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 planetary 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.

Machining systems have been evolved to produce more detailed products of high added value. This has been possible, in large part, due to the development of highly accurate multi-axis CNC machine tools. The conventional CNC of machine tools has individual axis controllers to maximize tracking performance. On the other hand, cross-coupling controllers can be integrated into the conventional CNC to enhance contouring performance. For this multi-axis cross-coupling control system, it is necessary to automatically adjust the controller gains depending on operating conditions and/or other external conditions from an optimization perspective. This paper proposes automatic modeling of feed drive systems that minimizes the difference in behavior between the system model and the actual system. Based on the modeling, an integrated auto-tuning method is also proposed to improve both tracking and contouring accuracy of a 3-axis cross-coupling control system as well as users’ convenience. The proposed methods are evaluated by both simulation and experiments.

In this paper, we investigate a new method to measure the thickness of thin transparent objects utilizing a step index multi-mode optical fiber sensor. The method mainly depends on the refraction rate of transparent target, the diameter of optical fibers and the distance to reflector. We confirmed the effects of these parameters through the experimental verification tests. The comparison between the theoretical vs. analytical results shows good agreements with each other. The proposed model also enables users to measure the thickness of thin transparent objects without considering the reflection from the target. This approach provides simple, costeffective and non-contact solutions to measure the thickness.

In this study an ANFIS-based trajectory tracking motion control algorithm is proposed for autonomous garage and parallel parking of a model car. The ANFIS controller is trained off-line using data set which obtained by Mandani fuzzy inference system and thereby the processing time decreases almost in half. The controller with a steering delay compensator is tuned through simulations performed under MATLAB/Simulink environment. Experiments are carried out with the model car for garage and parallel parking. The experimental results show that the trajectory tracking performance is satisfactory under various initial and road conditions.

When external force is applied to humanoid robot’s head, humanoid robot’s neck is rotated to prevent the damage of it. So, robot’s neck have to perceive forces (Fx of x-direction, Fy of ydirection and Fz of z-direction) and moments (Mx of x-direction, My of y-direction and Mz of zdirection) using the attached 6-axis force/moment sensor. Thus, in this paper, 6-axis force/moment sensor was developed to sense the forces and moments applied to robot’s head. The structure of 6-axis force/moment sensor was modeled newly, and it was designed using FEM software (ANSYS) and manufactured by attaching straingages on the sensing element, finally, the characteristic test of the sensor was carried out. As a result, it is confirmed that interference error is less than 3%. And, it is thought that the sensor can be used to measure the forces and the moments for humanoid robot’s head.

This research is intended to grasp the characteristics of heat flow inside auxiliary power device engine room to obtain the design basic data through numerical analysis and experiment. For experiment cost reduction, numerical analysis was done to obtain quantitative data by observing the change in temperature distribution of major parts according to changes in normal condition, incompressible condition, engine surface heat emission rate and absorption temperature with the use of commercial STAR-CD. The experiment was done by grasping the temperature distribution of major interested parts inside engine room in loaded and unloaded conditions during engine operation. The temperature distribution data here will serve as useful design data during APU engine room designing.

In diesel engines, it is inevitable that the torsional vibration is produced by the fluctuation of engine torque. Therefore, it is necessary to establish preventive measures to diminish the torsional vibration. The sleeve spring type damper is one of the preventive measures for reducing the torsional vibration. In this study, 2-roll bending process was proposed to manufacture sleeve spring; The program to calculate the initial radius including springback effect was developed and the FEA method to analyze elasto-plastic problem was verified through analysis of 90 degree bending process. The elasto-plastic analysis of 2-roll bending process was carried out by the FEA method verified to set a new criterion, and the new process design parameter(contact angle) in the 2-roll bending process was proposed.

This study proposes the structural optimization of a manifold valve. FE analysis is performed to evaluate the strength of a manifold valve. In addition, the structural optimization technique is applied to reduce its weight. In this study, the optimization method using the kriging interpolation method is adopted to obtain the minimum weight satisfying the strength constraint. The maximum stress and the weight are replaced by the metamodels. In this process, the sample points are generated by latin-hypercube design. Optimum designs are obtained by ANSYS Workbench and the in -house program.

Thick-walled cylinders, such as a cannon or nuclear reactor, are autofrettaged to induce advantageous residual stresses into pressure vessels and to increase operating pressure and the fatigue lifetimes. As the autofrettage level increases, the magnitude of compressive residual stress at the bore also increases. However, the Bauschinger effect reduces the compressive residual stresses as a result of prior tensile plastic strain, and decreases the beneficial autofrettage effect. The purpose of the present paper is to predict the accurate residual stress of SNCM8 high strength steel using the Kendall model which was adopted by ASME Code. The uniaxial Bauschinger effect test was performed to decide BEF, then this constant was used in calculation. There were some differences between theoretical solution and modified solution.

The hexagonal network-type PDMS microstructures were fabricated and they were employed to low-friction drag surfaces. While the lowest contact angle measured from the smooth surface was 108°, the highest contact angle measured from the microstructured surfaces was 145°. The moving speed of bullet-type capsule attached with a PDMS pad of smooth surface (CA=108°) was 0.1261 ㎧ and that with a PDMS pad of microstructured surface (CA=145°) was 0.1464 ㎧. Compared with the smooth surface, the microstructured surface showed 16.1% higher moving speed. The network-type microstructures have a composite surface that is composed with air and PDMS solid. Therefore, the surface does not wet: rather water is lifted by the microstructures. Because of the composite surface, water shows slip-flow on the microstructures, and thus friction drag can be reduced.