Showing papers in "Journal of the Korean Society for Precision Engineering in 1997"

Indirect Cutting Force Measurement and Cutting Force Regulation Using Spindle Motor Current

Abstract: Quasti-static cutting force variations in milling process are measured indirectly using spindle motor current. Quasi-static sensitivity of the spindle motor current is higher than that of the feed motor current. Magnitude of the spindle motor current is independent of cutting direction. The linear relationship between the cutting force and the spimdle motor RMS current at various spindle rotational speed is obtained. Frequency/ Voltage(F/V) converter voltage is measured to identify the spindle speed and to determine the cutting force at various spindle speeds. Overload on the tool during milling process can be detected using the proposed indirect cutting force measurement. Based on these measurements, cutting force is regulated at a constant level by feedrate control.

An Automated Die Design System for Blanking and Piercing of Stator and Rotor Parts

Abstract: This paper describes a research work of developing a computer-aided design of blanking and piercing for stator and rotor parts. Based on knowledge-based rules, the die design system, STRTDES2, is designed by considering several factors, such as complexities of blank geometry and punch profile, and availability of press equipment and standard parts. Therefore this system can carry out a die design for each process which is obtained from the result of an automated process planning system, STRTDES1 and generate part drawing and the assembly drawing of die set in graphic forms. Knowledges for die layout are extracted from plasticity theories, relevant references and empirical know-hows of experts in blanking industries.

A Study on the Development of Aluminum Piston by Forging Process

Abstract: In this study, the development of an aluminum forged piston was tried to substitute the cast piston, in which there were internal defects such as blow hole and shrink pipe. A gasoline engine piston was chosen as an example for developing the forged piston. Before aluminum forging, model, material (plasticine) test was carried out to investigate the forgeability and internal flow pattern of the forged piston at room temperature. From the result of model material test, an aluminum piston to be forged was redesigned. The aluminum pistion was forged in hot process. The quality of a forged piston was compared with that of a cast piston in the point of mechanical properties, internal defect and microstructure. It was proved that the forged piston was superior to the cast piston.

Fault Detection and Isolation of System Using Multiple Pi Observers

Abstract: Fault diagnosis problem is currently a subject of extensive research in the control field. Although there are several works on the fault detection and isolation observers and the residual generators, those are con- cerned with only the detection of actuator failures or sensor failures. So, the perfect detection and isolation for the actuator and sensor failures is strongly required in the field of the practical applications. In this paper, a strategy of fault diagnosis using multiple proportional integral (PI) observers including the magnitude of actuator failures is provided. It is shown that actuator failures are detected and isolated perfectly by monitoring the integrated error between actual output and estimated output by a PI observer. Also in presence of complex actuator and sensor failures, these failures are detected and isolated by multiple PI observers.

A study on the stroke sensitive shock absorber

Abstract: In the stroke sensitive shock absorber, the oil path is formed along the internal cylinder surface to make the oil flow during the piston's upper-lower reciprocation movement. In constrast with the conventional shock absorbesr which show one dynamic characteristic curve, stroke sensitive shock absorber shows two kinds of dynamic characteristics according to the stroke. In this study, in order to obtain more precise information about design and damping performance analysis, the analysis on the damping force generation process and dynamic behaviour characteristics of stroke sensitive shock absorber are performed by considering the valve characteristics.

A study on the formability estimation of deep drawing process by using taguchi method

Abstract: Despite the increasing demands for improved product design, a limited number of works have been reported in the field of sheet metal forming. In the present study, introducing the Taguchi method, an otpimal and robust combination of parameters in found and a data base management system is utilized for knowledge acquisition. Analysis data, estimation rules of formability and graphical representation of the analysis have been employed for the dewigner's understanding and evaluation. The developed system is applied to a deep drawing process. Through the present study, it is shown that the developed systerm is useful for the design and the formability estimation of sheet metal forming processes.

Tool fracture detection in end milling using cutting force and acoustic emission propagated through cutting fluid

Abstract: End milling experiments are conducted to investigate characteristics of acoustic emission (AE) and cutting force singals due to tool fracture. The AE signals are obtained with a sensor attached to cutting fluid discharge nozzle. Tool states are identified with scanning electron microscopy and optical microscopy. It is demonstrated that the AE signals provide reliable informations about the cutting processes and tool states. Morever, tool fracture can be detected successfully using both the AE count rate and the standard deviation of principal cutting force.

Study on Propeller Grinding Applied by a High Stiffness Robot

Abstract: This paper presents the robot program for propeller grinding. A robot manipulator is constructed by combining a parallel and a serial mechanism to increase high sitffness as well as workspace. The robot program involves inverse/direct kinematics, velocity mapping, Jacobian, and etc. They are cerived in efficient formulations and implemented in a real time control. A velocity control is used to measure the hight of a propeller blade with a touch probe and a position control is performed to grind the surface of the blade.

A study on precision drive mechanism for monochromator grating

Abstract: The extent of absorption and transmitance of the light that passes through some material is changed as the wavelength of the light varies, and which makdes it possible to estimate characteristics of the material. Spectrometer is a measurement system that can analyze the characteristics of material by using this principle. Its application field is so wide that it can be applied to all the arease that are concerned with analyzing materials : biological, environmental, medical and chemical area etc. This study is focused on developing precision sine drive mechanism for grating monochromator which is the most important part of the spectrometers. It is designed to be simple in struicture. It is achieved to derive basic principles to manipu- late precision sine drive mechanism : it should be aligned with a condition that .beta. , the angle between grat- ing normal and grating rod should be the same as .gamma. , the one between moving nut's normal and sliding guide. And also, it's found that the mis-alignments of the grating and mirrors are not the main factor in guaranteeing the linearity of sine drive mechanism. Performance evaluation is achieved by a standard sample by comparing experimental results with standard values. It results in wavelength accuracy of .+-. 0.5nm and resolution of 1nm. Conclusively, it can be verified that the sine drive mechanism developed in this study is not only simple in structure, but also stable and excellent in performanes.

Robust Hybrid Control for Uncertain Robot Manipulators

Abstract: An new class of robust position/force hybrid control law is proposed for uncertain robot manipulators. The uncertainty is nonlinear and (plssibly fast) time-varying. Therefore, the uncertain factors such as imper- fect modeling, friction, payload change, and external disturbance are all addressed. Based on the possible bound of the uncertainty, the controller is constructed and the stability study based on Lyapunov function is presented. To show that the proposed control laws are indeed applicable, the theoretical result is applied to a SCARA-type robot manipulator and simulation result is presented.

A Study on Damage Detection of Cutting Tool Using Neural Network and Cutting Force Signal

Abstract: A useful method to detect tool breakage suing neural network of cutting force signal is porposed and implemented in a basic cutting process. Cutting signal is gathered by tool dynamometer and normalized as a preprocessing. The cutting force signal level is continually monitored and compared with the predefined level. The neural network has been trained normalized sample data of the normal operation and cata-strophic tool failure using backpropagation learning process. The develop[ed system is verified to be very effective in real-time usage with minor modification in conventional cutting processes.

Optimal Design of Machine Tool Structure for Static Loading Using a Genetic Algorithm

Abstract: In many optimal methods for the structural design, the structural analysis is performed with the given design parameters. Then the design sensitivity is calculated based on its structural anaysis results. There-after, the design parameters are changed iteratively. But genetic algorithm is a optimal searching technique which is not depend on design sensitivity. This method uses for many design para- meter groups which are generated by a designer. The generated design parameter groups are become initial population, and then the fitness of the all design parameters are calculated. According to the fitness of each parameter, the design parameters are optimized through the calculation of reproduction process, degradation and interchange, and mutation. Those are the basic operation of the genetic algorithm. The changing process of population is called a generation. The basic calculation process of genetic algorithm is repeatly accepted to every generation. Then the fitness value of the element of a generation becomes maximum. Therefore, the design parameters converge to the optimal. In this study, the optimal design pro- cess of a machine tool structure for static loading is presented to determine the optimal base supporting points and structure thickness using a genetic algorithm.

Effect of Crack Closure on the Fatigue Crack Growth Behavior of Forged AI7050-T7452

Abstract: When a structure is made by the process of forging, it has the different mechanical properties from those it has before the process. This study is based on the crack closure phenomenon of the crack growth behavior of forged AI7050-T7452. The specimens were prepared in three kinds of forging ratio in order to find out the effects of crack closure on the forged material and compare the crack growth behavior with not-forged aluminum. COD method and strain gage method were used in measuring the crack closure stress and the results from those methods were compared each other. FEM analysis was applied to verify the effective stress intensity factor range by the superposition of the crack closure load to the crack tip. In the result of this study, the crack closure stress decreased with increasing the forging ratio due to the finer grain size and the brittle manner.

Life Prediction by Lethargy Coefficient under Dynamic Load

Abstract: Because of a complicated behavior of fatigue in mechanical structures, the analysis of fatigue is in need of much researches on life prediction. A method is developed for the dynamic tensile strength analysis by simple tensile test, which is for the failure life prediction by lethargy coefficient of various materials. Then it is programed to analyze the failure life prediction of mechanical system by virtue of fracture. Thus the dynamic tensile strength analysis is performed to evaluate life parameters as a numerical example, using the developed method.

A Study on Development of the Characteristic Analysis and CAD System for Hydraulic System Using Modular Approach

Abstract: In this study, an analysis and design for hydraulic control system was developed. By using this system, the operator is able to simulate dynamic performance of the system without possessing special knowledge of software or control engineering. A graphical user interface was adopted in the system and all speration for simulation can be done by using window facilities on the display. The electro-hydraulic servo system is simulated to present the performances of the program and compared with the result of Matlab and experiment.

A Finite Element Model for Predicting the Microstructural Evolution in Hot Rolling

Abstract: A full three-dimensional thermo-coupled rigid-viscoplastic finite element method and the currently developed microstructural evolution system which includes semi-empirical equations suggested by different research groups were used together to form an integrated system of process and micro- structure simulation of hot rolling. The distribution and time histroy of the momechanical variables such as temperature, strain, strain rate, and time during pass and between passes were obtained from the finite element analysis of multipass hot rolling processes. The distribution of metallurgical variables were calculated on the basis of instantaneous thermomechanical data. For the verification of this method the evolution of microstructure in plate rolling and shape rolling was simulated and their results were compared with the data available in the literature. Consequently, this approach makes it possible to describe the realistic evolution of microstructure by avoiding the use of erroneous average value and can be used in CAE of multipass hot rolling.

Chaotic analysis of tool wear using multi-sensor signal in end-milling process

Abstract: Ever since the nonlinearity of machine tool dynamics was established, researchers attempted to make use of this fact to devise better monitoring, diagnostics and control system, which were hitherto based on linear models. Theory of chaos which explains many nonlinear phenomena comes handy for furthering the analysis using nonlinear model. In this study, measuring system will be constructed using multi-sensor (Tool Dynamometer, Acoustic Emission) in end milling process. Then, it will be verified that cutting force is low-dimensional chaos by calculating Lyapunov exponents. Fractal dimension, embedding dimension. And it will be investigated that the relation between characteristic parameter calculated from sensor signal and tool wear.

Electrical discharge machining of $TiC/Al_2O_3$ Ceramic Composite

Abstract: Die sinking electrical discharge machining(EDM) was conducted for ceramic composite of 33 weight percent TiC based on AIO ceramic matrix according to the change of current and duty factor(DF) Material removal rate(MRR) was increased as the current and the duty factor increased, but better surface mor-pholoty was obtained in the region of lower current and duty factor From the scanning electron microscopy(SEM) photographs and the energy dispersive X-ray spectroscopy(EDX) of the EDMed surface, EDM trace formed by one discharge spark was analyzed Although the bending strength after EDM was highly decreased, reliability obtained by weibull analysis was increased twice The bending strength was recovered or more by barrel polishing after EDM From the FEM analysis of temperature for one spark, the possible melting region of AIOand TiC was obtained

유도탄의 초기 구속력이 발사안정에 미치는 영향

Abstract: 【This paper presents results on dynamic analysis of the missile initial motion arising from the missile detent force. Using ADAMS (Automatic Dynamic Analysis of Mechanical Syatem) software, a non- linear46-DOF (Degree of Freedom) model is developed for the launcher system including missile and lunch tube contact problem. From the dynamic analysis, it is found that initial angular velocity of the missile incre- ases when the missile detent force increases and also when rocket exhaust plume is taken into account. To achieve the missile launching stability, it needs to reduce the missile initial detent force and exhaust plume area of the lancher. Results of the dynamic analysis on the system natural frequency agree well with those obtained from experimental modal tests. The overall results suggest that the proposed method is a useful tool for prediction of initial missile stability as well as design of the missile launcher system.】

Induction Heating of a Billet for Semi-Solid Forging

Abstract: Semi-solid forging is a compound forging technology to develop conventional forging process. Among several steps of semi-solid forging process, the heating step of a billet prior to semi-solid forging step is necessarily required to obtain globular microstructure. For the forming operation to work properly, it is also important to heat the billet uniformly for the uniformity of solid-liquid distribution. To satisfy these requirements, induction heating has been generally used for a long time. This paper presents the method to find heating condition and the temperature distribution inside a billet with a induction heating apparatus by comparing the computer simulation with experiment for aluminium alloys A12024 and A356.

A Study on the Design of Automotive Tire Profile for High Speed Durability Improvement

Abstract: New approach to determine thd design of automotive tire profile was introduced. In this study, design technology for tire profile was combined with a finite element method to improve high speed durability. Static and dynamic behavior analysis of new concept tire was compared with conventional tire profile. To obtain the improved tire performance, appropriate design values, ie. design methodology, section profile selection, material properties, are needed.

Automatic Offline Teaching of Robots for Ship Block Welding Applications

Abstract: Computer aided process planning and Offline programming are decisive factors in successful implementation of automated robotic production. However, conventional offline programming procedure has proven ineffective due to time-consuming teaching process for robot programming and due to inefficient system modeling. The paper presents an efficient procedure to semi-automatically generate robot job programs for ship block welding applications. In the research, the teaching positions are automatically determined by predefined rules which are functions of the type and the dimensions of the given welding section of ship block. And a sequence of robot movements and welding conditions such as welding type, welding current, welding speed, and welding torch orientation, are determined by use of Standard Program which is experimentally proved to work well for the welding wection group. Finally, a robot program for the welding section is generated automatically. Based on the algorithm, a offline automatic teaching software is developed. The paper presents also the algorithm and structure of the software.

The Design of Cutter profiles for Manufacturing Rotors of Screw Compressor

Abstract: The purpose of this paper is to design cutter profiles for manufacturing rotors of screw compressor, which are based on universal milling machine. The surface profile of screw rotor which is helicoidal is derived as brief equation through the coordinates transformation of the section perpendicular to rotor axis. And the equations of contact lines between a cutter and the surface profile of screw rotor are derived. The computer program which can analyze the equation of contact lines numerically and design the cutter profiles of screw rotor is made, and verified through measuring screw rotors which are menufactured as the designed cutter by the computer program.

Reducing the Non Grinding Time in Grinding Operations(2nd report) -Decision of Dressing Chance and Depth by the Direct Measurement of Grinding Wheel Surface-

Abstract: In general, grinding is one of the final machining processes which determines the surface quality of machined products. Since the ground surface is affected by the states of grains and voids on the grinding wheel surface, the wheel should be dressed before the machined surface deteriorates over a quality limit This paper describes a systematic approach to decide a proper dressing chance and an optimal dressing depth for the working grinding wheel. An eddy current sensor and a laser displacement sensor are used to measure the loading on the working wheel surface and the topography of the dressed wheel surface respec- tively. The dressing chance can be properly decided through the relational locus between the amount of handing and the machined surface roughness. An optimal dressing depth to guarantee the less wheel loss and the higher wheel surface quality is decided through the analysis of the variance of topography for the dressed wheel surface, which decreases at three different rates according to the accumulated dressing depth.

A nesting system for blanking or piercing of irregular-shaped sheet metal products

Abstract: This paper describes a nesting system of a computer-aided design of blanking and piercing for irregularly shaped sheet metal products. An approach to the system is based on knowledge-based rules. A nesting system is designed by considering several factors, such as utilization ratio which minimises the scrab for single or pairwise operation, bridge width, grain orientation and design requirements which maximise the strength of the part when subsequent bending is involve. Therefore this system which was implemented blank layout and strip layout module can carry out a nesting with a best utilization and a process planning for irregular shaped sheet metal products in single or pairwise operation and generate the blank layout and strip layout in graphic forms. Knowledges for a nesting and a process planning are extracted from plasticity theories, relevant references and empirical know-hows of experts in blanking industries. This provides its efficiency and effectiveness for nesting irregularly shaped sheet metal products.

Constraint satisfaction algorithm in constraint network using simulated annealing method

Abstract: We have already presented the constraint satisfaction algorithm which could solve the closed loop porblem in constraint network by using local constraint propagation, variable elimination and constraint modularization. With this algorithm, we have implemented a knowledge-based system (intelligent CAD) for supporting machine design interactively. In this paper, we present newer constraint satisfaction algorithm which can solve inequalities or under-constrained problems in constraint network, interactively and effi- ciently. This algorithm is a hybrid type of using both declarative description (constraint representation) and optimization algorithm (Simulated Annealing), simultaneously. The under-constrained problems are represented by constraint networks and satisfied completely with this algorithm. The usefulness of our algorithm will be illustrated by the application to a gear design.

A Variance Learning Neural Network for Confidence Estimation

Abstract: Multilayer feedforward networks may be applied to identify the deterministic relationship between input and output data. When the results from the network require a high level of assurance, consideration of the stochastic relationship between the input and output data may be very important. Variance is one of the effective parameters to deal with the stochastic relationship. This paper presents a new algroithm for a multilayer feedforward network to learn the variance of dispersed data without preliminary calculation of variance. In this paper, the network with this learning algorithm is named as a variance learning neural network(VALEAN). Computer simulation examples are utilized for the demonstration and the evaluation of VALEAN.

Laser Engraving of Plasma Sprayed Ceramic Coatings

Abstract: Ceramic-coated anilox roll for printing is resistant to corrosion and wear, and hence has enhanced life and quality. Laser engraving is used typically for machining holes to store ink in this roll. Since engraved hole size and shape are directly related to laser processing parameters, it is necessary to know the rela- tionships among these parameters. In this study, the parameters for engraving of ;oasma sprayed ceramic coatings with Nd:YAG laser were studied. Relationships between hole shape and processing parameters were analyzed. CrOceramic was found to be most suitable for Nd:YAG laser engraving. It was found that hole depth can be increased by using higher energy pulses. Effect of using different assistant gases was small to the final results. For better results, it was suggested to use a very stable laser with shorter pulses and higher pulse energy.

Impact Damage of CFRP Laminated Composites Subjected to Impact Loading

Abstract: An investigation was performed to study the impact damage in CFRP laminated composites subjected to impact loading. A finite element model has been developed for predicting the impact damage in laminated composite plates resulting from the ballistic impact. The finite element model was based on the higher-order shear deformation theory and was used to predict the initial intraply matrix cracking and the shape and size of interface delamination in laminated composites. Numerical simulation was performed and then the initiation of the matrix cracking and the shape and size of impacted induced delamination were predicted, and te results were compared with those of impact experiments with the same dimension and stacking sequences. A linear relationship holds between impact velocity and length and width of delamination. As impact velocity is increased, the increase of delamination length is highger than the increase of delamination width.,