Using an IR (infrared) optical system of observation and research were performed long before. Nowadays satellites equipped with IR optical system observe the earth and universe. In this paper, we developed the IR optical system for main payload of the STSAT-3 (Science and Technology Satellite -3). We studied the ultra precision machining technique to fabricate FPL-53 lenses which is the IR optical material for space observation camera of the STSAT-3. DOE (Design of Experiment) was used to find best machining characteristic for FPL-53. Finally we fabricated FPL-53 aspheric lens with the form accuracy of P-V 0.36 ㎛.

Recently, there is a demand for a thermal imaging microscope in the medical field as well as the semi-conductor industry. Although the demand of the advanced thermal imaging microscope has been increased, it is very difficult to obtain the technology of developing a thermal camera, because it is used for defense industry. We developed the x5 zoom microscope which has 3 ㎛ spatial resolution to research the design and fabrication of the IR (Infrared) optical system. The optical system of the IR microscope consists of four spherical lenses and four aspheric lenses. We verified individual sensitivity of each optical parameter as the first order approach to the analysis. And we also performed structure and vibration analysis. The optical elements are fabricated using Freeform 700A. The measurement results of surface roughness and form accuracy using NT 2000 and UA3P are Ra 2.36 ㎚ and P-V 0.13㎛. Finally we ascertained resolution power of 3 ㎛ using USAF (United State Air Force) 1951 IR resolution test chart.

The usage of ultra-precision machining is increasing by the manufacturing of precision optical elements such as camera lens, laser printer, CD player, DVD and microscope parts etc.. The WC alloy material is in wide use by mold core to improve the productivity and accuracy in manufacturing those precision parts. The WC alloy mould core can be machined effectively by the parallel grinding process which is an excellent technique for manufacturing of surface profile hard to machining materials such as the hardened metal alloy, Ceramics, Glass and so on. Magnetic assisted polishing as a final polishing process has also been utilized to obtain ultra-precision mirror surface with the elimination of traces presented on ground surface. It is able to deduce the optimal ultra-precision machining conditions of the WC alloy material from the experiment and analyses results.

Technical demands for aspheric glass lens formed in market increases its application from simple camera lens module to fiber optics connection module in optical engineering. WC is often used as a metal core of the aspheric glass lens, but the long life time is issued because it fabricated in high temperature and high pressure environment. High hard thin film coating of lens core increases the core life time critically. Diamond Like Carbon(DLC) thin film coating shows very high hardness and low surface roughness, i.e. low friction between a glass lens and a metal core, and thus draw interests from an optical manufacturing industry. In addition, DLC thin film coating can removed by etching process and deposit the film again, which makes the core renewable. In this study, DLC films were deposited on the SiC ceramic core. The process variable in FVA(Filtered Vacuum Arc) method was the substrate bias-voltage. Deposited thin film was evaluated by raman spectroscopy, AFM and nano indenter and measured its crystal structure, surface roughness, and hardness. After applying optimum thin film condition, the life time and crystal structure transition of DLC thin film was monitored.

Vibration of a hydraulic excavator’s body and boom occurs when the boom quickly stops after upward or downward motion. The main objective of this research is to present an idea of suppressing the vibration. Three parameters which affect the vibration are defined and analyzed thoroughly and a heuristic method suppressing the vibration is presented in this paper. Experimental results show that the proposed method works very well.

There are many unbalanced models such as helicopter’s rotor blades, small-sized precision motor in industrial applications. In the real products, their gravity center usually does not accord with the desired gravity center. If the deviation is large between them, it can be a major cause of vibration and noise as the part of model rotate. Therefore the gravity center in the rotational parts should be controlled properly because of static and dynamic balancing of the parts. In the research, the rotor blade of unmanned helicopter has been selected to obtain the high quality of balancing. In order to achieve the purpose, measuring system has been developed. In the system applied principle is three point weighting method, which is one of the Multiple-point Weighting Method. It has circle fitting for compensation of machining error, after measuring the values. From this study, the results showed that the proposed measurement procedure gives reliable and precise gravity center.

In this study, position tracking and force reflection control of a master-slave manipulator which will be used for handling objects contaminated by radioactivity has been addressed. Since available measurements concerning on dynamic motion of the master-slave manipulator are restricted, a simple constrained control structure was suggested. In the consideration of the uncertain dynamic behaviors of the slave manipulator which is dependent upon mass and shape of work pieces grasped and dynamic properties of the environment contacted, a simple structured sliding mode control was suggested to guarantee robustness with respect to parameter uncertainties and external disturbances. The proposed control was applied to a 1-DOF master-slave link system. The control performances were verified along with some computer simulation results.

We developed a model-based controller for 6-DOF micropositioning of a precision stage using H_∞ norm. For the design, a state-space system of the mathematical model of the stage is derived. In developing the controller, weighting functions are effectively designed in consideration of upper bounds of the sensitivity of the control loop and control input. Step responses in open and closed loop control are provided to verify the micropositioning performance of the stage. By applying the developed controller we prove that the inverse of the weighting function forms the upper bound of the control loop. It is also found that the controller makes the same sensitivity shape with all the DOFs due to the use of H_∞ norm. The developed controller is expected to be applied successfully for industrial use.

The fabrication method of aspheric lens is changed from machining to press molding so as to improve the productivity. In the case of the press molding method, the temperature control of the molding die is most impotent, because the temperature of each molding die determines the quality of lens. But any practical method for direct measuring of the lens temperature and the die internal temperature is yet unknown. Besides, in the case of the press molding system in which the heating and pressing and cooing of a die is done at one work station, the cycle time for the system is yet too long. The paper shows an improved structure of radiant sequential system in which the heating and pressing and cooing of dies is done at individual work station so as to cut down the cycle time. To know the die internal temperature, numerical results are given using ANSYS. An experimental radiant sequential system is developed and tested. Finally, the Taguchi method is applied in order to optimize the setting conditions of individual work station.

Every mechanical part for mass production has dimensions with tolerances in engineering drawing. Tolerance is given to guarantee assemble parts together satisfying functional requirements and dimensional constraints. Tolerance is essential factor for standardization of parts or assembly and has huge influence on manufacturing cost. It will be desirable to have tolerances as broad as possible for minimizing manufacturing cost. This paper describes tolerance analysis of u-joint assembly that is a part of automobile steering system. Within the range of tolerances of parts, accumulated effect is estimated by arithmetic calculation, probability theory and Monte carlo simulation. Each result is compared to investigate the method for increasing productivity.

The bonding process of LCD panel is attaching an inner lead to an outer lead in the production line of LCD panel module. It is composed of an OLB process and a PCB bonding process. Since bonding tool assembly is one of the core parts of the bonding equipment that determines the durability and performance of the final product, much design efforts to enhance uniformity and efficiency of the process have been made. In this paper, FE analyses have been employed to determine the bonding tool size. Bonding tool of long bar shape has been simplified as a piece with same heater pitch, and appropriate boundary conditions such as convection and radiation are considered. Thermal analysis results by the FEM have been validated by the experiments. With the use of FE analysis varies design parameters and the corresponding effects have been evaluated. It was observed that the approach presented in this paper could be employed for the design of LCD module bonding tool.

The design of press bonding tool in LCD module equipment is a very complex and difficult task because many designable variables are involved while their effects are not known. It takes longtime experiments and much expenses to verify the effects of these design variables. However the optimization of bonding tool using OLB(outer lead bonding) and PCB Bonding is a very important problem in LCD manufacturing process, so much design efforts have been made for improving the bonding tool performance. In this paper, a reasonable and fast process which gives optimized solution under the design requirements has been presented. Both analytical and statistical methods are employed in this process. A reliable analytic model using experiment-oriented FE analysis can be obtained, in which the regression equations that predict the tool efficiency from various DOE method are found. Improvement of tool efficiency could be estimated by the regression equations using meaningful factors converged by RSM(Response Surface Method). With this process a reasonable optimized solution that meets a variety of design requirements can be easily obtained.

Gas turbines operation for power generation increased rapidly since 1990 due to the high efficiency in combined cycle, relatively low construction cost and low emission. But the operation and maintenance cost for gas turbine is high because the expensive superalloy hot gas path parts should be repaired and replaced periodically. This study analyzed the initiation and propagation of the crack at the gas turbine blades which are coated with MCrAlY as a bond coat and TBC as a top coat. The sample blades had been serviced at the actual gas turbines for power generation. Total 7 sets of blades were analyzed and they have different EOH(equivalent operation hour). Blades were sectioned and the cracking distribution were measured and analyzed utilizing SEM(scanning electron microscope) and optical microscope. The blades which had 52,000 EOH of operation had cracks at the substrate and the maximum depth was 0.2 ㎜. Most of the cracks initiated at the boundary layer between TBC and bond coat and propagated down to the bond coat. Once bond coat is cracked, the base metal is exposed to the oxidation condition and undergoes notch effect. Under this environment, the crack branched at the interdiffusion layer and propagated to the substrate. Critical cracks affecting the blade life were analyzed as those on suction side and platform.

A gas turbine consists of an upstream compressor and a downstream turbine with a combustion chamber, and also the compressor and the turbine are generally coupled using a single shaft. Large scale gas turbine compressor is designed as multi-stage axial flow and the blade is fantype which is thick and wide. Recently radial cracking happens occasionally at the compressor blade tip of large scale gas turbine. So, FEM was performed on the compressor blade and vibration modes and dynamic stresses were analyzed. According to the analysis, 9th natural frequency mode of the blade, which is 2 strip mode, is near the vane passing frequency by the vane located at the upstream of the blade.

For a present study, woven type carbon fibers were surface-modified by oxygen plasma to improve adhesive strength between carbon fibers and epoxy. The change of hydrophilic properties by the plasma modification was investigated through the contact angle measurement and the calculation of surface energy of carbon fiber due to the oxygen plasma modification. FESEM and XPS analyses were performed to study the chemical and physical changes on the surface of carbon fibers due to the oxygen plasma modification. Pin-on-disk wear tests were conducted under dry condition using unmodified and plasma-modified carbon/epoxy composites to investigate the effect of plasma modification on the wear behavior of woven type carbon/epoxy composites. The results showed that the friction coefficient and the wear rate of plasma-modified carbon/epoxy composites were lower than those of unmodified carbon/epoxy composites, respectively. XPS analysis showed that new functional group of a carbonyl type was created on the carbon fibers by the O2 plasma treatment, which enhanced adhesive strength between carbon fibers and epoxy, leading to improve wear properties