The old technique of sandblasting which has been used for decoration of glass surface has recently been developed into a powder blasting technique for brittle materials such as glass, silicon and ceramics, capable of producing micro structures larger than 100μ m. In this study, we introduced oblique powder blasting, and investigated the effect of the impacting angle of particles, the scanning times and the stand-off distance on the surface roughness and the weight-loss rate of samples with no mask, and the wall profile and overetching of samples with different mask pattern in powder blasting of soda-lime glass. The varying parameters were the different impact angles between 50° and 90°, scanning times of nozzle up to 40 and the stand-off distances 70㎜ and 100㎜. The widths of mask pattern were 0.2㎜, 0.5㎜ and 1㎜. The powder was alumina sharp particles, WA #600. The mass flow rate of powder during the erosion test was fixed constant at 175g/min and the blasting pressure of powder at 0.2㎫.

At the large-sized mold for injection molding, the remaining gas in the mold causes some problems with final products. In order to solve these problems, air-bent was drilled on the surface of mold. However, this method leaves the scar on the surface of a product. Therefore, porous material was developed to the removal of remaining gas in this study. Porcerax II, which is a commercialized porous material, were developed in USA. It requires the electric discharge machining(EDM) process to make pores on the surface of the materials. The electric discharge machining (EDM) process, however, cause the increase of the time and cost for the fabrication of the mold. In this study, high speed machining(HSM) process was applied to the fabrication of porous mold without electric discharge machining(EDM) process. Some characteristics of the developed materials machined by high speed machining(HSM) and electric discharge machining(EDM) including air-permeability and porosity were compared with those of Porcerax II. Besides, in order to be applied to the molding process, hardness and tensile & yield strength were compared between Porcerax II and developed materials.

A method for form error prediction in side wall machining with a flat end mill is suggested. Form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. Developed model can predict the surface form error about three hundred times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.

Recently the high speed end-milling processing is demanded the high-precise technique with good surface roughness and rapid time in aircraft, automobile part and molding industry. The working factors of high speed end-milling has an effect on surface roughness of cutting surface. Therefore this study was carried out to analyze the working factors to get the optimum surface roughness by design of experiment. From this study, surface roughness have an much effect according to priority on distance of cut, feed rate, revolution of spindle and depth of cut. By design of experiment, it is effectively represented shape characteristics of surface roughness in high speed end-milling. And determination(R²) coefficient of regression equation had a satisfactory reliability of 76.3% and regression equation of surface roughness is made by regression analysis.

This paper presents a method for impeller modeling and 5-axis machining by the reverse engineering. The impeller is composed of pressure surface, suction surface and leading edge, and so on. The surfaces can be modeled by using the characteristic curves such as hub curves, shroud curves and fillet curves. The characteristic curves are extracted from the scanned data and the inspection is performed between the surfaces generated by using the characteristic curves and the scanned data. Then, An impeller is machined by 5-axis macinining and post-processing with inverse kinematic solution.

This paper presents a prediction model for the aerosol generation of cutting fluid in turning process. Experimental studies have been carried out in order to identify the characteristics of aerosol generation in non-cutting and cutting cases. The indices of aerosol generation was mass concentration comparable to number generation, which is generally used for environment criterion. Based on the experimental data, empirical model for predicting aerosol mass concentration of cutting fluid could be obtained by a statistical analysis. This relation shows good agreement with experimental data.

Cutting by a high speed laser cutting machine is one of most effective technologies to improve productivity. This paper has studied to obtain the cutting characteristics and optimal cutting conditions in a high speed feeding type laser cutting machine by Tacuchi method in design of experiments. A L?(3⁴) orthogonal array is adopted to study the effect of adjustment parameters. The adjustment parameters consist of cutting speed, laser power, laser output duty and assistant gas pressure. And the quality feature is selected as surface roughness of sheet metal. Variance analysis is performed in order to evaluate the effect of adjustment parameters on the quality feature of laser cutting process.

This study carries out the performance improvement and simplification of hydraulic modulator that plays an important role in vehicle stability control systems. The mathematical models for each component of a modulator, such as pump, wheel cylinder, check and solenoid valve, accumulator, damper are derived in detail. All the mathematical models are combined to form a modulator system and implemented through a computer program, which can be controlled by a user friendly GUI. To verify the simulation, comparison between simulation and experiments has been made. After the verification of the validity of the simulation, the effects of the design parameters of the modulator on the wheel cylinder pressure is investigated. The results show that the modulator without MPA has advantage in early time pressure rise rate, and it can be simplified.

From the Beckmann's reflection model of wave incident, reflected light from a surface is known to have not only specular but also diffuse components. The specular component dominant a surface for a mirror-like surface is distributed on the almost the same area as the spot on the surface, but the diffuse component region dominant for a rough surface spreads scattered on the larger areas than the spot. Therefore, statistic parameters from the scattered light distribution are more meaningful in the diffuse region, while the magnitude of rather meaning in the specular region. In usual, there need two sensors to acquire two kinds of information: Photo-detector for light intensity magnitude and image sensor for light intensity distribution. But dual sensor scheme requires a beam splitter usually to feed light to each sensor, and moreover there is not a combination rule to relieve the different sensor characteristics. In this study a new method is proposed for acquisition of the dual information using only an image sensor. Specular region is established on an image area being distinguished from a diffuse component, and laser power is adjusted so that no pixel of the image sensor in the specular region is saturated. Simulation based on the light reflection theory and the experimental results are quite well matched, and thus the proposed method was proved to be very useful for mirror-like surface measurement.

This study addresses the contamination sensitivity test of a typical fuel pump for automotive vehicle. The objective of the study is to find the contamination sensitivity coefficient of fuel pump on specific contaminant particle sizes so that optimal fuel filter could be selected. To achieve the objective, the degradation of discharge flow rate of fuel pump was measured under the experiments of various contaminants size ranges of ISO test dust up to 80㎛. The fundamental theory of contamination sensitivity was introduced and the contamination sensitivity coefficients were estimated using the experimental data. Maximum contamination sensitivity coefficient of 5 x 10－? L/min . Ea was found on the contaminant size range of 40㎛-50㎛. The magnified picture of the surface of vane disc revealed that the abrasive wear was the principal cause of discharge flow rate degradation. Hence, this study revealed that high efficiency filter on the contaminant particle size range of 30㎛-70㎛ especially should be used to maintain the service life of the fuel filter.

In this study, when variable-amplitude load with various applying mode acts on the pre-crack tip, we examined how fatigue cracks behave. Hence aspects of the deformation caused by changing the applying mode of single overload and propagation behavior of fatigue crack were experimentally examined: What kinds of the deformation would be formed at pre-crack and its tip? What aspects of the residual plastic deformation field would be formed in front of a crack? How aspects of the plastic zone could be evaluated? As applying mode of single overloading changes, the deformation caused by tensile and shear loading variously showed in each applying mode. The different aspects of deformation make influence on propagation behavior of cracks under constant-amplitude fatigue loading after overloading with various modes. We tried to examine the relationship between aspects of deformation and fatigue behavior by comparing the observed deformation at crack and crack propagation behavior obtained from fatigue tests.

Injection molding is the one of the most important processes for mass production of plastic parts. Usually injection molds for mass production are constituted to multi-cavity runner system to manufacture the more parts at a time. Multi-cavity molds are designed to geometrically balanced runner system to uniformly fill to each cavity.But,when injection molding is performed using a mold with balanced runner system filling imbalances are occurred between the cavity to cavity. The previous studies by Beaumount at.al reported that filling imbalance occurred by thermal unbalance on the mold and viscosity variation of resins and so on. In this study, we conducted experiments in order to know the causes of filling imbalance for 3 plate type mold with 8 cavities. And we exhibited a new so called 4BF mold (4 plate type Balanced Filling Mold) to be possible filling balance. We conducted a experimental injection molding to verify the efficiency of the 4BF mold. In the results of the experiment, we could confirmed the balanced filling possibility of the 4BF mold.