Using the multiple regression analysis cutting forces of turning processes have been predicted based on the cutting conditions such as feed rate(f), depth of cut(d), and cutting velocity(v). The statistical inference of the equation was checked by ANOVA test. The validity of the proposed regression analysis was verified by two sets of cutting tests of 27 cutting conditions and the additional cutting tests of 18 cutting conditions. From the results of analytical and experimental studies, it was found that there was no significant difference between the measured and predicted cutting forces. Also, the shear and friction characteristics of turning processes were analyzed with predicted cutting forces.

Ultra precision grinding technology has been developed from the refinement of the abrasive, the development of high stiffness equipment and grinding skill. The conventional wafering process which consists of lapping, etching, 1st, 2nd and 3rd polishing has been changed to the new process which consists of precision surface grinding, final polishing and post cleaning. Especially, the ultra precision grinding of wafer improves the flatness of wafer and the efficiency of production. Furthermore, it has been not only used in bare wafer grinding, but also applied to wafer back grinding and SOI wafer grinding. This paper focuses on the flatness of the ground wafer. Generally, the ground wafer has concave profile because of the difference of wheel path density, grinding temperature and elastic deformation of the equipment. Wafer tilting is applied to avoid non-uniform material removal. Through the geometric analysis of wafer grinding process, the profile of the ground wafer is predicted by the development of profile simulator.

A new method to fabricate the fine magnetic abrasives by using mechanical alloying is proposed. The mechanical alloying process is a solid powder process where the powder particles are subjected to high energetic impact by the bal1s in a vial. As the powder particles in the vial are continuously impacted by the bal1s, cold welding between particles and fracturing of the particles take place repeatedly during the bal1 milling process using a planetary mill. After the manufacturing process, fine magnetic abrasives which the guest abrasive particles clung to the base metal matrix without bonding material can be obtained. The shape of the newly fabricated fine magnetic abrasives was investigated using SEM and its polishing performance was verified by experiment. It is very helpful to finishing the injection mold steel in final polishing stage. The areal rms surface roughness of the workpiece after several polishing processes has decreased to a few nanometer scales.

Electrical discharge machining (EDM) is one of the most extensively used non-conventional material removal process. The recent trend in reducing the size of product has given micro EDM a significant amount of research attention. Micro EDM is capable of machining not only micro holes and micro shafts as small as a few micrometers in diameter but also complex three dimensional micro cavities. But, longitudinal tool wear by electrical discharge is indispensable and this affects the machining accuracy in micro EDM process. Therefore, newly developed tool wear compensation strategy called round trip method is suggested and verified by experiment. In this method, machining depth of cut, overlap effect and critical travel length are also considered.

Finishing is the final process in molds manufacturing and consumes much process time. Also, it influences on surface quality of molds. But, there are few systematic methods to control the process. In this work, basic experiments were carried out to study the machining characteristics of the finishing tools. From the experiments, critical surface roughness and wear coefficient are suggested to reduce the number of finishing steps and to plan a systematic finishing procedure. Comparison experiments were carried out between the expert's method and the new method, which is based on the results of this research. From the experiments, it is verified that the systematic method takes less time and generates less form error in the machined surface than the worker's method.

The objective of this study is to suggest the form rolling technology to produce high precision worm on the base of three dimensional finite element simulation and experiment. It is important to determine the initial workpiece diameter in form rolling because it affects the quality of tooth profile. The calculation method of the initial workpiece diameter in form rolling is suggested and it is verified by finite element simulation. The form rolling processes of worm shaft used as automotive part using both the rack dies of counter flow type and the roll dies are considered and simulated with the same numerical model as actual process by the commercial finite element code, DEFORM-3D. Deformation modes of workpiece between the form rolling by the rack dies of counter flow type and the roll dies are investigated from the result of simulation. The experiments using rack dies and roll dies are performed under the same conditions as those of simulation. The surface roughness, the straightness and the profile of worm are measured precisely using the worm shafts obtained from experiment. The results of simulation and experiment in this study show that the form rolling process of worm shaft using the rack dies is decidedly superior to that using roll dies from the aspect of the precision of worm such as the surface roughness, the straightness and the profile of worm.

In this paper, we propose an adaptive mechanism based on immune algorithm and neural network identifier technique. It is also applied for an autonomous guided vehicle (AGV) system. When the immune algorithm is applied to the PID controller, there exists the case that the plant is damaged due to the abrupt change of PID parameters since the parameters are almost adjusted randomly. To solve this problem, we use the neural network identifier (NNI) technique for modeling the plant and humoral immune algorithm (RIA) which performs the parameter tuning of the considered model, respectively. After the PID parameters are determined in this off-line manner, these gains are then applied to the plant for the on-line control using an immune adaptive algorithm. Moreover, even though the neural network model may not be accurate enough initially, the weighting parameters are adjusted to be accurate through the on-line fine tuning. Finally, the simulation and experimental result for the control of steering and speed of AGV system illustrate the validity of the proposed control scheme. These results for the proposed method also show that it has better performance than other conventional controller design methods.

The particle amount monitoring technique using ultrasound is proposed to determine the proper maintenance time of the filter in the supply process of pure gas in the unit of oxygen plant. There are advantages that it is adaptable in high temperature and high pressure, and it is not disturbed by being exposed in the gas flow, and it can be implemented very economical1y. The applicability of the ultrasonic technique is pre-studied through the theoretical analysis for the dependency of attenuation of ultrasonic wave on the particles in the gas flow. For the purpose, absorption, scattering and dispersion models are considered, and the attenuation by absorption and the change rate of the propagation speed are calculated for the specific range of particle size and the ultrasonic wave frequency. It was expected by simulation that the absorptive attenuation by particles was the most sensitive to the change of particle amount. The experimental result showed high correspondence with the theoretical expectation so that this ultrasound attenuation measurement was proved to be highly effective for monitoring the amount of floating particles in the gas flow.

This paper presents the remote measurement of the ECU signals adopted with KWP 2000 protocol using the wireless communication technique of bluetooth. The bluetooth technology will be the most promising network paradigm which can open the new area in the information technology. Especially, bluetooth module is able to link all the electrical products and personal computers to cellular phone or PDA. This research has a try to design a wireless measurement model of ECU signal based on the car telemetry system using bluetooth device. In order to measure the ECU signals, we designed the interface circuits which is able to communicate between the ECU system and the terminal circuits according to the ISO, SAE regulation of communication protocol standard. A microprocessor S3C3410X is used for the system control and communication of ECU signals. The embedded system software is programmed to measure the ECU signals using the ARM compiler and ANCI C based on Micro/OS-II kernel to communicate between two bluetooth modules using bluetooth stack. The remote measurement of ECU signals using the bluetooth was designed and implemented to evaluate the performance of wireless network to the transmit measurement data. The possibility for the remote measurement of the self diagnosis signals of ECU adopted with KWP2000 protocol verified through the developed systems and algorithms in embedded system.

This paper presents the development of a keypad test system for the improvement of working environment and productivity using PICI6F877 microprocessor. In order to detect the fault of keypad products, hardware and software design is performed in this system. Keypad fault detection system is controlled by the 8 bit one chip PIC microcontroller for the exactness and speed. Developed panel of the keypad test system is comprised of the sub-panel for selecting in the inspected keypad types and the main panel for displaying the working order and fault position. Furthermore, all data from keypad inspection are stored in main memory of personal computer for the database. All these functions lead to the improvement of working speed and environment.

In this paper, we studied a vibration problem that is critical and common to most precision measurement systems. For micro mechanical part measurements, results obtained from the vision-based precision measurement system may contain errors due to the vibration. In order to defeat this generic problem, for the current study, a PC based image processing technique was used first, to assess the effect of the vibration to the precision measurement and second, to develop an in-situ calibration algorithm that automatically compensate the measurement results in real time. We used a set of stereoscopic CCD cameras to acquire the images for the dimensional measurement and the reference measurement. The mapping function was obtained through the in-situ calibration to compensate the measurement results and the statistical analysis for the actual results is provided in the paper. Based on the current statistical study, it is expected to obtain high precision results for the micro measurement systems.

A combined optimal design problem of structural and control systems is discussed by taking a 3-D flexible structure as an object. We consider a minimum weight design problem for structural system and disturbance suppression problem for the control system. The conditions for the existence of controller are expressed in terms of linear matrix inequalities (LMI). By minimizing the linear sum of the normalized structural objective function and control objective function, it is possible to make optimal design by which the balance of the structural weight and the control performance is taken. We showed in this paper the validity of combined optimal design of structural and control systems.

In the present work a finite element formulation using dynamic-explicit time integration scheme is used for numerical analysis of auto-body panel stamping processes. The lumping scheme is employed for the diagonal mass matrix and dynamic explicit formulation. Analyzed auto-body panel stemping process correction of forming using software called Dynaform using dynamic extensive method. Further, the simulated results for the auto-body panel stamping processes are shown and discussed. Its application is being increased especially in the automotive industrial area for the cost reduction, weight saving, and improvement of strength.