3D images are generally manufactured by complex production processes. We suggested a simple method to make 3D images based on a mechanical machining technology in this study. We designed a tetrahedron consisted of many arcs having the depth of 100 ㎛ and the pitch of 500 ㎛, and machined them on an aluminum plate using end-milling under several conditions of feed-rate and depth of cut. The area of undeformed chip including depth of cut and feed-rate can predict quality of the machined arcs more precisely than the undeformed chip thickness including only feed rate. Moreover, a diamond tool can improve the quality than a CBN tool when many arcs are machined. Based on the analysis, the designed tetrahedron having many arcs was machined with no burr, and it showed different images when observed from the left and right directions. Therefore, it is verified that a 3D image can be designed and manufactured on a metal plate by end-milling under optimized machining conditions.

Plastic array lens are cheap to manufacture; however, plastic is not resistant to high temperatures and moisture. Optical glass represents a better solution but is a more-expensive alternative. Glass array lens can be produced using lithography or precision-molding techniques. The lithography process is commonly used, for instance, in the semiconductor industry; however, the manufacturing costs are high, the processing time is quite long, and spherical aberration is a problem. To obtain high-order aspherical shapes, mold-core manufacturing is conducted through ultra-precision grinding machining. In this paper, a 4 X 1 mold core was manufactured using an ultra-precision machine with a jig for the injection molding of an aspherical array lens. The machined mold core was measured using the Form TalySurf PGI 2+ contact-stylus profilometer. The measurement data of the mold core are suitable for the design criterion of below 0.5 ㎛.

ELID grinding is an excellent technique for the mirror grinding of the variety of the advanced metallic or nonmetallic materials. The focus of this study is the development of an automaticcontrol electrolysis-speed device for the automation of the ELID-grinding process. For the development of the automatic-control electrolysis-speed device, analysis experiments regarding the ELID cycle and oxide-layer removal and creation were conducted according to a truing and dressing process. Also, a comparative experiment was conducted to confirm the variance of the electrolysis speed in accordance with changes of the voltage. The experiment results for the developed automatic-control electrolysis-speed device show that the developed device could control the electrolysis speed according to voltage changes through the use of the data that are monitored during the ELID-grinding process.

Infrared (IR) optic lens can be fabricated by a single point diamond turning (SPDT) machine without subsequent polishing process. However, this machining process often leaves microcracks that deteriorate the surface quality. In this work, we propose an experimental design to remove micro-cracks on IR lens. The proposed design gathered data between cutting process condition and Rt surface roughness. This is of great importance because the scale of microcracks is a few micrometer. Rt surface roughness is suitable for analyzing maximum peak height signals of the profile. The experimental results indicate that feed per revolution variable is one of the most dominant variable, affecting the generation micro-cracks on IR lens surfaces.

A conical roll-shaping process was proposed for fabrication of a metallic spiral blade applied to a small-scale wind turbine system. A spiral blade has continuously different curvatures, with a range of 100 to 350 ㎜ radius. To fabricate this complex shape, we developed a conical rollshaping process having two main conical rollers for feeding a blank sheet, and two cylindrical side rollers for control of local bending. For clear understanding of the process parameters, numerical analyses were conducted using a commercial code, Pam-Stamp. This study optimized the effects of process parameters, such as gap and angle between the main rollers and side rollers, and also the movement of side rollers. In order to increase the forming efficiency, a central rotation point was also calculated by the analytical approach. This developed rolling process can thus be utilized in a sheet metal forming process for obtaining spirally curved sheet metal shapes.

In this study, multibody dynamic and mechanical analyses were conducted for the structure of roller chain bucket elevator system. The fatigue life of the roller chain elevator system was determined under static and fatigue loadings. Results of multibody dynamic analysis suggested that the maximum contact force occurred at the drive sprocket engagement point with the roller chain due to maximum tension. Fatigue analysis results suggest that the high load roller chain system is durable and safe because its life time is more than 700,000 cycles, close to its designed value (1,000,000 cycle). However, the contact portion of plate and pin needed a safety factor. The dynamic analysis of the heavy load roller chain was conducted with a multibody dynamic analysis program. The results obtained in this study can be utilized for dynamic analysis of roller chain systems in all industries.

A gerotor is suitable for miniature manufacturing because it has a high discharge per cycle and a simple structure, while also being widely used as lubrication oil of engines and the hydraulic source of automatic transmission. In the automobile industry, it has been necessary to continuously improve the flow rate and noise of internal gear pumps for better fuel efficiency through optimal gerotor design. In this study, to obtain an optimal gerotor with an ellipse-elliptical involute-ellipse combined lobe shape, an automatic program was developed for calculating performance parameters and drawing a gerotor profile. An oil pump was assembled with the optimal gerotor together with the port used at the actual field and CFD analysis was performed on this assembly using Ansys-CFX. A performance test for the oil pump was carried out and showed good agreement with the results obtained from the theoretical analysis and the CFD analysis.

Stand-alone cervical cage consists of a PEEK body, Ti plate, and screw, which are configured as a single-piece. Through a single operation, this implantable medical device is capable of completely fixing the cervical vertebral body. For example, instead of a plate, which is normally used, the intervertebral disc is removed and replaced with a cervical cage. It should be noted that in Korea, KFDA guidelines for a stand-alone cervical cage have not yet been suggested. Therefore, the aim of this study is to present the systematic study of the static compression test, static torsion test, dynamic compression test, and expulsion test. Further, the test method is designed to refer to the ASTM standard and relative literature.

The purpose of this study was to evaluate and compare by finite element analysis the biomechanical performance, in terms of cervical stand-alone cage screw insert angle (Type 3 – 5: 2 Screws) and screw arrangement (Type 6 and 7: 3 Screws / Type 8 and 9: 4 Screws), and the range of motion (ROM) of traditional anterior cervical discectomy of a fusion device (Type 1: Cage / Type 2: Cage + ACP). Our study suggests that the biomechanical behavior of a postoperative cervical spine could indeed be influenced by design features, such as screw angle and number of screws. In particular, ROM and the risk of subsidence were more sensitive during extension about type 5 (Insert Angle 20°). Our study also suggested that the number of screw asymmetries between up and down for type 6 and 7 could result in differences in the risk of screw fracture manifesting in different clinical aspects.

The aim of this paper is to investigate the improvement of surface characteristics of Stellite21 deposited layer by powder feeding type of direct energy deposition (DED) process using a plasma electron beam. Re-melting experiments of the deposited specimen is performed using a three-dimensional finishing system with a plasma electron beam. The acceleration voltage and the travel speed of the electron beam are chosen as process parameters. The effects of the process parameters on the surface roughness and the hardness of the re-melted region are examined. The formation of the re-melted region is observed using an optical microscope. Results of these experiments revealed that the re-melting process using a plasma electron beam can greatly improve the surface qualities of the Stellite21 deposited layer by the DED process.