In this study, the casting/forging process was applied in manufacturing a low control arm, in order to prove that application of casting/forging process to Al6061 is likely to get the effect of light weight compared with existing steel products and to reduce the cost of materials. Firstly, In order to set up the optimum casting condition of the forging material, Al6061, casting experiments were carried out by controlling pouring temperature of the aluminum for casting, mold temperature, and pouring time. 700℃ pouring temperature, 300℃ mold temperature and 10-second pouring time were taken into account as the optimum casting conditions. With respect to a hot forging test, it is practiced on the basis of a temperature of materials, strain rate, and reduction rate so as to observe each microstructure and examine strain-stress curve simultaneously; examine tensile test and hardness test; eventually set up the optimum hot forging condition. A hot forging test, tensile test, hardness experiment, and microstructure observation were carried out on condition of 70% reduction rate, 500℃ temperature of materials, and 1 strain rate. As a result of those experiments, 330MPa tensile strength, 16.4% elongation, and 122.8Hv hardness were recorded. In oder to get a sound preform which has no unfilling cavity and less flash, two preforms were proposed on the basis of volume rate of the final product; the optimum volume rate of preform for the low control arm was 115%.
In conclusion, it is confirmed that using the forging material rather than casting materials in casting/forging process is likely to get more superior mechanical properties. Compared with Al6061, performed by means of general forging, moreover, cast/forged Al6061 can not only stimulate productivity by reducing production processes, but cut down the cost of materials by reusing forging scraps.

Laser surface hardening technologies have been used to improve characteristics of wear and to enhance the fatigue resistance for automotive parts. The objective of this research work is to investigate the influence of the process parameters, such as. power of laser and defocused spot position, on the characteristics of laser heat treatment for the case of SM45C medium carbon steel. CW Nd:YAG laser is selected as the heat source. The optical lens with the elliptical profile is designed to obtain a wide heat treatment area with a uniform hardness. From the results of the experiments, it has been shown that the maximum hardness is approximatly 780 Hv when the power and the travel speed of laser are 1,095 Wand 0.6 m/min, respectively. In addition, the hardening width using the elliptical lens was three time larger than that using the defocusing of laser beam.

Since human listening is very sensitive when the sound hit him, the subjective index of sound quality is required. Therefore, at each situation of sound evaluation its composed with the sound quality factor. But, when substituting the level of one frequency band we could not see the tendency of substitution at whole frequency band during the sound quality evaluation. In this study a design of experiment is used. The frequency domain is divided into an equally 12 parts and each level of domain whether is given increase or decrease due to the change of frequency band based on "sharp" and "annoy" of the sound quality is analyzed. By using the design of experiment the number of test is reduce very effectively by the number of experiment and each band the main effect will be as a solution. The case of sound quality for 'sharp' and 'annoy' at each band, the change of band (increase or decrease of sound pressure or keep maintain) which will be the most effects on the characteristics of sound quality can be identify and this will be able to us to select the objective frequency band. Through these obtained results the physical changes of level at arbitrary frequency domain sensitivity can be adapted.

In order to measure surface roughness profile, stylus type equipments are commonly used, but the stylus keeps contact with surface and damages specimens by its tip pressure. Therefore, optics based measurement systems are developed, and light phase interferometer, which is based on light interference phenomenon, is the most noticeable research. However, light interference based measurements require translation mechanisms of nano -meter order in order to generate phase differences or multiple focusing, thus the systems cannot satisfy the industrial need of on-the-machine and in-process measurement to achieve factory automation and productive enhancement. In this research, we focused light reflectance phenomenon rather than the light interference, because reflectance based method do not need translation mechanisms. However, the method cannot directly measure surface roughness profile, because reflected light consists of several components and thus it cannot supply surface height information with its original form. In order to overcome the demerit, we newly proposed an image processing based algorithm, which can separate reflected light components and conduct parameterization and reconstruction process with respect to surface height information, and then confirmed the reliability of proposed algorithm by experiment.

A new spherical-type 3-degree-of-freedom parallel mechanism consisting of a two degree-of-freedom parallel module and a serial module is proposed. Two alternative designs for the serial sub-chain are suggested and compared. The first design employs RU joint arrangement for the serial sub chain structure. The second design incorporates a gear chain to drive the distal revolute joint of the serial sub-chain from the base platform of the mechanism. This modification significantly improves kinematic characteristics of the mechanism within its workspace. Firstly, the closed-form solutions of both the forward and the reverse position analysis are derived. Secondly, the first-order kinematic model with respect to three inputs which are located at the base is derived. Thirdly, it is confirmed through simulation that the modified mechanism has much more improved isotropic characteristic throughout the workspace of the mechanism. Lastly, the proposed mechanism is implemented to verify the results from this analysis.

Recently, the in-line vision inspection has become the subject of growing research area in the visual control systems and robotic intelligent fields that are required exact three-dimensional pose. The objective of this article is to study the pc based in line visual inspection with the hand-eye structure. This paper suggests three dimensional structured light measuring principle and design method of laser sensor header. The hand-eye laser sensor have been studied for a long time. However, it is very difficult to perform kinematical analysis between laser sensor and robot because the complicated mathematical process are needed for the real environments. In this problem, this paper will propose auto-calibration concept. The detail process of this methodology will be described. A new thinning algorithm and constrained hough transform method is also explained in this paper. Consequently, the developed in-line inspection module demonstrate the successful operation with hole, gap, width or V edge.

This study has been focused on the development of a high speed feeding type three-dimensional bending machine. It is designed for manufacture of copper pipe for heat exchangers. For the purpose of design of the machine, analysis of bending process, structural analysis and reliability evaluation of the machine by a laser interferometer are carried out. The analysis is carried out by FEM simulation using commercial softwares, DEFORM, MARC and CA TlA V5. In addition, the machine has attained high accuracy and repeatability. In order to improve the accuracy of this machine, the maximum speed, positioning accuracy and repeatability of feed are measured by the laser interferometer. The final results of analysis are applied to the design of a high speed feeding type three-dimensional bending machine and the machine is successfully developed.

It is generally accepted that fracture toughness of fiber-reinforced polymer composites is affected by strain rate in an atmospheric pressure condition. For a present study, the strain rate effect on the fracture toughness of fiber-reinforced laminated composites in the hydrostatic pressure condition was investigated. For this purpose, fracture tests have been conducted using graphite/epoxy laminated composites applying three steps of the strain rate at 270 MPa hydrostatic pressure condition. The strain rates applied were 0.05 %/sec, 0.25 %/sec, and 0.55 %/sec. Fracture toughness was determined from the work factor approach as a function of applied strain rate. The result showed that fracture toughness decreased as the strain rate increased. Specifically, the fracture toughness decreased 12% as the strain rate increased from 0.05 %/sec to 0.55 %/sec.

GIS(Gas Insulated Switchgear) is used in electric power system, to insure non conductivity, breaking capacity and operating reliability. The commercial dynamic analysis code COSMOS MOTION and 3-D modeling program SOLID WORKS were used to simulate dynamic analysis of the closing resistors of the GIS in this paper. To reduce chatter vibration of closing resistors, the motion of moving and fixed parts of closing resistors were simulated by varying the spring constant, the damping coefficient and the mass of moving and fixed parts. The simulated results were compared with experimental results. As a result, chatter vibration of closing resistors of the GIS could be reduced by using the results. These data can be used to determine the spring constant, the damping coefficient and mass of a moving part to reduce chatter vibration when the next model is developed.

The vibration problems associated with gear coupled rotors have been the focus of much engineering work. These systems are complex and difficult to analyze in that they have the problems associated with conventional rotors plus those additional problems associated with the gear couplings. This paper examines the problems peculiar to the gear mesh. Because of the meshing action of gears, the elasticity of the gear teeth introduces time-varying stiffness coefficients into the governing equations of motion. This means that system response must be thought of in terms of Mathieu-type equations, where multiple-frequency response occur due to the periodic coefficients. The meshing action of the gears also couples the lateral and torsional gear motions. Gear errors, such as tooth profile and spacing errors, produce forces and torque that excite the system at multiple frequencies, some of which are much higher than shaft rotational speed. To investigate how to the time-varying stiffness in the gear teeth and the gear errors act one the dynamic response of the gear coupled rotors, a three-dimensional dynamic model with lateral-tortional oscillation is developed. The harmonic balance technique is employed to solve this mathieu-type problem.