In this work, the surface integrity smoothened with a ball end mill was investigated. Because surface integrity mainly affects the manual finishing process, RVAM (Remaining Volume After Machining) was introduced, and it gives the relation between machining process and finishing process. Runout and phase shift which adversely affect surface integrity were considered in the generation of surface topography. Cutting points in ball end milling were identified with positional vectors and a set of vectors which have the minimum height in unit area was selected for the generation of surface and RVAM RVAM variation according to runout and phase shift was calculated and experimentally verified in proposed HSM conditions for mold machining. From the simulations and the experiments, a desirable High Speed Machining condition was suggested.
In this work, optimal finish machining condition considering total time for mold or electrode manufacturing was investigated. First, manual finishing time according to the machining condition was analyzed for the work material. The effect of runout and phase shift of tool path on surface finish was also considered in those analyses. Secondly, optimal manual finishing processes were determined for various machining conditions. Finally, finish machining time and corresponding manual finishing time were taken into account for the estimation of the total time of manufacturing mold. Though small feed per tooth and pick feed reduced the manual finishing time, the finish machining time increased in such conditions. With a machining condition of feed per tooth of 0.2 ㎜ and pick feed of 0.3 ㎜, the minimum total time of manufacturing mold was achieved in our machining condition.
A robust motion controller based on self-organizing fuzzy control (SOFC) and feed-back tracking control technique is proposed for a two-wheel driven mobile robot. The feed-back control technique of the controller guarantees the robot follows a desired trajectory. The SOFC technique of the controller deals with unmodelled dynamics of the vehicle and uncertainties. The computer simulations are carried out to verify the tracking ability of the proposed controller with various driving situations. The results of the simulations reveal the effectiveness and stability of the proposed controller to compensate the unmodelled dynamics and uncertainties.
This paper describes the development of automatic making system of a frame element for flame prevention. The frame element is made by turning a thin plate and a formed plate on the small pipe. The couple plate (two plates) should be pulled with constant force to manufacture a good frame element. This is because if the gap between one couple plate and other couple plate is different, it will not prevent flame. In this paper, the automatic making system of a frame element for flame prevention was made, and which could automatically manufacture a frame element. The characteristic test of the made frame element by that system was performed, and its result was very good.
In this study, to design aluminum scrap recycling equipment, fluid flow and thermal analysis considering electromagnetic phenomenon were carried out by using ANSYS program. The magnetic flux generated by electromagnetic pump has influence on fluid velocity of AI liquid metal with molten metal motion and thermal generation. To investigate the effect of the number of phase on fluid flow and thermal generation, electromagnetic force and magnetic flux were obtained by computer simulation. In addition, the results obtained by fluid flow and thermal analysis, recycling equipment of aluminum scrap with the cooling technology of electromagnetic coil, the most suitable phase and current were proposed.
Vibration of a non-linear system under random parametric excitations was evaluated by probabilistic methods. The non-linear characteristic terms of a system structure were quasi-linearized and excitation terms were remained as they were. An analytical method where the square mean of error was minimized was used. An alternative method was an energy method where the damping energy and restoring energy of the linearized system were equalized to those of the original non-linear system. The numerical results were compared with those obtained by Monte Carlo simulation. The comparison showed the results obtained by Monte Carlo simulation located between those by the analytical method and those by the energy method.
Seals are usually made from elastomer, a kind of rubber, and it has the non-linearity and hyper-elasticity. U-type seals are used to prevent the leakage of internal fluid sealed in hydraulic actuator because they have more excellent performance than O-rings or rectangular seals. As a core part of hydraulic actuator, U-type seal gives much effect on performance and reliability of actuator. This study considers an NBR U-type seal under high pressure of a hydraulic actuator, and provides its deformation, stress-strain characteristic and contact force using the non-linear finite element analysis. Analysis results are compared with the experimental ones performed by the self-developed testing equipment. Verification result shows that this study presents a good application process for the effective design of U-type seals under high operation pressure.
In this study, the dynamic impact analysis for the passenger air-bag(PAB) module has been carried out by using FEM to predict the dynamic characteristics of vehicle ride safety against head impact. The impact performance of vehicle air-bag is directly related to the design parameters of passenger air-bag module assembly, such as the tie bar bracket's width and thickness, respectively. However, the product's design of PAB module parameters are estimated through experimental trial and error according to the designer's experience, generally. Therefore, the dynamic analysis of head impact test of the passenger air-bag module assembly of automobile is needed to construct the analytical methodology. At first, the FE models, which are consist of instrument panel, PAB Module, and head part, are combined to the whole module system. Then, impact analysis is carried out by the explicit solution procedure with assembled FE model. And the dynamic characteristics of the head impact are observed to prove the effectiveness of the proposed method by comparing with the experimental results. The better optimized impact performance characteristics is proposed by changing the tie bracket's width and thickness of module. The proposed approach of impact analysis will provides an efficient vehicle to improve the design quality and reduce the design period and cost. The results reported herein will provide a better understanding of the vehicle dynamic characteristics against head impact.
A product is designed through the collaboration among engineers in several fields such as design, analysis, and manufacturing. These series of functions are performed repeatedly during the design process. An easy access and exchange of the model data is one of the important elements that help to shorten production development time. Especially, the importance of data exchange between CAD and CAE applications is increasing in the field of verification and estimation of the products. However, information and knowledge of model which is generated by a CAD software cannot be transferred by a function of CAE software, as an exchange of product data between CAD and CAE applications. It causes a delay in design analysis and eventually discourages a designer's effort in improving his design. Therefore, we need to integrate a commercial CAD and CAE applications effectively and to use the same interface on a product model obtained in a distributed environment. This paper shows how to implement a model exchange between CAD and CAE by a web-service and how to provide a communication environment among engineers.
The rail clamp is very important device to prevent that a container crane slips along a rail due to the wind blast as well as to locate the crane in the set position during an operating mode. Recently, the design wind speed criteria were intensified from the wind speed of 16㎧ to 35㎧ during an operating mode, and from 50㎧ to 75㎧ during a stowed mode in Korea, according to the 'Inspection Criteria for Facilities and Equipments in Port' reformed after typhoon 'Maemi'. In order to design the wedge type rail clamp for the reinforced design wind speed criteria of 35㎧, we carried out the finite element analysis of the rail clamp with respect to the wedge angle, and analyzed the relationship between the wedge angle and the sliding distance of the rail clamp.
Micro machining of tungsten carbide by electrochemical machining was studied. In ECM, machining conditions and electrolyte should be chosen carefully according to the property of workpiece materials. In this paper, sulfuric acid and nitric acid were used for tungsten carbide machining and machining characteristics were investigated according to machining conditions such as electrolyte, workpiece potential and applied pulse voltage. By using mixture of sulfuric acid and nitric acid, micro structures with sharp edge and good surface quality were obtained. Micro electrochemical turning was also introduced to fabricate micro shafts.
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