ABSTRACT This research uses Taguchi Method, combined with Computer Aided Design and Manufacturing, processing the work piece into the saddle type. Next, diverse sampling methods are applied to measure the profile of surface with Coordinate Measuring Machine, with an aim to analyzing the main factors that influence cutting and seeking the last conditions for cutting out the curved surface; in addition, I will probe into the contribution rate of each factor which influences the precision during the process of measurement. The following results of this research are expected to be offered to the circles of vocational education as a basis of processing and measuring instruction. In this way, it will not take too much time to try and error and therefore, the practice course can be more efficient. 1. With reference to the documents that are focused on the factors affecting the cutting, this thesis, by means of Taguchi Method, shows that during the process of cutting saddle-type curved surface, the rotating speed of the axle is the most influential, whose contribution rate is 59.38%. 2. Since most documents are on circles, balls or cone objects, this thesis will aim at the measurement of saddle-type curved surface, with an intention to further the measuring technique. 3. It is found that as to the saddle-type curved surface, random sampling can get the profile of surface with minimal errors, and has no such trouble as using HSS or LHS, which can reduce time and cost. 4. In the experiment of Taguchi Method, according to analysis of variance, the influence of the sampling area is the greatest while the choice of sampling method only contributes to 3.46%.

In this dissertation, a numerical method to design a curved surface for accurately flank milling with a general tool of revolution is presented. Instead of using the ruled surface as the design surface, the flank millable surface can better match the machined surface generated by flank milling techniques, and provide an effective tool to the designer to control the properties and the specifications of the design surface. A method using the least squares surface fitting to design the flank millable surface is first discussed. Grazing points on the envelope of the moving tool modeled by the grazing surface are used as the sample points and a NURBS surface is used to approximate the given grazing surface. The deviation between the grazing surface and the NURBS surface can be controlled by increasing the number of the control points. The computation process for this method is costly in time and effort. In engineering design, there is a need for fast and effortless methods to simplify the flank millable surface design procedure. A technique to approximate the grazing curve with NURBS at each tool position is developed. Based on the characteristics of the grazing surface and the geometries of the cutting tool, these NURBS representations at a few different tool positions, namely at the start, interior and end, are lofted to generate a NURBS surface. This NURBS surface represents the grazing surface and is treated as the design surface. Simulation results show that this design surface can accurately match the machined surface. The accuracy of the surface can be controlled by adding control points to the control net of the NURBS surface. A machining test on a 5-axis machine was done to verify the proposed flank millable surface design method. The machined surface was checked on a CMM and the obtained results were compared with the designed flank millable surface. The comparison results show that the machined surface closely matches the design surface. The proposed flank millable surface design method can be accurately used in the surface design.

In this dissertation, a numerical method to design a curved surface for accurately flank milling with a general tool of revolution is presented. Instead of using the ruled surface as the design surface, the flank millable surface can better match the machined surface generated by flank milling techniques, and provide an effective tool to the designer to control the properties and the specifications of the design surface. A method using the least squares surface fitting to design the flank millable surface is first discussed. Grazing points on the envelope of the moving tool modeled by the grazing surface are used as the sample points and a NURBS surface is used to approximate the given grazing surface. The deviation between the grazing surface and the NURBS surface can be controlled by increasing the number of the control points. The computation process for this method is costly in time and effort. In engineering design, there is a need for fast and effortless methods to simplify the flank millable surface design procedure. A technique to approximate the grazing curve with NURBS at each tool position is developed. Based on the characteristics of the grazing surface and the geometries of the cutting tool, these NURBS representations at a few different tool positions, namely at the start, interior and end, are lofted to generate a NURBS surface. This NURBS surface represents the grazing surface and is treated as the design surface. Simulation results show that this design surface can accurately match the machined surface. The accuracy of the surface can be controlled by adding control points to the control net of the NURBS surface. A machining test on a 5-axis machine was done to verify the proposed flank millable surface design method. The machined surface was checked on a CMM and the obtained results were compared with the designed flank millable surface. The comparison results show that the machined surface closely matches the design surface. The proposed flank millable surface design method can be accurately used in the surface design.

Today there is a great need for communication between people and even between things, using systems onboard e.g. aircraft, cars, ships and satellites. As a consequence, these communications needs require antennas mounted on or integrated in the surfaces of different vehicles or platforms, i.e. conformal antennas. In order to ensure proper operation of the communication systems it is important to be able to determine the characteristics of these antennas. This thesis is about the analysis and design of conformal antennas using high frequency asymptotic methods. Commonly used eigenfunction solutions or numerical methods such as FDTD, FEM or MoM are difficult to use for arbitrarily shaped electrically large surfaces. However, the high frequency approximation approach together with an accurate ray tracing procedure offers a convenient solution for these surfaces. The geodesics (ray paths) on the surfaces are key parameters in the analysis and they are discussed in detail. In the first part of the thesis singly and doubly curved perfectly electrical conducting (PEC) surfaces are studied, with respect to the mutual coupling among aperture type elements. A synthesis problem is also considered where the effect of the mutual coupling is taken into account. As expected, the mutual coupling must be included in the synthesis procedure to be able to realize the prescribed pattern, especially in the shaped main lobe. Furthermore, the polarization of the antenna elements is very important when considering antennas on generally shaped surfaces. For such antennas the polarization must most likely be controlled in some way for a proper function. For verification of the results two experimental antennas were built at Ericsson Microwave Systems AB, Mölndal, Sweden. The first antenna is a circular cylinder with an array of rectangular waveguide fed apertures and the second antenna is a doubly curved surface (paraboloid) with circular waveguide fed apertures. It is found that it is possible to obtain very accurate results with the asymptotic method when it is combined with the Method of Moments, i.e. a hybrid method is used. The agreement compared to measurements is good at levels as low as –80 dB in many cases. The second part of the thesis is about the development of a high frequency approximation for surface field calculations on a dielectric covered PEC circular cylinder. When using conformal antennas in practice they have to be covered with a radome for protection and with the method developed here this cover can be included in the analysis. The method is a combination of two different solutions, one valid in the non-paraxial region of the cylinder and the other is valid in the paraxial region. The method is verified against measurements and reference results obtained from a spectral domain moment method code. / QC 20100616

Surface mean pressures, oil flow visualization, and 3-velocity-component laser-Doppler velocimeter measurements are presented for a turbulent boundary layer of momentum thickness Reynolds number, 7300 and thickness delta over two circular based axisymmetric bumps of height H = delta and 2delta and one rectangular based symmetric bump of H = 2delta. LDV data were obtained at one plane x/H ¥ 3.26 for each case. Complex vortical separations occur on the leeside and merge into large stream-wise mean vortices downstream for the 2 axisymmetric cases. The near-wall flow (y+ < 90) is dominated by the wall. For the axisymmetric cases, the vortices in the outer region produce large turbulence levels near the centerline and appear to have low frequency motions that contribute to turbulent diffusion. For the case with a narrower span-wise shape, there are sharper separation lines and lower turbulence intensities in the vortical downstream flow. Fine-spatial-resolution LDV measurements were also obtained on half of the leeside of an axisymmetric bump (H/delta = 2) in a turbulent boundary layer. Three-dimensional (3-D) separations occur on the leeside with one saddle separation on the centerline that is connected by a separation line to one focus separation on each side of the centerline. Downstream of the saddle point the mean backflow converges to the focal separation points in a thin region confined within about 0.15delta from the local bump surface. The mean backflow zone is supplied by the intermittent large eddies as well as by the near surface flow from the side of the bump. The separated flow has a higher turbulent kinetic energy and shows bimodal histograms in local and U and W, which appear to be due to highly unsteady turbulent motions. By the mode-averaged analysis of bimodal histograms, highly unsteady flow structures are estimated and unsteady 3-D separations seem to be occurring over a wide region on the bump leeside. The process of these separations has very complex dynamics having a large intermittent attached and detached flow region which is varying in time. These bimodal features with highly correlated local u and w fluctuating motions are the major source of large Reynolds stresses local u2, w2 and -uw. Because of the variation of the mean flow angle in the separation zones, the turbulent flow from different directions is non-correlated, resulting in lower shearing stresses. Farther from the wall, large stream-wise vortices form from flow around the sides of the bump. / Ph. D.

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