In this study, wire was used as the filler material for the laser repair welding, and the phenomenon in which the supplied filler material was melted and beaded down into the specimen was examined with varying laser powers and welding speeds. The optimal processing condition was found to be the laser power of 1,300 W, the welding speed and feed wire supply speed of 0.5 m/min and the defocused distances of +2㎜. At this time, the heat input(E) was 65 ~ 75 J/㎟, and no internal defect occurred. When repair welding was carried out as the optimal processing for the part that had an external defect with the radius of 2㎜, the filler metal was melted, resulting in the volume smaller than the defect part and thus causing the part unfilled. Therefore, it was found to be necessary to carry out repair welding two to three times by multiple passes rather than does it only once by single pass.

Titanium alloy is one of the hard processing materials made by the traditional manufacturing method because of the excellent mechanical strength. Ablation of titanium alloy is investigated by using a femtosecond laser which is a regenerative amplified Ti:sapphire laser with 1㎑ repetition rate, 184fs pulse duration time and 785㎚ wavelength. Experiments are carried out under various ablation conditions with different pulse overlap ratios for the rectangular shape and micro hole. Test results show that the ablation characteristic according to pulse overlap ratio of titanium alloy seems to be as non-linear type at the different zone of energy fluence. The optimal condition of rectangular shape processing is obtained at the laser peak power 1.3㎽, pulse overlap ratio of 90%, beam gap of 1 ㎛. The micro hole has a good quality from the pulse overlap ratio of 99% at the same laser peak power. With the optimal processing condition, the fine rectangular shape and micro hole without burr and thermal damage are achieved.

The shape of combustion nozzles varies from large diameter to small diameter ones. In the case of small nozzle, nozzle exit can be easily winkled or damaged in machining process. Femtosecond laser is a micro machining technology that is able to drill a small nozzle without damaging the nozzle exit. In this experiment, a small nozzle of combustion was fabricated by using a femtosecond laser. The fabricated nozzle of combustion provided a very small nozzle diameter with clean nozzle exit without wrinkling or collateral damage.

Previous researches show that linearly integrated Hall sensor arrays (LIHaS) can detect cracks in the steel structure fast and effectively. This paper proposes an algorithm that estimates the size and shape of cracks for the developed LIHaS. In most nondestructive testing (NDT), just crack existence and location are obtained by processing 1-dimensional data from the sensor that scans the object with relative speed in single direction. The proposed method is composed with two steps. The first step is constructing 2-dimensionally mapped data space by combining the converted position data from the time-based scan data with the position information of sensor arrays those are placed in the vertical direction to the scan direction. The second step is applying designed Laplacian filter and smoothing filter to estimate the size and shape of cracks. The experimental results of express train wheels show that the proposed algorithm is not only more reliable and accurate to detecting cracks but also effective to estimate the size and shape of cracks.

Stroke patients can’t use their hands because of the paralysis of their fingers. Their fingers are recovered by rehabilitating training, and the rehabilitating extent can be judged by grasping a spherical object. At present, the used object in hospital is only a spherical object, and can’t measure the force of fingers. Therefore, doctors judge the rehabilitating extent by touching and watching at their fingers. So, the spherical object measuring system which can measure the force of their fingers should be developed. In this paper, the finger-force measuring system with a sixaxis force/moment sensor which can measure the spherical-object grasping force is developed. The six-axis force/moment sensor was designed and fabricated, and the force measuring device was designed and manufactured using DSP (digital signal processing). Also, the grasping force test of men was performed using the developed finger-force measuring system, it was confirmed that the average force of men was about 120N.

The present research works investigated into the low velocity impact characteristics of DP 780 high strength steel sheet with 1.7 ㎜ in thickness subjected to free boundary condition using three-dimensional finite element analysis. Finite element analysis was carried out via ABAQUS explicit code. Hyper-elastic model and the damping factor were introduced to improve an accuracy of the FE analysis. An appropriate FE model was obtained via the comparison of the results of the FE analyses and those of the impact tests. The influence of the impact energy and nose diameter of the impact head on the force-deflection curves, impact time, absorption characteristics of the impact energy, deformation behaviours, and stress-strain distributions was quantitatively examined using the results of FE analysis. The results of the FE analysis showed that the absorption rate of impact energy lies in the range of the 70.7-77.5 %. In addition, it was noted that the absorption rate of impact energy decreases when the impact energy increases and the nose diameter of the impact head decreases. The local deformation of the impacted region was rapidly increased when the impact energy was larger than 76.2 J and the nose diameter was 20 ㎜. A critical impact energy, which occur the instability of the DP780, was estimated using the relationship between the plastic strain and the impact energy. Finally, characteristics of the plastic energy dissipation and the strain energy density were discussed.

The transmission case has bearing loads. The case should be designed with more stiffness and lightweight under high external loads. In this study, we performed FEA(Finite Element Analysis) for the transmission case and performed topology optimization base on the results of FEA. We performed topology optimization with the control of the shape size which is the results of topology optimization and suggested the shaped of the transmission case of topology optimization.

FormFactors is one of the most critical design factors in early development of mobile phone, and proper selection of FormFactors is necessary for smoothness of product development and customer satisfaction. Especially, emergence of mobile convergence added so various functions besides its original call function that importance of selecting FormFactors has increased because multiform FormFactors are needed. However there is problem such as frequent change of decision making in existing process because established process picks out FormFactors sensibly and arbitrarily through idea pull and so forth. We proposed FormFactors selection process by Axiomatic Design, set approach method and block approach method for reasonable and systematical FormFactors selection. First of all, we set the purpose of mobile phone development, and it is examined by Axiomatic Design. FormFactors design matrix is deduced through this process, the numbers of axes and rails are proposed using set approach method, and then patterns of FormFactors are embodied by block approach method. Particularly process application was tried through case study of mobile phone development, and we ensured that new FormFactors can be presented to a designer by systematical verification if change of customer requirements occurs through our process.

The fatigue characteristic of a material or a structure is derived from fatigue tests of standard specimens. However, many test results of standard specimens are very different from those of real structures. One reason for this difference is the constraint effects according to the geometrical difference. Therefore, to calculate more accurate fatigue life, the constraint effect must be considered by comparing test results of standard specimens with those of real structures. In this study, a blade of an air-conditioner was evaluated by both the test and the analysis. The results showed that a standard specimen is conservative, compared with a structure specimen. And fatigue life of an air-conditioner's blade was predicted from those.

Since a tower crane is too high for a worker to ascend and by the wind in the high altitude, the possibility of a safety accident is very high, a lift assist is used. In this study, the hydraulic fall prevention device using the pressure generation device by Seok, et al.? was developed. For this, the effects on the fall prevention performances of factors such as gear clearance, oil viscosity, rotative velocity and so on were evaluated by the analysis of fluid flow using FEM and the prototype was producted and a function test was performed.

Heat treatment with carburized quenching process is widely used for automotive helical gear to improve its surface properties of hardness and strength. However, the gear can be deformed with the process over the allowable tolerance, which possibly makes noise, vibration and heat problems in operation. In this study, deformation of helical gear during heat treatment of carburized quenching was analyzed with a numerical method, incorporating coupled calculations of thermal conduction, carbon diffusion, phase transformation and thermal stresses. With the analysis, the effect of coolant temperature in quenching on the deformation was investigated. The result of the analysis revealed that the higher the coolant temperature became, the more change of helix angle and the more compressive stresses in the surface generated, because of delayed generation of martensite in the part.

The object of this study is to investigate the definite method for pitting damaged surfaces. Pitting is a sort of fatigue damages and it is made by a repetitive load. For a judgment between damages or not, sensing vibrations of test equipment is simple. However, it is not only difficult to observe a growth of pitting but also impossible to detect the juncture of initial pitting. Therefore, a method for the pitting damaged area measuring technique was effectively implemented by Two Roller Machine. The change of surface damaged area was measured by an optical microscope in regular time and calculated by the use of dark and bright ratio of test specimens' pictures taken by optical microscope. In conclusion, S - N Curves gained by Failure rate - Cycle graph was led and the curves are able to be chosen as occasion demands for a failure area percentage.

In this paper, double ball-bar is used to estimate the geometric errors of a rotary table, which includes one-axial motion, two-radial motions and two-tilt motions, except the angular positioning error. To simplify the measurement procedures, three measurement steps have been designed and developed. At each measurement step, one end of the double ball-bar is fixed at the nose of spindle and the other end is located on the rotary table. And specific circular test path is planned to keep the distance between two balls as constant at ideal case. The relationship including the geometric errors of a rotary table and the measured distance between two balls which is distorted by the geometric errors is defined by using ball-bar equation. Each geometric error is modeled as 4^th order polynomial considering C¹-continuity. Finally the coefficients of polynomial are calculated by least-square method. Simulation is done to check the validation of the suggested method considering set-up errors and measurement noise. Suggested method is applied to estimate geometric errors of a rotary table of a 5-axis machine tool.