An Experiment was carried out to find the scheme for minimization of burr formation on inclined exit surface in drilling. Several drills with different geometry are used for drilling the workpiece with inclined exit surface. Step drills are specified with step angle and step size. The influence of the inclination angle of exit surface on burr formation was observed, which enables to analyze the burr formation mechanism on inclined exit surface. Along the edge on the inclined exit surface, burrs are formed by the bending deflection to feed direction and also burrs are formed in exit direction of cutting edge. To minimize the burr formed in feed direction, the comer angle which is formed by the inclination angle and step angle must be large enough not to be bent to burr. By decreasing step angle of drill and decreasing the distance between two axes of two holes, burr formation at the intersecting holes can be minimized.
Burr formation mechanisms are analyzed according to the drill geometries and cutting conditions. Several schemes for burr minimization on inclined exit surface were proposed.

Fitting process carried out in automobile transmission assembly line is classified into three classes; heat fitting, press fitting, and their combined fitting. Heat fitting is a method that heats gear to a suitable range under the tempering temperature and squeezes it toward the outer diameter of shaft. Its stress depends on the yield strength of gear. Press fitting is a method that generally squeezes gear toward that of shaft at room temperature by press. Another method heats warmly gear and safely squeezes it toward that of shaft. Warm shrink fitting process for automobile transmission part is now gradually increased, but the parts (shaft/gear) assembled by this process produced dimensional changes of gear profile in both radial and circumferential directions. So that it may cause noise and vibration between gears. In order to solve these problems, we need an analysis of warm shrink fitting process, in which design parameters are involved; contact pressure according to fitting interference between outer diameter of shaft and inner diameter of gear, fitting temperature, and profile tolerance of gear.
In this study, an closed form equation to predict contact pressure and fitting load was proposed in order to develop optimization technique of warm shrink fitting process and verified its reliability through the experimental results measured in the field and FEM, that is, thermal-structural coupled field analysis. Actual loads measured in the field have a good agreement with the results obtained by theoretical and finite element analysis and also the expanded amounts of the gear profile in both radial and circumferential directions are within the limit tolerances used in the field.

Sandwich structures, which are composed of a thick core between two faces, are commonly used in many engineering applications because they combine high stiffness and strength with low weight. Accordingly, the usage of sandwich structure is very widely applied to the aircraft, the automobile and marine industry, etc., because of these advantages. In this paper, we have investigated the buckling protection of an inner structure plate and the useful corrugated configuration for contact, and the fabrication method of the inner structure plate for large area using the continuous molding process. Also, we have guaranteed the accuracy of the molding process through the micro corrugated mold fabrication and secured the accuracy and analyzed aspect properties of the inner structure plate fabricated for a large area using the partial mold process. We have compared molding simulation according to the aspect thickness of the corrugated configuration with the molding experiment results.

The lead frame manufactured by stamping process plays an important role in connecting semiconductor to PCB board. As a result of the miniaturization of semiconductor, its corresponding lead frame punch has been narrow. In case of the punch with high slenderness ratio such as lead frame punch, the punch can be broken suddenly due to buckling. To prevent the fracture of lead frame punch, some manufacturers have experientially attached stiffeners to weak parts of punch. The purpose of this study, therefore, is to suggest the guideline for design of stiffened punch. The optimal position and the number of stiffeners to be attached to punch are investigated by elastic buckling analysis. The elastic buckling analysis consists of the eigenvalue buckling analysis and nonlinear buckling analysis. The critical buckling load of elastic buckling analysis is compared with that of buckling test. Finally, the guideline for attaching stiffeners is suggested through analysis of cross section of lead frame punch such as moment of inertia and eccentricity.

Machining accuracy is closely related with tool deflection induced by cutting forces. In this research, cutting forces and tool deflection in end milling are expressed as a closed form of tool rotational angle and cutting conditions. The discrete cutting forces caused by periodic tool entry and exit are represented as a continuous function using the Fourier series expansion. Tool deflection is predicted by direct integration of the distributed loads on cutting edges. Cutting conditions, tool geometry, run-outs and the stiffness of tool clamping part are considered together for cutting forces and tool deflection estimation. Compared with numerical methods, the presented method has advantages in prediction time reduction and the effects of feeding and run-outs on cutting forces and tool deflection can be analyzed quantitatively. This research can be effectively used in real time machining error estimation and cutting condition selection for error minimization since the form accuracy is easily predicted from tool deflection curve.

The synthesis of optimal controllers for multivariable systems usually requires an accurate linear model of the plant dynamics. Real systems, however, contain nonlinearities and high-order dynamics that may be difficult to model using conventional techniques. This paper presents a novel learning method for the synthesis of LQR controllers that doesn't require explicit modeling of the plant dynamics. This method utilizes the sign of Jacobian and gradient descent techniques to iteratively reduce the LQR objective function. It becomes easier and more convenient because it is relatively very easy to get the sign of Jacobian instead of its Jacobian. Simulations involving an overhead crane and a hydrofoil catamaran show that the proposed LQR-LC algorithm improves controller performance, even when the Jacobian information is estimated from input-output data.

In this paper a adaptive backstepping control scheme is proposed for control of a de motor driving a one-link manipulator. Fuzzy logic systems are used to approximate the unknown nonlinear function including the parametric uncertainty and disturbance throughout the entire electromechanical system. A compensation controller is also proposed to estimate the bound of approximation error. Thus the asymptotic stability of the closed-loop control system can be obtained. Numerical simulations are included to show the effectiveness of the proposed controller.

We discuss two possibilities of using femtosecond pulse lasers as a new interferometric light source for enhanced precision surface-profile metrology. First, a train of ultra-fast laser pulses yields repeated low temporal coherence, which allows unequal-path scanning interferometry, which is not feasible with white light. Second, the high spatial coherence of femtosecond pulse lasers enables large-sized optics to be tested in non symmetric configurations with relatively small-sized reference surfaces. These two advantages are verified experimentally using Fizeau and Twyman-Green type scanning interferometers.

A hybrid focus method with multiple laser slits is newly proposed for the measurement of surface morphology with depth discontinuity, and it is based on the integration of DFD and DFF. Rough depth information is estimated through calibration tables which are constructed by DFD with multiple laser slits, and then DFF is applied to only each specific depth range using the rough depth information resulting from DFD. The proposed hybrid method gives more accurate results than DFD and DFF, and faster measurement than DFF in the vicinity of depth discontinuity. Its performance is verified through experiments of calibration blocks with sharp depth discontinuity.

This paper addresses the methodology development for the automated machining setup planning system using case-based reasoning(CBR). The case-based reasoning is used to develop a setup planning system, which consists of part input and representation module, case retrieval module, and case adaptation module. We present new approaches in the part input and representation module and the case retrieval module focusing on the similarity index determination. An illustrative example is included to demonstrate the proposed method.