The Forming Limit Diagram (FLD) is a criterion used to assess the formability of sheet metal during a manufacturing process. Traditionally, FLDs are obtained through manual measurements using Mylar tape or through the use of automatic deformation measurement systems such as ARMIS and ARGUS. However, the use of Mylar tape is not user-friendly and can result in errors. Additionally, the cost of using automatic measuring equipment is high. To address these challenges, we propose a method that utilizes a low-cost USB digital microscope and the Python-based open-source library, OpenCV, to obtain forming limit diagrams. This approach allows for the measurement of deformation on specimens by analyzing circles printed on them. To evaluate the performance of this method, a circular grid was printed on a sus430 0.3 t specimen and a nakajima test was conducted. The strain data obtained using this system was then compared to the FLD obtained with the ARGUS system. The results confirmed that the formability of sheet metal can be assessed at a lower cost using our proposed method.

In Hopkinson bar theory, stress, strain, and strain rate can be determined by analyzing the dimensions of the specimen. When conducting Split-Hopkinson Pressure Bar (SHPB) experiments, the stress-strain curve is obtained by considering the entire length and width of the specimen. However, in Split-Hopkinson Tensile Bar (SHTB) experiments, it is important to only consider the regions where deformation occurs in order to accurately determine the dynamic material properties. This study introduces a method for selecting the dimensions of the deformed region (LD and WD) in plate specimens for SHTB experiments using Finite Element Analysis (FEA). The analysis involved varying the length and width of a 1 mm thick SUS430 specimen, and the deformed region was determined using the proposed method. The stress-strain curves obtained from this region were then compared with the input Cowper-Symonds model. The validity of the proposed approach was confirmed, as the percentage error between them ranged from 2.54 to 6.62%.

In this study, based on directed energy deposition (DED) technology, one of the additive manufacturing technologies, a porous material fabricated by mixing various aluminum alloys and foaming agent was manufactured. First, the foaming agent formed pores inside the deposited materials and differences in foaming characteristics were observed depending on the type of aluminum. Also, the foaming characteristics according to the laser power, which is a representative process variable, were analyzed. As a result, a closed-cell porous material with a maximum porosity at a laser power of 1,100 W was manufactured. Results of the compression test showed that the porous material made by the pores generated therein collapses to absorb energy, and the internal pores disappear to become high density. Therefore, Young’s modulus and yield stress were reduced by the pores inside the sample of pure aluminum and Al6063. However, it was found that the specific energy absorption, which is an advantage of the foamed materials, increased compared to non-porous materials. The findings of this study confirmed that it was possible to manufacture DED-applied foam materials using aluminum powder and a foaming agent.

The Human Machine Interface (HMI) is dependent on the Computerized Numerical Control (CNC). As a result, the HMI software is developed according to the interface method of each CNC in duplicate. Even though the same function of HMI software module is developed using the same data item, it must be implemented separately in different development environments. This is because each CNC has a different address system and provides unique data interface method. In this study, we proposed a unified interface system that can standardize and integrate data interface method to support the development of HMI software module applicable to machine tools adopting multi-vendors’ CNCs. To clearly define this work, we developed new parameters, methods, and address system based on the machine state model, composed of data elements of machine tool structure, process, and status, provides the same interface by capsulizing existing CNC interfaces. The proposed interface system is designed to provide an API (Application Programming Interface) in the form of a library. The implementation architecture is designed and details of the operating logic within the detailed components and interfaces are elaborated. The implementation and test results are illustrated to verify an application example of the proposed unified interface system.

This paper describes analysis results of vibration characteristics and modal test for a small-scale quad-rotor drone. The rotor arm has a slender body with a propeller and motor at its tip. Rotor system generates excitation for an unbalanced mass. Therefore, the drone platform is involved in the possibility of resonance. For advance identification of the possibility of resonance, confirmation of eigen-mode being closest to the propeller operation range is necessary. Material properties of CFRP tubes used for the rotor arm were acquired by finding the natural frequency based on Rayleigh method. A simplified quad-rotor FE model consisting of rotor arm assembly with tip mass was built to perform numerical analysis, and a free-free boundary condition was applied to provide flight status. Modal tests for the actual platform with impact hammer instrument were performed to verify analysis results. Separation margin from hazardous eigen-mode was checked on the propeller operation range.

The shell body is the main exterior part of a compressor, and production of shell bodies has increased along with a growing demand for air conditioners, refrigerators, air compressors, and so on. Cracks frequently occur in the process of welding a shell body. In this study, a deep drawing process for creating a shell body from a blank is developed. The technique consists of a four-step deep drawing and a two-step trimming process. Analysis is performed by DEFORM software to examine the safety of the deep drawing and trimming processes. The deep drawing process for the shell body developed in this study would have wide application in many industrial fields.

The Split Hopkinson pressure bar (SHPB) test method, which is composed of three cylindrical bars, measuring devices and frames, is known for its reliable technique of acquiring the mechanical properties of specimens under a high strain rate. This paper demonstrates the processing of design and fabrication of SHPB. First of all, numerical analysis is applied in order to determine the design parameters of SHPB apparatus and verify the validity of design for a SHPB facility. Following this, SHPB apparatus were fabricated in accordance with acquired design parameters by simulation. In order to verify the validity of SHPB apparatus, experimental results using Al6061-T6 were compared with numerical data obtained from a corresponding simulation. The result of this comparative study demonstrates the applicability and validity of the fabricated apparatus.

This paper details a new ultra-precise turning method for increasing surface quality, “Multi Point B Axis Control Method.” Machined surface error is minimized by the compensation machining process, but the process leaves residual chip marks and surface roughness. This phenomenon is unavoidable in the diamond turning process using existing machining methods. However, Multi Point B axis control uses a small angle (<1 °) for the unused diamond edge for generation of ultra-fine surfaces; no machining chipping occurs. It is achieved by compensated surface profiling via alignment of the tool radial center on the center of the B axis rotation table. Experimental results show that a diamond turned surface using the Multi Point B axis control method achieved P-V 0.1 μm and Ra 1.1nm and these ultra-fine surface qualities are reproducible.

The high-velocity electromagnetic forming (EMF) process is based on the Lorentz force and the energy of the magnetic field. The advantages of EMF include improved formability, wrinkle reduction, and non-contact forming. In this study, numerical simulations were conducted to determine the practical parameters for the EMF process. A 2-D axis-symmetric electromagnetic model was used, based on a spiral-type forming coil. In the numerical simulation, an RLC circuit was coupled to the spiral coil to measure various design parameters, such as the system input current and the electromagnetic force. The simulation results show that even though the input peak current levels were at the same level in each case, the forming condition varied due to differences in the frequency of the input current. Thus, the electromagnetic forming force was affected by the input current frequency, which in turn, determined the magnitude of the current density and the magnetic flux density.

A equivalent stiffness modeling has been performed for extracting the equivalent stiffness properties which are orthotropic elastic model from a large scale wind turbine rotor blade so that structure model can be constructed more simply for the three dimensional static aeroelastic analysis. In order to present the procedure of equivalent stiffness modeling, NREL 5MW class wind turbine rotor having the three stiffness information which are flapewise, edgewise and torsional stiffness was chosen. This method is based on applying unit moment at the tip of the blade as well as fixing all degree of freedom at the blade root and calculating the displacement from the load analysis to obtain the elastic modulus corresponding to equivalent stiffness referred to the NREL reports on blade divided into 5 sections respectively. In addition, one section was divided into 3 parts and the trend functions were used to make the equivalent stiffness model more correctly and quickly. Through the comparison of stiffness between the reference values and calculated values from equivalent stiffness model, the investigation of the accuracy on the stiffness values and the efficiency for constructing the model was conducted.

This paper presents the design and dynamic model of the finger exoskeleton actuated by Ionic Polymer Metal Composites (IPMC) to assist a tip pinch task. Although this exoskeleton will be developed to assist 3 degree-of-freedom motion of each finger, it has been currently made to perform the tip pinch task using 1 degree-of-freedom mechanism as the first step. The six layers of IPMC were stacked in parallel to increase the low actuation force of IPMC. In addition, the finger dummy was manufactured to evaluate the performance of the finger exoskeleton. The pinch task experiments, which were performed on the finger dummy with the developed exoskeleton, showed that the pinch force close to the desired level was obtained. Moreover, the dynamic model of the exoskeleton and finger dummy was developed in order to perform the various analyses for the improvement of the exoskeleton.

In this study, glassy carbon was ground for lens core of glass mold press. Ultraprecision grinding process was applied for machining of core surfaces. During the process, brittle crack occurred because of hard-brittleness of glassy carbon. Author investigated optimized grinding conditions from the viewpoint of ductile mode grinding. Geometrical undeformed chip thickness was adopted for critical chip thickness that enables crack free surface. Machined cores are utilized for biaspheric glass lens fabrication and surfaces of lens were compared for verification of ground surface.

This paper is focused on the procedure of the development of a micro air vehicle which has vertical take-off and landing capability for indoor reconnaissance mission. Trade studies on mission feasibility led to the proposal of a coaxial rotorcraft configuration as the platform. The survey to provide a guide for preliminary design were conducted based on commercial off-theshelf platform, and the rotor performance was estimated by the simple momentum theory. To determine the initial size of the micro air vehicle, the modified conventional fuel balance method was applied to adopt for electric powered vehicle, and the sizing problem was optimized with the sequential quadratic programming method using MATLAB. The designed rotor blades were fabricated with high strength carbon composite material and integrated with the platform. The developed coaxial rotorcraft micro air vehicle shows stable handling quality with manual flight test in indoor situation.

This paper presents the dynamic analysis on the joint torque of a finger for the tip pinch task. The dynamic model on finger movement was developed in order to predict the joint torques of an index finger, and the finger was assumed as a three-link planar manipulator. Analysis of the model revealed that the joint stiffness was one of the most important parameters affecting the joint torque. The stiffness of the finger joint was experimentally measured, and it was used in analyzing the finger joint torque required for performing the tip pinch task. The obtained joint torque for the tip pinch task will be used as the design requirements of the finger exoskeletal orthosis actuated by the polymer actuator whose allowable torque limit is relatively low compared to that of a mechanical actuator.

Recently, due to the tremendous growth of media technology, demands of the aspheric glass lens which is a high-performance and miniaturized increase gradually. Generally, the aspheric glass lens is manufactured by Glass Molding Press (GMP) method using tungsten carbide (WC) mold core. In this study, the thermal deformation which was occurred by GMP process was analyzed and applied it to compensate the aspheric glass lens. The compensated lens was satisfied that can be applied to the actual specifications.