluid flow direction.

Recently, we have proposed a hypothesis that spinal structures have a stress sensor driving feedback mechanism. In the human spine, spinal structure could react to modify muscular action in such a way so as to equalize stress at the disc, therefore reduce the risk of injury. In this analysis, abdominal muscle and abdominal pressure, which were not included in the previous study, were added to identify those effects in spine stability during upright stance posture for the case where the intervertebral disc plays the role of mechanoreceptor. The musculoskeletal FE model was consisted with detailed whole lumbar spine, pelvis, sacrum, coccyx and simplified trunk model. Muscle architecture with 46 local muscles containing paraspinal muscle and 6 rectus abdominal muscles were assigned according to the acting directions. The magnitude of 4㎪ was considered for abdominal pressure. Minimization of the nucleus pressure deviation and annulus fiber average tension stress deviation was chosen for cost function. Developed model provide nice coincidence with in-vivo measurement (nucleus pressure). Analysis was conducted according to existence of co-activation of abdominal muscle and abdominal pressure. Antagonistic activity of abdominal muscle produced stability of spinal column with relatively small amount of total muscle force. In contrast to the abdominal muscle, effect of abdominal pressure was not clear that was partly depending on the assumption of constant abdominal pressure.