This paper describes a research work on the development of computer-aided design system for deep drawing & ironing of a high pressure vessel. An approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, handbook, experimental results and empirical knowledge of field experts. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FEM software, DEFORM and ANSYS, to form a useful package. It is composed of five main modules, which are calculation of product thickness, input, production feasibility check, process planning, and autofrettage process modules and two submodules, which are folding check and process variable verification submodules. Programs for the system have been written in AutoLISP on the AutoCAD 2000 using personal computer. The developed system makes it possible to design and manufacture large high pressure vessel requiring D.D.I. process more efficiently.

High-speed machining is one of the most effective technology to enhance productivity especially for hardened die material. High-speed machining can give great advantages for machining of dies and molds. But selection of machining condition is very difficult because of complicated machining mechanism. This paper presents the selection of machining condition in high-speed machining of STD11. Depth of cut, feed rate and spindle revolution are control factors. The effect of the control factors on surface roughness and machining error in Z-direction is discussed to improve machining accuracy.

Productivity and machining performance can be improved by cutting analysis including cutting force prediction, surface error prediction and machining stability evaluation. In order to perform cutting analysis, cutting force coefficients database have to be constructed. Since cutting force coefficients are dependent on cutting condition in the existing research, a large number of calibration tests are needed to obtain cutting force coefficients, which makes it difficult to build the cutting force coefficients database. This paper proposes a generalized method for constructing the cutting force coefficients database us ins cutting-condition-independent coefficients. The tool geometry and workpiece material were considered as important components for database construction. Cutting force coefficients were calculated and analyzed for various helix and rake angles as well as for several workpiece. Furthermore, the variation of cutting force coefficients according to tool wear was analyzed. Tool wear was found to affect tool geometry, which results in the change of cutting force coefficients.

It was already proven experimentally that the laminated grinding wheel is superior to the general grinding wheel in the productivity of grinding. However, it can't be guaranteed when the workpiece material is cemented carbide. Because of its extreme hardness, the grinding wheels made up of super-abrasives are used for grinding it. So, to investigate the performance in extremely hard materials grinding using super-abrasive grinding wheels, the surface roughness characteristics of cemented carbide ground by the laminated diamond wheels are studied experimentally. Through this study, it is found that the similar surface roughness characteristics, those were found in the studies on the laminated aluminum oxide wheels, are still available.

The first stage rotating blade of industrial gas turbine is one of the components that is normally run in exposed state at the highest temperature of the combustion gas stream. For this reason superior materials and advanced cooling technology are required to allow higher heat resisting characteristics of the component. The 1st stage blade of a selected commercial gas turbine blade made of directionally solidified Ni-based superalloy has a row of cooling holes on its trailing edge. In most cases, minor cracks have been found at some of the root cooling holes after one cycle operation (24,000 hrs) or even shorter operation time because of the high temperature gradient and the frequently alternating thermal stress. In the repair process, unfortunately, it is usually very difficult to get rid of the damage due to the fact that cracks are initiated at the root cooling hole and propagated deep into the hole. In this study, the feasibility of removing the sidewall cracks in the hole by utilizing EDM drilling has been investigated. Also the criteria of surface integrity for EDM drilling were established to achieve high quality repair as well as machining accuracy.

In most shipyards, the measurement of 3-dimensional relative position of pipes should be connected in the block depends on the manual operation. It results a very tedious and inefficient procedure, thus the proper measurement system is needed to improve productivity and accuracy. This paper describes the development of pipe measurement system including system concepts, measuring procedures, system calibration, and its accuracy and productivity. And also, the possibility and things to be improved for application in shipyard are discussed in this paper.

It is very important to inspect the color of printed texture in the textile process. The standard colorimetric system used for the recognition of the color in the textile industry. It uses XYZ color system defined by CIE (Commission Internationale de 1Eclairage), but is too expensive. Therefore, in this paper, we propose a color inspection system of the printed texture using a color scanner. Because the scanner uses RGB value for color, it is necessary the mapping from RGB to XYZ. However, the mapping is not simple, and the scanner has even positional deviation because of the geometric characteristics. To transform from RGB to XYZ, we used a NN (neural network) model and also compensated the positional deviation. In real experiments, we could get fairly exact XYZ value from the proposed color inspection system in spite of using a color scanner with large measuring area.

In this paper, a technical method for removing the solder from PCBs has been proposed to simplify the pulverizing process and to get higher quality of materials for recycling of the electronic parts in the Printed Circuit Boards (PCBs). There are several techniques to remove the solder from PCB, such as physical and chemical method, vibration, suction and blowing and so on. Among them, the suction technique turned out the best method by investigation. In the suction method, there are three variables for removing the solder. They are a temperature of the thermal wire, a velocity of moving PCB and a gap between PCB and thermal wire. To find the optimal variables for the system, an experiment has been conducted by a trial and error method. The optimal variables were found $220^{\circ}C$ of temperature, 11.58mm/s of velocity, 10mm of gap (A gap between suction hole and bottom of PCBs is 5mm). The result of the experiment shows that 50% of the solder were removed.

The development of a fast, accurate, and inexpensive position-controlled pneumatic actuator that may be applied to a variety of practical positioning applications with various external loads is described in this paper. A novel modified pulse width modulation (MPWM) valve pulsing algorithm allows on/off solenoid valves to be used in place of costly servo valves. A comparison between the system response of standard PWM technique and that of the novel modified PWM technique shows that the control performance is significantly increased. A state feedback controller with position, velocity and acceleration feedback is successfully implemented as the continuous controller. Switching algorithm of control parameter using learning vector quantization neural network (LVQNN) is newly proposed, which estimates the external loads of the pneumatic actuator. The effectiveness of the proposed control algorithms are demonstrated through experiments with various loads.

This paper presents the experiments on the approximation of a hydraulic servo system using a real time recurrent neural networks (RTRN) with time varying weights. In order to verify the effectiveness of the RTRN algorithm in hydraulic servo system, we design the experimental hydraulic system and implemented the real time approximation of system output. Experimental results show that approximated output of the RTRN well follows the position trajectory of the electro-hydraulic servo system. And also it is verified that the 2-D RNN can be implemented in sampling time even though high sampling frequency experimentally.

A new mechanical probe for 3-D feature measurement on coordinate measuring machines (CMMs) is presented. The probe is composed of the contact stylus and the three-component force sensor. With the stylus mounted on the force sensor, the probe can not only measure 3-D features, but also detect contact force acting on the stylus tip. Furthermore, the probing direction and the actual contact position can be determined by the relationship among three components of contact force to be detected. In this paper, transformation matrix representing the relationship between the external force acting on the stylus tip and the output voltages of measurement gauges is derived and calibrated. The prototype of probe is developed and its availability is investigated through the experimental setup for calibration test of the probe. A series of experimental results show that the proposed probe can be an effective means of improving the accuracy of touch probing on CMM.

This research describes a image-processing technique for the scratch detecting algorithm for ITO coated glass. We use the modified logical thresholding method (called adaptive logical thresholding method) for binarization of gray-scale glass image. This method is useful to the algorithm for detecting the scratch of ITO coated glass automatically without need of any prior information of manual fine-tuning of parameters.

To analyze the applications of all types of mechanical systems, general purpose analysis programs have been developed and commercialized. However, it is customary to develop and use customized programs even though they sometimes require more work than a general purpose program. A customized program is simplified to adapt to a particular application from the beginning, is designed for small computers, and developed with hardware-in-the-loop in mind so it can be applied effectively. By adding design knowledge and bundling know-how to an analysis program, analysis time can be reduced. And because an analysis has to work in conjunction with other analysis programs, a proprietary program that the user can easily modify can be useful. In this thesis, a multi-body dynamics analysis system is presented using one of the most useful programming techniques, object-oriented concept. The object-oriented concept defines a problem from the physical world as an abstract object, an abstract model. The object becomes encapsulated with the data and method. Simulation is performed using the object's interface. It is then possible for the user and the developer to modify and upgrade the program without having particular knowledge of the analysis program. The method presented in this thesis has the following advantages. Since the mechanical components of the multi-body system converts independent modeling into a class, the modification, exchange, distribution, and reuse of elements are increased. It becomes easier to employ a new analysis method and interface with other S/W and H/W systems. To employ a new analysis method, there is no need to modify elements of the main solver and the Library. In addition, information can be communicated to each object through messaging. It makes the modeling of new elements easier using inheritance. When developing a S/W for the computer simulation of physical system, it is reasonable to use object-oriented modeling. Also, for multi-body dynamics analysis, it is possible to develop a solver that is user-oriented.

In this study we do for the thing to develop automatic geometry design program of a mechanical element that we have used in CAD/CAM system. The program, which produces automatically three-dimensional surface and a solid model that have been used in CAD/CAM system, widely create automated two and three-dimensional model to by inputting several necessaries for a design, fur the design element. It is emphasized if you are just a beginner having only basic knowledge of the mechanical engineering, you might be able to design easily a three-dimensional model. The software to be used to develop automatic geometry design program is visualLISP to be a developer program of AutoCAD.

This paper presents the impact minimization of a biped robot by using genetic algorithm. In case we want to accomplish the designed plan under the special environments, a robot will be required to have walking capability and patterns with legs, which are in a similar manner as the gaits of insects, dogs and human beings. In order to walk more effectively, studies of mobile robot movement are needed. To generate optimal motion for a biped robot, we employ genetic algorithm. Genetic algorithm is searching for technology that can look for solution from the whole district, and it is possible to search optimal solution from a fitness function that needs not to solve differential equation. In this paper, we generate trajectories of gait and trunk motion by using genetic algorithm. Using genetic algorithm not only on gait trajectory but also on trunk motion trajectory, we can obtain the smoothly stable motion of robot that has the least impact during the walk. All of the suggested motions of biped robot are investigated by simulations and verified through the real implementation.

The purpose of this paper is to establish an effective inspection system by using OMM (On-Machine Measurement) system based PC-NC. This system can reduce manufacturing lead time because part is inspected each process. Inspection process planning is accomplished by determining the number of measuring points, their location, measuring path using fuzzy logic, Hammersley method, traveling salesperson problem. Inspection with contacted sensor improve quality as inspection feature is developed to based machining feature. This method is tested by simulation and experiment, then analyzed measuring data and geometry tolerance.

In the present work, the effect of plasma treatment of aluminum on the fracture toughness of CFRP/aluminum composites was investigated. The surface of the aluminum was treated by a DC plasma. The plasma treatment was carried out at volume ratio of acetylene gas to nitrogen gas of 5:5 and the treatment time used was 30 sec. Cracked lap shear specimens of aluminum/CFRP composites were made using secondary bonding procedure. Fracture toughness of aluminum/CFRP composites was determined using the work factor approach. Then, the fracture toughness of plasma-treated aluminum/CFRP composites was compared with that of untreated aluminum/CFRP composites. The results showed that the fracture toughness of plasma-treated aluminum/CFRP composites was about 50 % higher than that of untreated aluminum/CFRP composites.

The object of this work is to develop an assessment system for pipeline integrity. The internal algorithm and the database of the system are described in this paper. The system consists of four module applications; the effect of corrosion in pipeline, crack, SCC (stress corrosion cracking) and fatigue module. The database of the system is separated to mainly four parts; geometry of pipeline, material properties, boundary condition and general properties. This system may give a guideline for maintenance and modifications.

Hydrostatic bearings are widely used in precision machines due to their high motion guide accuracy, low friction and high load carrying capacity. It is very useful to estimate the moving characteristics of hydrostatic bearings in the design stage. A new method is suggested for the analysis of fluid film in hydrostatic bearings. A combined mesh of 8 node solid elements with negligible deformation resistance and spring-dashpot elements is used in conjunction with the user subroutine of ABAQUS to represent the fluid film. The mesh can be used to capture the deformation of the bearing structure as well as the varying properties of fluid film. Analysis results from the finite element model are compared with theoretical solutions, results from FLUENT analysis and some previous works. With this method, static and dynamic analyses of the system containing the bearings can be performed efficiently.

A method of the shape design sensitivity analysis based on the boundary integral equation formulation is presented for two-dimensional inhomogeneous thermal conducting solids with multiple domains. Shape variation of the external and interface boundary is considered. A sensitivity formula of a general performance functional is derived by taking the material derivative to the boundary integral identity and by introducing an adjoint system. In numerical analysis, state variables of the primal and adjoint systems are solved by the boundary element method using quadratic elements. Two numerical examples of a compound cylinder and a thermal diffuser are taken to show implementation of the shape design sensitivity analysis. Accuracy of the present method is verified by comparing analyzed sensitivities with those by the finite difference. As application to the shape optimization, an optimal shape of the thermal diffuser is found by incorporating the sensitivity analysis algorithm in an optimization program.

The modular self-wiping co-rotating twin screw extruder (SWCOR) has become the most important of twin screw machines. Screw design is one of the most important factors in determining performance of screw extruder. The screw flight and screw channel geometry of SWCOR is determined by the screw diameter, centerline distance, helix angle, and flights number. The maximum allowable throughput rate on a twin screw extruder is determined by a combination of free volume and available specific torque. In this paper we designed geometrical parameters of extruder screw and presented optimal specific torque value in K=1.55, and then developed screw design program for the screw cutting by the use of JAVA API in the twin screw extruder.

A Web-based dynamic simulation system, called O-DYN, for multibody dynamic systems is developed. All the interfaces of the system are accessible via Web browsers, such as Netscape or Explorer. The system uses a block-diagram type O-DYN/Modeler developed in JAVA Applet as a preprocessor. The O-DYN postprocessor composed of O-DYN/Plotter and O-DYN/Animator is developed in JAVA Applet. The O-DYN/Solver for predicting the dynamic behavior is run on the server. Anyone who wants to simulate the dynamics of multibody systems or share results data can access the analysis system over the Internet regardless of their OS, platform, or location.

In this study, in order to investigate a modeling technique of the structure with bolted joints, four kinds of finite element model are introduced; a solid bolt model, a coupled bolt model, a spider bolt model, and no bolt model. All proposed models take account on prestrained effect and contact behavior of flanges to be joined. Among these models, a solid bolt model, which is modeled by using a 3-D solid element and a surface-to-surface contact element between the head/nut and the flange interfaces, has the best accurate responses compared with the experimental results. In addition, coupled bolt model, which couples the degree of freedom between the head/nut and the flange, shows the best effectiveness and usefulness in view of computational time and memory usage. Finally, the bolt model proposed here is adopted for structural analysis of a large diesel engine of a ship consisting of several parts which is connected by long stay bolts.

By the localization of electro-chemical dissolution region, we succeeded in a few micrometer size hole drilling on stainless steel with the radial machining gap of about 1 ${\mu}{\textrm}{m}$. Tens of nanosecond duration voltage pulses were applied between WC micro-shaft and stainless steel in the 0.1 M $H_2SO_4$ solution. Pt balance electrode was used to drill the high aspect ratio micro-hole without generation of Cr oxide layer on the machined surface. The effects of applied voltage, pulse duration, and pulse period on localization distance were investigated according to machining time. We suggested the taper reduction technique especially brought up on blind-hole machining. High quality micro-holes with 8 ${\mu}m$ diameter with 20 ${\mu}m$ depth and 12 ${\mu}m$ diameter with 100 ${\mu}m$ depth were drilled on 304 stainless steel foil. The various hole shapes were also produced including stepped holes and taper free holes.