In this study, focusing on reducing a load in forming helical gears, the extrusion using two-step processes for manufacturing helical gear is proposed. The process is composed of the extrusion step in which spur gear to be used as a preform in next step is formed, and the torsion step in which the preform of spur gear is formed to helical gear. Upper-bound theory for the two-step process is applied and compared with the results of experiment. The result of upper-bound solution has a good agreement with that of the experiment and the FE analysis. The newly proposed method can be used as an advanced forming technique to remarkably reduce a forming load, to prolong a tool life, and to replace the conventional forming process of helical gears. Results obtained from the extrusion using two-step processes enable the designer and manufacturer of helical gear to be more efficient in this field.

In this paper, we proposed a new ultrasonic distance measurement system with high accuracy and long range. To improve accuracy and enlarge range, the time of flight of ultrasonic is calculated by the period detecting method. In the proposed ultrasonic distance measurement system, the ultrasonic transmitter and receiver are separated but synchronized by RF(Radio frequency) module. The experiment has been implemented from short distance 1m to maximum available distance 30m. And the period detecting method is compared with the conventional threshold level method. Experimental results show the accuracy and range of the distance measurement are improved by this period detecting method.

In this paper, two types of novel planar Translational Parallel Manipulators (TPMs) by using parallelogram mechanism are conceived. One is made up of two Pa-P (Parallelogram-Prismatic) legs connecting the base to the moving platform. The other consists of two P-Pa legs, which is the kinematic inversion of the former. Since connecting links in a parallelogram mechanism are subject to only tensile/compressive load and all the heavy actuators are mounted at the base, the proposed manipulators can be applied for planar positioning/assembly tasks requiring high stiffness and high speed. The position, velocity, and statics are analyzed, and the design methodology using prescribed workspace and velocity transmission capability is presented. Finally, two types of prototype manipulators have been developed.

In order to improve the recyclability and to reduce the recycling cost and time, the disassembly technology should be systemized because the worn out products can be reused or recycled after disassembly processes. This paper attempts to propose the integrated CATIA-based DfD (Design for Disassembly) support system to promote the disassemblability of products. The system is composed of two modules; evaluation of disassemblability, generation of DID alternatives. The disassemblability of current vehicle is evaluated to identify the weak point in terms of disassembly using the DELMIA and developed evaluation system. Furthermore a new expert system is developed to propose the optimal redesign rule and principle for generating the DfD alternatives. In order to generate the DfD alternatives, a CATIA-based design support system is implemented. The system can provide quick results and ensure consistency and completeness of the redesign alternatives.

A sandwich plate with a truss core is composed of two face sheets and a pyramidal truss core between face sheets. This paper shows how to estimate the shear modulus of a truss core, experimentally. To determine the shear modulus of truss cores, 3-point bending tests are performed. For tests, metallic sandwich beams with truss cores are fabricated. Two kinds of truss cores are tested to investigate the shear modulus. Each test is repeated under different widths in order to increase accuracy. As a result, the shear modulus of sandwich beam is properly calculated. The deflection of a sandwich beam with a truss core by shear deformation takes the major contribution of the total deflection and the shear modulus of sandwich beam should be considered whenever it is designed.

The distortion of printed pattern is frequently observed in gravure offset printing process, which can be a serious problem in printing process for printed electronics. The mechanism of pattern distortion is studied and the factors which affect the amount and shape of distortion are found using FEM. The amount and shape of distortion is influenced by material properties of the roller, thickness of roller, applied load, and so on. As the printing pressure increases and Possion ratio increases, the degree of the image distortion increases. And the increase of the thickness of rubber roller brings a large distortion of image, too. In some cases, the distortion of printed pattern can reach a few hundred micro­millimeters. The comparison of the experiment result and the simulation result shows good agreement in their quantitative tendency.

This paper presents the development of a new inchworm actuation system using the shearing deformation of the piezoelectric actuators. In this new actuation system, piezoelectric shearing/expanding actuators, an inertial mass and an advanced preload system are configured innovatively to generate the motion of an inertial mass. There are two modes in the new actuation system: (1) stick mode, and (2) clamp mode. In stick mode, the deformation of the piezoelectric shearing actuators drives an inertial mass by means of the friction force at their contact interface. On the other hand, in clamp mode, the piezoelectric expanding actuators provide the gripping force to an inertial mass and, as a result, eliminate its backward motion following the rapid backward deformation of the piezoelectric shearing actuators. To investigate the feasibility of the proposed new actuation system, the experimental system is built up, and the static performance evaluation and dynamic analysis are conducted. The open-loop performance of the linear motion of the proposed new actuation system is evaluated. In dynamic analysis, the mathematical model for the contact interface is established based on the LuGre friction model and the equivalent parameters are identified.

In this paper, a new air bearing stage with magnetic preload and a linear motor has been developed for the small precision machine systems. The new air bearing stage is unique in the sense that permanent magnets attached bottom of the iron core of table are used not only for preloading air bearings in vertical direction but also for generating thrust force by current of the coil at base. The characteristics of air bearings using porous pads were analyzed with numerical method, and the magnetic circuit model was derived for linear motor for calculating required preload force and thrust force. A prototype of single axis miniature stage with size of 120(W)×120(L)×50(H) ㎣ was designed and fabricated and examined its performances, vertical stiffness, load capacity, thrust force and positioning resolution.

The present CNC machining system if without any CAM software has been limited to 2D or 2.5D plane cut using lines, arcs and curves. If the CNC is equipped with a surface interpolation module and a surface reorganizing module inside it, we can easily try 3D surface machining without aid of CAM software. The existing NURBS surface interpolator is simple and direct to use for a unit surface. However, it enables only machining of each reference surface individually even when machining a simple composite surface. In this paper, we propose a method which can unify and reorganize various reference surfaces with a newly defined NURBS surface cycle command: a multi-repetitive cycle command such as in a CNC turning center. We also introduce a reorganizing rule for reference surfaces using NURBS properties. The usefulness of the proposed method is verified through computer simulation.

3D nano-scale manufacturing is an important aspect of advanced manufacturing technology. A key element in ability to view, fabricate, and in some cases operate micro-devices is the availability of tightly focused particle beams, particularly of photons, electrons, and ions. The use of ions is the only way to fabricate directly micro-/ nano-scale structures. It has been utilized as a direct-write method for lithography, implantation, and milling of functional devices. The simulation of ion beam induced physical and chemical phenomena based on sound mathematical models associated with simulation methods is presented for 3D micro-/nanofabrication. The results obtained from experimental investigation and characteristics of ion beam induced direct fabrication will be discussed.

The length of root canal has to be measured for endodontic treatment. Several electronic apex locators were developed to measure the length of root canal by other researchers. And their accuracies were verified by X-ray or micrometer method. But these methods did not consider the non-linear bends of pulp and had ± 0.5 ㎜ error which was large enough to measure the length of root canal.
The purpose of this study is the introduction of a new method to measure the length of root canal and the verification of the accuracy of an electronic apex locator using a Micro-CT. The length of root canal of 6 teeth were measured with the electronic apex locator. When the electronic apex locator reads 0.5, 0.6, 0.7, 0.8, 0.9 and 1.0 ㎜ length of the file which was inserted in the hole of the tooth to measure the length of root canal. The average (± Standard deviation) length of root canal of6 teeth measured by the Micro-CT was 0.49 ± 0.03, 0.59 ± 0.04, 0.68 ± 0.03, 0.78 ± 0.03, 0.90 ± 0.04 and 1.01 ± 0.03 ㎜, respectively. The maximum error of the electronic apex locator was 0.06 ㎜.