bluuebunny/crossref_metadata_2025 huggingface dataset:
High-Accuracy Machining of Thin-Walled Workpiece by Non-Rotational Tool-Analysis of Machining Accuracy Based on Deflection of Tool and Workpiece Using FEM-
Authors: Iwabe Hiroyasu ,   Graduate School of Science and Technology, Niigata University, Ikarashi 2-nocho, Nishi-ku, Niigata, Japan, Matsuhashi Hideaki , Akutsu Hayato , Shioya Tomoyuki , Takao Hitoshi ,   Isuzu Motor Ltd., 8 Tsuchidana, Fujisawa, Kanagawa, Japan,   NSK Ltd., 78 Toriba-machi, Maebashi, Gunma, Japan,   Panasonic Co. Ltd., 1-5 Sakuragaoka, 5-Chome, Kusatsu, Japan
Published: April 2016

In this paper, the FEM analysis and the machining of a workpiece using a non-rotational tool are attempted in order to produce a highly accurate surface on a thin wall. Also, the machining accuracy of the thin wall produced by the non-rotational tool is compared with that produced by an end mill. The main results are as follows. (1) FEM models for the tool and workpiece are made and the machining accuracy is predicted based on the deflection analysis using FEM due to the cutting force. (2) The tendency of the shape of machined surface is almost coincident with that of the predicted shape, so the propriety of the method of analysis is verified. (3) Both dimensional and shape error on the inside and outside surfaces of the workpiece produced by the non-rotational tool prove larger than the predicted values. Although the shape error proved a little larger than the predicted value, the target value of 5μm was achieved. (4) It is shown that the dimensional error due to under cutting decreases with the decrease in the radius of the tool edge. And also, on and after the second cutting process, the cutting at the commanded depth of cut was achieved even if the micro depth of cut.
Machining Porous Calcium Polyphosphate Implants for Tissue Engineering Applications
Authors: Rouzrokh Amir ,   Department of Mechanical & Mechatronics Engineering, University of Waterloo, 200 University Ave West, Waterloo, Ontario N2L 3G1, Canada, Yi-HsuanWei Christina , Erkorkmaz Kaan , Pilliar Robert M. ,   Faculty of Dentistry, Institute of Biomaterials & Biomedical Engineering, University of Toronto, 124 Edward Street, Toronto, Ontario M5G 1G6, Canada
Published: April 2016

The emergence of biodegradable bone substitute materials promises new breakthroughs in the field of tissue engineering. However, such materials like Hydroxyapatite and Calcium Polyphosphate (CPP) are relatively new in the world of manufacturing. Reliable processing data is required in order optimize the production of biomedical implants made from these materials. This paper investigates the machining characteristics of CPP.Milling studies are conducted to determine the suitable cutting speeds and conditions which produce accurately machined porous surfaces. This is required for the CPP material to fulfill its biomedical function. A force model is also developed by identifying the cutting coefficients, which helps to predict and limit the machining forces, thereby avoiding unwanted chipping of the implant. Results of these studies have been successfully incorporated into planning the 5-axis machining of a CPP construct for a tissue engineered tibial-plateu (lower knee joint) implant.
Precision Mechanisms Based on Parallel Kinematics
Authors: Oiwa Takaaki ,   Department of Mechanical Engineering, Faculty of Engineering, Shizuoka University, 3-5-1 Johoku, Hamamatsu, Shizuoka 432-8561, Japan
Published: April 2016

The parallel kinematic mechanism has been applied to simulators and robots for its high speed or multiple degrees of freedom. In recent years, however, it has begun to be used for precision mechanisms, such as machine tools, measuring machines, or fine-motion mechanisms. This review outlines the parallel kinematic mechanism and compares it with the conventional orthogonal coordinate mechanism to describe its nature and characteristics as a precision mechanism. It also introduces some cases in which the parallel kinematic mechanism is applied to fine motion mechanisms and three-dimensional coordinate measuring machines in addition to machine tools and robots. Finally, it discusses the problems and future of this parallel kinematic mechanism.
Kinematic Analysis and Design of 3-RPSR Parallel Mechanism with Triple Revolute Joints on the Base
Authors: Takeda Yukio ,   Department of Mechanical Sciences and Engineering, Tokyo Institute of Technology, 2-12-1 O-okayama, Meguro-ku, Tokyo 152-8552, Japan, Xiao Xiao , Hirose Kazuya , Yoshida Yoshiki , Ichiryu Ken ,   Monozukuri Mechatro Research Laboratory, Kikuchi Seisakusho Co., Ltd., 2161-12 Miyama-cho, Hachioji-shi, Tokyo 192-0152, Japan
Published: April 2016

The present paper proposes a new six-DOF parallel mechanism with three connecting chains. This mechanism can have a large angle of orientation of the output link. Joints in each connecting chain are arranged from the base in order of revolute, prismatic, spherical and revolute joints. All three revolute joints on the base are coaxial. With this structure, the output link can perform a full rotation around the vertical axis. The orientation capability of this mechanism is demonstrated. Equations for displacement analysis and the Jacobian matrix are derived. A design and prototype of this mechanism for a pipe-bender are shown.
Calibration Method for a Parallel Mechanism Type Machine Tool by Response Surface Methodology –Consideration via Simulation on a Stewart Platform Mechanism–
Authors: Yachi Hiroshi ,   Graduate School of Natural Science and Technology, Kanazawa University, Kakuma-machi, Kanazawa-shi, Ishikawa 920-1192, Japan, Tachiya Hiroshi
Published: April 2016

This paper proposes a calibration method for parallel mechanisms usingResponse Surface Methodology. This method is a statistical approach to estimating an unknown input-output relationship using a small set of efficient data collected on an intended system. Although identifying locations causing positional errors in a parallel mechanism and precisely measuring the position and posture of the output point are difficult, the proposed calibration method based onResponse Surface Methodologyaims to compensate for positional and postural errors, without indentifying the locations causing these errors, by using a small yet efficient measurement data set. This study analyzes the effectiveness of the method we propose by applying it to a Stewart platform, which is a typical spatial 6-DOF parallel mechanism.
A Gravity-Powered Mechanism for Extending the Workspace of a Cable-Driven Parallel Mechanism: Application to the Appearance Modelling of Objects
Authors: Gosselin Clément ,   Laboratoire de Robotique, Département de Génie Mécanique, Université Laval Québec, 1065 avenue de la médecine, Québec, Qc, Canada, Bouchard Samuel
Published: April 2016

This paper presents a gravity-powered passive onedof mechanism used to extend the workspace of a six-degree-of-freedom cable-driven parallel mechanism. The passive mechanism is mounted on the platform of the cable-driven mechanism in order to increase the useful workspace of the system. The application that stimulated the development of the mechanism is a system for capturing the light field of an object to reproduce the appearance of artefacts. The concept is based on a six-degree-of-freedom (6-dof) cable-driven parallel mechanism that is used to move a high resolution camera around the object. The geometry of the mechanism is optimized in order to cover a workspace defined as a hemisphere centred on the object.
Effect of Nozzle Shape on Micro-Cutting Performance of Thin Metal Sheet by Pulsed Nd: YAG Laser
Authors: Okamoto Yasuhiro ,   Graduate School of Natural Science and Technology, Okayama University, 3-1-1 Tsushimanaka, Kita-ku, Okayama 700-8530, Japan, Uno Yoshiyuki , Suzuki Hiroshi
Published: April 2016

In precision laser cutting, the generation of dross can be reduced by using a high-pressure assist gas flow. However, our previous work made it clear that, for a conventional convergent nozzle, the pressure of assist gas on a workpiece is reduced to less than half of the cylinder gas pressure because of the generation of Mach Shock Disk. Furthermore, the removal of material from the micro-kerf becomes difficult since the fluidity of molten material is low in the narrow kerf. Therefore, nozzle shapes were investigated to improve the removal of material from the micro-kerf, and their effect on the fine cutting of a thin metal plate using a pulsed Nd: YAG laser was also discussed. The height of dross could be reduced by using a Laval throat nozzle with an initial expansion zone compared with that for a straight throat nozzle. The pressure on the workpiece was greater, and the straightness of the assist gas flow was excellent when the Laval throat nozzle with the initial expansion zone was used. Moreover, it was confirmed that the molten material could be effectively removed from the micro-kerf even at a middle cylinder gas pressure of around 600 kPa. Therefore, the Laval throat nozzle with the initial expansion zone can be used for fine cutting owing to its reduction of dross.
Development of a Forging-Type Rapid Prototyping System (Tool Path Generation Considering Deformation Process)
Authors: Asakawa Naoki ,   Faculty of Mechanical Engineering, Institute of Science and Engineering, Kanazawa University, Kakuma-machi, Kanazawa, Ishikawa 920-1192, Japan, Tanaka Hidetake ,   Department of Mechanical Engineering, Nagaoka University of Technology, 1603-1 Kamitomioka, Nagaoka, Niigata 940-2188, Japan
Published: April 2016

This study deals with the development of a CAM system that considers the deforming process for a forgingtype rapid prototyping system. An industrial robot that has high degrees of freedom is employed to handle the hammering unit. A special CAM system suitable for the hammering work is developed using parametric curve interpolation. The tool path is generated considering continuity in order to avoid fracture or breakage. Using the system, metal hammering experiments are carried out. The system successfully shaped workpieces according to the generated path. The experimental results confirm the ability of the system to improve, owing to the parametric curve interpolation, forming properties.
Image Measurement on Curvature Around Seam Line for Motion Control of Laser Welding Robot
Authors: Matsushita Akihiko ,   Graduate School of Information Science and Technology, Hokkaido University, North 14 West 9, Sapporo 060-0814, Japan, Hokari Takuya , Kaneko Shun’ichi , Ohfuji Hitoshi , Fukuda Kaoru ,   School of Engineering, Hokkaido University, North 14 West 9, Sapporo 060-0814, Japan,   SANKO-STEEL, Zenibako 3-515-1, Otaru-shi 047-0261, Japan
Published: April 2016

Automating robot laser welding requires that the laser irradiation direction and laser focus positioning influencing welding strength are controlled precisely. Since the edge of the welded object can be transformed on processing by such as cutting, bending and grinding, the direct measurement is necessary to control the laser irradiation. Especially, the information of the curvature around the seam line is important because the precision influences the molten direction. The image measurement for curvatures around the seam line derives a three-dimensional approximation of the welded object’s curved surface from core-lines of images of the laser for measurement. By results of experiments the effectiveness and the limitations of our proposal are demonstrated.
Special Issue on Micro/Nano Machining – Processes, Systems and Control
Authors: Rahman Mustafizur
Published: April 2016

In recent years, the trend in miniaturization of products is pervasive in areas such as information technology, biotechnology, environmental and medical industries. Micro-machining is the key supporting technology that has to be developed to meet the challenges posed by the requirements of product miniaturization and industrial realization of nanotechnology. Micro-machining techniques can be carried out by techniques based on energy beams (beam-based micro-machining) or solid cutting tools (tool-based micro-machining). Beambased micro-machining have some limitations due to poor control of 3D structures, low material removal rate and low aspect ratio. Moreover, these processes require special facilities and the maximum achievable thickness is relatively small. Some of these limitations can be overcome by tool-based micro-machining techniques using ultra precision machine tools and solid tools used as cutting elements to produce the micro-features with well controlled shape and tolerances. Tool-based micro-machining techniques essentially include precision machining processes as turning, milling, grinding and electrical discharge machining (EDM), whereby material removal is done at the micron level. The advantages of such processes are that almost every material such as metals, plastics and semiconductors can be machined with no limitation in machining shapes. Recently, combinations of conventional material removal processes, such as turning and milling, have been hybridized with non-conventional machining processes like EDM and EDG to fabricate micro-structures with high dimensional accuracy. In order to achieve meaningful implementation of compound micro-machining techniques three important areas are required to be addressed. These are: development of machine tools capable of performing compound micro-machining (i.e. micro turning, micro milling, micro EDM, etc. on the same machine and setup), understanding of process physics to provide relevant background for modeling,measurement, identification of control parameters and application of feedback control in order to control compound and hybrid manufacturing processes and development of compound and hybrid processes. An integrated effort in these areas is needed for successful implementation of tool-based micro-machining. An attempt has been made in this special issue to highlight latest articles on these areas. I would like to express my sincere appreciation to the authors, reviewers and editors for their invaluable contributions for this issue.
Microscopic Textured Surfaces for Micro-Fluidic Applications
Authors: Garg Mayank ,   Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, 400 076, India, Agrawal Amit , Singh Ramesh K. , Joshi Suhas S.
Published: April 2016

Many attempts have been made to fabricate textured surfaces that imitate the configurations of naturally occurring surfaces, the most common being the hierarchical microstructure on a lotus leaf. In addition, numerical simulations have also been performed to evaluate limited variations in the configurations of the textured surfaces. However, in reality, the surfaces occurring in nature have numerous variations. In this work, an attempt is made to consider a few of these variations on a surface bearing micro-pillars used in a micro-channel. The variations in the surface texture geometry include a change in the orientation, height, and corner radius of micro-pillars. Numerical simulations are performed using CFD-based methods to evaluate the pressure drop across the micro-channels bearing the textured surfaces on their bottom face. It is observed that the surfaces bearing uniform, upright pillars offer the least resistance to fluid flow while flat surfaces offer the highest resistance. While the orientation of the pillars with respect to flow direction does not change the pressure drop significantly, the pillars with rounded edges and the pillars with larger standard deviations in their heights offer considerably more resistance to the flow of fluid than the uniformly upright pillars. This study will help designers to incorporate these variations in their surface design to obtain the desired results.
Design Concept and Structural Configuration of Advanced Nano-Pattern Generator with Large Work Area “ANGEL”
Authors: Yoshioka Hayato ,   Precision and Intelligence Laboratory, Tokyo Institute of Technology, 4259-G2-19 Nagatsuta, Midori-ku, Yokohama, Kanagawa 226-8503, Japan, Shinno Hidenori
Published: April 2016

Industrial demands for ultra-precision machining have rapidly increased in a wide range of industries, e.g., aerospace, semiconductors, optics, molds, etc. In particular, various structured surfaces with micro- and nano-sized patterns have recently been required for advanced science and engineering fields. In order to rationally meet such requirements, it is indispensable to develop an ultra-precision machine tool with both nanometer-level machining accuracy and a large machining area. In this paper, therefore, the design concept and structural configuration of a desirable ultra-precision machine tool are proposed based on a new design concept. The machine tool developed here has a perfect non-contact structure and achieves three-dimensional nano-machining over a wide area with nanometer spatial resolution.
Development of a Liquid Packaging Machine Positioning Control on Moving Film
Authors: Honma Katsumi ,   Yushin Co., Ltd., 964 Yanagawa-Shinden, Sanjo, Niigata 955-0002, Japan, Nakajima Shin-ichi ,   Niigata Institute of Technology, 1719 Fujihashi, Kashiwazaki, Niigata 945-1195, Japan
Published: April 2016

A liquid packaging machine produces liquid packaging bags from roll film by cooperatively controlling the vertical seal roller, horizontal seal roller, and cut roller. These rollers are driven separately by servomotors as a multi-axis servo mechanism. Positioning control on the moving film is essential to make bags of accurate size. To achieve accurate positioning without lowering productivity, we propose two control methods. One is a two-step velocity control of the horizontal seal roller. This method enables continuous and high speed production of bags of arbitrary size. The second is phase control, which determines the accuracy of the cutting position on the film according to the sealing position. Phase control changes the rotary phase difference of the horizontal seal roller and the cut roller by adjusting the high feeding velocity of the cut roller, or by adjusting the low feeding velocity of the cut roller. The control system developed was applied to a DANGANV liquid packaging machine.
Mechanical Design and Control of 3-DOF Active Scanning Probe Using Parallel Link Mechanism
Authors: Harada Takashi ,   Department of Mechanical Engineering, Faculty of Science and Engineering, Kinki University, 3-4-1 Kowakae, Higashioskaka, Osaka 577-8502, Japan, Dong Ke ,   Graduate School of Science and Engineering, Kinki University
Published: April 2016

A 3-DOF active scanning probe using a Parallel Link Mechanism (PLM) is proposed. It employs a small touching force control and can be used for small position sensing devices which works within sizes of few millimeters. The device is attached to the tip of coordinate measuring machines or numerical-control machine tools and used as a scanning probe. In this paper, the characteristics of the mechanism, optimum design, and a control system of the PLM are introduced. The kinematics and differential relations of the PLM are derived. An optimum design for the PLM is proposed as that in which the mechanism’s manipulability is equal in all directions. This implies that the force and position sensitivities of the PLM share an isotropic relationship. A prototype of the PLM is developed. The PLM is constructed on three voice coil motors that are vertically aligned on a base plate, and a sensing stylus is fixed on an end plate. Universal joints with ball bearings are developed for reducing the joint resistance. Position and force control methods for the scanning probe are introduced. For stable scanning motion, a disturbance observer-based mechanical impedance control is formulated. An experimental system for measuring the position of the probe using image processing is developed. It is found that the standard deviation of the positioning error along the z direction is less than 3 µm, whereas those along the x and y directions is larger because of the tilt of the end plate caused by alignment errors of the PLM’s mechanical parts.
Development of Micro Contact Detection Probe for Microhole Quality Control
Authors: Ogura Ichiro ,   Advanced Manufacturing Research Institute (AMRI), National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Namiki, Tsukuba, Ibaraki 305-8564, Japan, Okazaki Yuichi
Published: April 2016

The contact detection probe we propose for measuring microhole profiles uses a simple 1 DOF and optical fibers arranged in a cross-profile. When two contact balls - one on the lower end of a vertical beam and the other on the upper end - contact a microhole wall, the vertical beam rotates with the horizontal support beam at the center. An optical sensor measures measurement ball displacement, detecting contact. The probe was first balanced on a groove created to hold the probe by gravity alone. In this method, low contact force measurement is easily achieved. Based on Experimental results showed, however, that probe output was not stable with drift, failing to achieve desirable repeatability, so we glued both ends of the horizontal beamto the base. Simple contactmeasurement yielded repeatability exceeding 50 nm and resolution of 20 nm. Contact ball diameter measurement was implemented and experiments conducted to evaluate ball diameter. Testing the probe frequency response showed that the probe can scan measurement within a low 10 Hz input frequency. Profile measurement experiments and microhole diameter measurement demonstrated the effectiveness of this probe as on-machine measurement device for microholes.
Verification of Interim Check Method of CMM
Authors: Asano Yusuke ,   Tokyo Denki University, 2-2 Kanda-Nishiki-cho, Chiyoda, Tokyo 101-8457, Japan, Furutani Ryoshu , Ozaki Miyu
Published: April 2016

In industry, the Coordinate Measuring Machine (CMM) is a major geometrical measurement method because of its precision and general versatility. The CMM is conventionally used in a thermostatic chamber, but its use in the production line environment is increasing. Many factors - dust, thermal fluctuation, and collision, to name a few - deteriorate measurement precision and make it necessary to inspect the CMM daily. However, the daily inspection method is not established. Study of CMM is mainly about calibration in controlled environment like a thermostatic chamber. It is unfeasible to calibrate the CMM everyday because of its cost. So some researchers have studied about daily inspection of CMM. This paper describes daily CMM inspection procedures and how to evaluate these uncertainty. This method treats axis scale errors and interaxis squareness errors from geometric errors of CMM. These factors influence the measurand. QuickCheck (Trapet Precision Engineering) is used as an artifact. In the linear model using QuickCheck, influences of alignment error is evaluated parameters.
Two-Wavelength Laser Interferometer System Which Reduces the Uncertainty Caused by the Fluctuation of the Refractive Index of Air
Authors: Miyata Kaoru ,   Mitutoyo Corporation, 430-1 Kamiyokoba, Tsukuba-shi, Ibaraki-ken 305-0854, Japan, Oozeki Hidekazu , Nakagawa Hideyuki , Masuda Hiroki , Sakai Hisayoshi
Published: April 2016

Laser interferometers are widely used to measure highly sensitive length and displacement, e.g., in which refractive index fluctuations of air adversely affect measurement accuracy. To compensate for these effects, the two-wavelength interferometer studied has not yet proved practical in industrial use. We studied the interferometer’s performance and practicality, using uncertainty analysis to extract its features. Based on our results, we developed a two-wavelengthMichelson interferometer with wavelengths of 1064 nm and 532 nm. It was calibrated and evaluated using a highprecision laser interferometer whose optical path was in a vacuum. Results confirmed measurement accuracy of 100 nm/50 mm (k=2) under unstable air conditions - superior to a traditional laser interferometer.
3D Measurement of the Inner Shape of a 1-Cell Accelerator Cavity
Authors: Enami Kazuhiro ,   Mechanical Engineering Center, High Energy Accelerator Research Organization, 1-1 Oho, Tsukuba, Ibaraki 305-0801, Japan, Kume Tatsuya , Higashi Yasuo , Ueno Kenji
Published: April 2016

We strive to develop a 3D coordinate measuring machine, which is able to measure the inner shape of intricately-shaped accelerator cavities. At present day, the ILC (International Linear Collider) project is progressing through international collaboration. The major goal of ILC is to produce and investigate Higgs bosons. ILC consists of two linear accelerators facing each other, and will hurl electrons and positrons toward each other at nearly the speed of light. Accelerator cavities are important components to accelerate particles to near light speed. A cavity’s inner shape influences the accelerating performance. Therefore, it is important to measure the inner 3D shape of a cavity. However, it is difficult to measure the inner shape of cavities with complex shapes. Additionally, we must measure them without contact because a micro defect on the surface causes serious degradation of performance. We are developing inner shape measuring machine with high accuracy using triangulation method. However, optical condition of the internal surface is bad for precision measurement. Therefore, we have to improve accuracy. In order to measure precisely, we developed calibration system using a cylindrical artefact. In this paper, we measured inner 3D shape of a one-cell cavity. Final goal is to measure 9-cell cavities.
Simulation-Based Analysis of Influence of Error on Super-Resolution Optical Inspection
Authors: Kudo Ryota ,   Department of Precision Engineering, The University of Tokyo, Hongo 7-3-1, Bunkyo-ku, Tokyo 113-8656, Japan, Usuki Shin , Takahashi Satoru , Takamasu Kiyoshi ,   Division of Global Research Leaders, Shizuoka University, Johoku 3-5-1, Naka-Ku, Hamamatsu 432-8561, Japan
Published: April 2016

Microfabricated structures such as semiconductors and MEMS continue shrinking as nanotechnology expands, demand that measures microfabricated structures has risen. Optics and electron beam have been mainly used for that purpose, but the resolving power of optics is limited by the Rayleigh limit and it is generally low for subwavelength-geometry defects, while scanning electron microscopy requires a vacuum and induces contamination in measurement. To handle these considerations, we propose optical microfabrication inspection using a standing-wave shift. This is based on a super-resolution algorithm in which the inspection resolution exceeds the Rayleigh limit by shifting standing waves with a piezoelectric actuator. While resolution beyond the Rayleigh limit by proposed method has been studied theoretically and realized experimentally, we must understand the influence of experimental error factors and reflect this influence in the calibration when actual application is constructed. The standing-wave pitch, initial phase, and noise were studied as experimental error factors. As a result, it was confirmed that super-resolution beyond the Rayleigh limit is achievable if (i) standingwave pitch error was 5% when standing-wave pitch was 300 nm or less and (ii) if initial phase error was 30° when standing-wave pitch was 300 nm. Noise accumulation was confirmed in studies of the noise effect, and a low-pass filter proved effective against noise influence.
Generation and Assessment of Random Surface Texture over a Wide Area
Authors: Kobayashi Yoshikazu ,   Department of Computer Science, College of Engineering, Nihon University, 1 Nakagawara, Tokusada, Tamuramachi, Koriyama, Fukushima 963-8642, Japan, Shirai Kenji , Hara Yasuhiko , Mizoguchi Tomohiro , Kawasaki Kiyotaka
Published: April 2016

Product surface textures are designed to improve their aesthetic, tactile, and mechanical quality. Surface texture manufactured with microrough patterns over a wide area differs from common geometric product machining. We have proposed generating a surface texture with regular patterns by milling. Here we propose generating a random-pattern surface texture using image processing. Digital surface-texture data consists of “real” three-Dimensional (3D) machining information. Wide-area digital surface-texture data such as scattered point data, Initial Graphics Exchange Specifications (IGES), and Standard Triangulated Language (STL) require humongous memory. The complexity and area of surface texture processed to generate tool paths is limited by computational considerations and generating the tool path for a widearea surface texture is time-consuming, so we propose generating random wide-area-pattern surface texture without the need for wide-area digital texture data. Instead, this uses only wide-area image data and narrowarea digital data. A wide-area tool path is generated by image quilting, which creates a patchwork in which patches represent both image and digital data for narrow-area surface texture, reducing surface distortion for patch boundaries. This paper introduces the generation of random pattern texture and machined samples assessing patch-boundary distortion.
The Simulation and Inspection for the Starting Phenomenon of Slit Coating Process on Glass Substrate
Authors: Chou Ta-Hsin ,   Industrial Technology Research Institute, No. 195, Sec. 4, Chung Hsing Rd., Chutung, Hsinchu, Taiwan 31040, R.O.C., Yang Wen-Hsien , Cheng Kuei-Yuan , Chang Yu-Chen , Luo Thomas ,   Yuan Ze University, 135, Yuan-Tung Road, Chung-Li, Taiwan 32003, R.O.C.
Published: April 2016

We developed a two-dimensional Computational Fluid Dynamics (CFD) model of a slit nozzle and coating for photoresist, using the Volume Of Fluid (VOF) to calculate the transient free surface. Parameters studied in simulation, including contact angle, liquid feed rate, slit gap, and coating gap. Simulation results yielded information on operation and buildup conditions, enabling us to examine microscopic fluid flows. Experiments used a slit coater (ITRI) having a slit nozzle 370 mm wide and a 100 µm slit gap, and set on a vertical moving table. A glass substrate was fixed on a horizontal moving table by a vacuum pump. Photoresist is pumped from a tank to the slit nozzle by a plunger. During coating, a CCD camera facing the slit gap imaged coating conditions. Experimental parameters studied included substrate speed, coating gap, and photoresist feed rate. The substrate was operated at 10 to 20 mm/second, the coating gap was set at 100 µm, and the photoresist feed rate was from 0.4 to 0.8 ml. Simulation and experimental results confirmed that CFD simulation was possible in designing the slit nozzle and preverifying coating. Photoresist coating was possible below 1.5 µm thick with 5%uniformity.
High-Resolution Tolerance Against Noise Imaging Technique Based on Active Shift of Optical Axis
Authors: Usuki Shin ,   Division of Global Research Leaders, Shizuoka University, Johoku 3-5-1, Naka-ku, Hamamatsu 432-8561, Japan, Miura Kenjiro T. ,   Graduate School of Science and Technology, Shizuoka University, Johoku 3-5-1, Naka-ku, Hamamatsu 432-8561, Japan
Published: April 2016

Optical imaging resolution is determined by both optical parameters such as light wavelength and the objective lens Numerical Aperture (NA) and by spatial sampling such as Charge-Coupled Device (CCD) camera pixel size. Focused on improving optical imaging pixel resolution, we reviewed multiframe Super-Resolution (SR) implemented in previous measurement to improve image resolution, but found its computational cost to high and calculation too long. Pixeldisplacement estimation also adversely affects resulting image quality and is difficult to apply practically due to SR registration calculation sensitivity to noise. The resolution improvement we have proposed uses active subpixel shifting of the optical axis based on actively controlling spatial image displacement using a glass-plate-parallel substrate and a galvano scanner. Multiframe SR registration is used but without pixel-displacement estimation. Theoretically, our proposal may improve image resolution stably at higher speed but to clarify this, we developed optics and rebuilt the multiframe SR.We then computationally analyzed improved resolution and noise tolerance using a Modulation Transfer Function (MTF). Optical and aliasing noise have been suppressed and image resolution improved in high measurement, making higherresolution imaging faster and cheaper thanks to our proposal.
Roll-to-Roll Embossing of Sunlight Guide Film with Wide Outgoing Angle
Authors: Chou Ta-Hsin ,   Industrial Technology Research Institute, No. 195, Sec. 4, Chung Hsing Rd., Chutung, Hsinchu, Taiwan 31040, R.O.C., Yang Wen-Hsien , Huang Tzu-Yu , Hocheng Hong ,   National Tsing Hua University, No. 101, Sec. 2, Kuang Fu Rd., Hsinchu, Taiwan 30013, R.O.C.
Published: April 2016

Artificial lighting consumes over 20% of the total energy used by commercial buildings. Sunlight guides used in windows guide sunlight to the ceilings of indoor rooms. Microstructure film designed and fabricated by roll-to-roll embossing improves solar energy use. A roller mold was fabricated with a diamond turning lathe and used for UltraViolet (UV) cured embossing. After embossing, sunlight guide film 400 mm wide was fabricated. The film microstructure prism and curved surfaces 21 µm high and spaced at 18 µm intervals. When sunlight illuminates the inclined or curved surface, incoming rays are reflected from the outgoing surface in total internal reflection. Specimen performance wasmeasured using measurement installation including a light source, photodetector, and a rotating table. These produced sunlight guide film able to adopt elevation angles of 40°-70°. The outgoing angle exceeded a 30° average above the transom’s outgoing horizontal 90° angle, which is defined by full width at half maximum of outgoing light intensity. Experimental results showed of the microstructure film had high energy efficiency and a broad range of outgoing angles, reducing energy consumption by 19% in artificial building lighting for an ideal room model.
QA for Blood Chemical Analysis by ISO-GUM
Authors: Iwaki Yasuo ,   Chaos Applied Research Office, The Society of Instrument and Control Engineers, Kansai Chapter, 4-55 Otabicho kuga Fushimuku, Kyoto 612-8493, Japan
Published: April 2016

International Organization for Standardization (ISO) standard Quality Assurance (QA) is required for final report values in clinical Blood Chemical Analysis (BCA). In the medical field, an External Quality Assurance Scheme (EQAS) is required in order to make wide area medicine system useful and to prevent clinical mistakes stemming from ambiguous data. The fact that QA is based on statistical analysis for many years by Quality Engineering (QE) has been discussed. An improvement so that the ISO need not depend on statistical analysis for QA was proposed. Then ISO published a Guide of express Uncertainty inMeasurement (ISO-GUM) [1] in 1993. There are the two mainly changed parts at ISO-GUM. The first is changing evaluation of the ambiguous data into uncertainty from an error. The second is adding Exploratory Data Analysis (EDA) for the analysismethod to Analysis Of Variance (ANOVA) [2] in order to make abnormal distribution possible. ANOVA was only reported on the current situation of measurement result, while EDA came to be required in investigations of cause by ISO-GUM. This research is to help establish policies ensuring BCA result. This research results were used for information technology (IT) era in medical treatment in the European Union (EU) in 2010.
Full Leg Control of a Quadruped Robot Using Linear Visual Servoing with a Stereo Omnidirectional Camera
Authors: Inoue Yukinari ,   Noritsu Kouki Co. Ltd., 579-1 Umehara, Wakayama, Japan, Maru Noriaki ,   Systems Engineering, Wakayama University, Sakaedani 930, Wakayama, Japan
Published: April 2016

The authors have previously proposed foot tip control for quadruped robots using linear visual servoing (LVS) with a normal stereo camera. However, a normal stereo camera has a narrow field of view and is incapable of seeing all four legs simultaneously. Consequently, it has been a problem that the control of all the legs have required that the rotatation of the camera be controlled. This article proposes a method by which a stereo omnidirectional camera is provided at a position low on the body to control all four legs through LVS. In this article, we at first present a transformation equation from an omnidirectional image to a binocular visual space, and we develop a servo equation of LVS in which an omnidirectional image is used. Then, through simulation, we confirm trajectories with the LVS applied to foot tip control. We also conduct an experiment using TITAN-VIII to demonstrate the efficacy of the proposed method.
Development of Table-on-Table-Type Five-Axis Machining Center: New Structure and Basic Characteristics
Authors: Takayama Naoshi ,   Graduate School of Engineering, Osaka University, 2-1 Yamada-oka, Suita, Osaka 565-0871, Japan, Ota Hidehito , Ueda Kensuke , Takeuchi Yoshimi ,   Mori Seiki Co., Ltd., 362, Idono, Yamatokoriyama, Nara 639-1183, Japan
Published: April 2016

The demand for five-axis machining centers has been increasing rapidly, as companies seek “intensive processes” and “high accuracy.” However, it is generally more difficult for five-axis machining centers to achieve the same or higher accuracy than three-axis machining centers since it is necessary to have two more rotary feed axes besides the three linear feed ones. Many kinds of five-axis machining centers with various structures have been developed to date; an analysis of the advantages and disadvantages of major five-axis machining center structures was done first. As a result of this analysis, this paper focuses on the “table-on-table type” five-axis machining center. It is capable of accuracy because of its wide range of rotation for the rotary axis and its advantages in the adjustment process of the axis. and this paper proposes a five-axis machining center which has this construction. Furthermore, a new high-speed, highaccuracy, “table-on-table type” of five-axis machining center which uses a direct-drive motor for the rotary axis and a driven center of gravity for the linear axis has been developed based on this concept, and its accuracy has been verified.
Precision Cutting of Structured Ceramic Molds with Micro PCD Milling Tool
Authors: Suzuki Hirofumi ,   Department of Mechanical Engineering, Chubu University, 1200 Matsumoto, Kasugai, Aichi 487-8501, Japan, Furuki Tatsuya , Okada Mutsumi , Fujii Katsuji , Goto Takashi ,   NS Tool Co. Ltd., 2-11 Matsuzakataira, Taiwa-cho, Kurokawa, Miyagi 981-3408, Japan
Published: April 2016

Micro milling tools made of PolyCrystalline Diamond (PCD) have been developed to machine ceramic micro dies and molds. Cutting edges are ground with diamond wheels. PCD milling tool wear is evaluated by cutting binder-less tungsten carbide spherical molds and machining structured surfaces for trial. Results of experiments clarified that PCD milling tool life is over 10 times that of resinoid diamond grinding wheels, and that form accuracy was 0.1 µm-0.3 µm P-V and surface roughness was 10 nm Rz.
Ultra-Precision Machining of Tungsten-Based Alloys by Cutting and Burnishing
Authors: Sugita Naohiko ,   School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan, Nishioka Kazuhiko , Mitsuishi Mamoru
Published: April 2016

This paper proposes ultra-precision machining of tungsten alloy maximizing burnishing between the cutting tool and workpiece during cutting by combining strengths of the crystal grain and binder phase. Turning experiments conducted using workpieces of tungsten-based alloys 50 mm in diameter and 10 mm thick produced high-quality surface roughnessRzof 0.13 µm, achieved on a CNC lathe.
Effect of Grain Size in Stainless Steel on Cutting Performance in Micro-Scale Cutting
Authors: Komatsu Takafumi ,   Komatsuseiki Kosakusho Co., Ltd., 942-2 Shiga, Suwa-city, Nagano 391-0012, Japan, Matsumura Takashi , Torizuka Shiro ,   Mechanical Engineering, Tokyo Denki University, 2-2 Kanda Nishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan,   Materials Reliability Center, National Institute for Material Science, 1-2-1 Sengen, Tsukuba, Ibaraki 305-0047, Japan
Published: April 2016

The cutting processes of ultra fine grain stainless steels are compared to that of normal grain steel in microscale cutting with a single point tool made of single crystal diamond. Cutting force is measured with oscillation in the dynamic component. Vibration in cutting force is reduced with the grain size. Shear angles are measured to discuss the cutting process with changes in depth of cutting. The large shear angle is observed when the grain size becomes small. The surface finish is also improved when the ultra fine grain steel is machined.
Prevention of Depth-of-Cut Notch Wear in CBN Tool Edge by Controlling the Built-up Edge
Authors: Kiyota Hiroki ,   Nagoya Institute of Technology, Gokiso-cho, Showa-ku, Nagoya 466-8555, Japan, Itoigawa Fumihiro , Kakihara Atsushi , Nakamura Takashi
Published: April 2016

During the cutting of Inconel 718 with a Cubic Boron Nitride (CBN) tool under roughmachining conditions, notch wear is prominently formed at the depth-ofcut line. In this study, close-up observations around the tool edge by a high-speed video camera were conducted to investigate the cause of notch wear. The results suggest that notch wear is caused by unstable extrusion of the Built-Up Edge (BUE) that forms under the chamfered edge as well as by secondary chip formation due to the side flow at the depth-of-cut line. The BUE extrusion behavior depends on the tool geometry, such as the chamfer angle, the chamfer width and the rake angle. The secondary chip easily forms if the curled BUE is unstably extruded. However, the stable uncurled BUE extrusion causes neither the secondary chip nor the notch wear. Therefore, optimization of the tool geometry to obtain a stable BUE extrusion is examined to suppress the notch wear.
On-Machine Optical Surface Profile Measuring System for Nano-Machining
Authors: Sawano Hiroshi ,   Precision and Intelligence Laboratory, Tokyo Institute of Technology, 4259 Nagatsuta, Midori-ku, Yokohama, Kanagawa 226-8503, Japan, Takahashi Motohiro , Yoshioka Hayato , Shinno Hidenori , Mitsui Kimiyuki ,   Department of Mechanical Engineering, Keio University, 3-14-1 Hiyoshi, Kohoku-ku, Yokohama, Kanagawa 223-8522, Japan
Published: April 2016

There has been an increasing demand for machining of precision parts recently. In order to meet such requirements, nano-machining systems with on-machine surface profile measuring function are required. This paper presents a newly developed on-machine shape measuring system with an optical probe. In this system, an astigmatic focus error detection method is applied to the optical probe. In addition, the influence of the uneven reflection from the surface can be reduced by using two quadrant photodiodes. The results of surface profile measurement confirm that the system developed provides a resolution of 1 nm scale and a repeatability of approximately 50 nm.
Identification of 5-Axis Machine Tools Feed Drive Systems for Contouring Simulation
Authors: Sencer Burak ,   Ultraprecision Engineering Laboratory, Nagoya University, Furo-cho, Chikusa-ku, Nagoya City, Aichi 464-8603, Japan, Altintas Yusuf ,   Manufacturing Automation Laboratory, University of British Columbia, 2054-6250 Applied Science Lane Vancouver, B.C. V6T 1Z4 Canada
Published: April 2016

An identification technique is introduced for identifying closed loop transfer function of machine tool’s feed drive systems to be used in simulation of the tracking and contouring performance of Computer Numerical Controlled (CNC) machine tools. The identification is performed from air-cutting tests utilizing only standard G-codes containing linear motion commands. A general transfer function model is derived for representing the closed loop tracking response of the feed drive system. The model considers the drive to be controlled by commonly used controller schemes such as P-PI Cascade, PID or the Sliding Mode Controller (SMC) with feed-forward dynamic and friction compensation. The parameters of the model transfer function are fitted tominimize the discrepancy between the actual and predicted axis position on the axis. In order to guarantee the stability of the identified model transfer function, bounds on the pole locations are imposed. The resultant constrained non-linear optimization problem is solved efficiently using the Particle Swarm Optimization (PSO) method. For achieving reliable convergence of the stochastic PSO algorithm, a parameter tuning strategy is presented. Simulation and experimental studies show that the identified feed drive model captures the fundamental dynamics of the drives system accurately for simulating their closed loop response. Combined with the kinematics of the machine, contouring errors of 5-axis CNC machine tools during simultaneous multi-axis motion are predicted.
Ultrasonic-Assisted Grinding of Ultra-High Purity SUS 316L
Authors: Shimada Keita ,   Tohoku University, 6-6-01 Aoba, Aramaki-aza, Aoba-ku, Sendai, Miyagi 980-8579, Japan, Yoshihara Nobuhito , Yan Jiwang , Kuriyagawa Tsunemoto , Sueishi Yuichiro , Tezuka Hideshi ,   Iwate University, 4-3-5 Ueda, Morioka, Iwate 020-8551, Japan,   Tokyo Electric Power Company, 4-1 Egasaki-cho, Tsurumi-ku, Yokohama, Kanagawa 230-8510, Japan
Published: April 2016

Ultra-High Purity (UHP) alloys providing such excellent properties as high corrosion resistance and toughness are difficult to machine efficiently due to these very properties. To improve machining efficiency, we applied ultrasonic-assisted micro-grinding to UHP alloy machining. We discuss the theoretical model we built of ultrasonic-assisted grinding to study grinding force using statistical calculation. We theoretically estimated and experimentally confirmed the effect of ultrasonic assistance on reducing grinding force.
Simulation of Cylindrical Plunge Grinding Processes Considered Successive Change of Workpiece Shape
Authors: Onozaki Tohru ,   Research & Development Center, JTEKT Corporation, 1-1 Asahi-machi, Kariya, Aichi 448-8652, Japan, Saito Akira , Yoritsune Masashi
Published: April 2016

A simulation method of cylindrical plunge grinding processes is described, which has considered successive change of workpiece shape due to core elements of grinding machine. Each element is modeled and integrated in the simulation procedure. The validity of the method is shown by comparing predicted and experimental results of grinding force histories, workpiece diameter histories and final workpiece shapes. The method is also applied to reduce grinding time by controlling infeed rate. The new process with reduced time is derived and the practicality of the method is verified by conducting experiments.
Residual Stress Model for Speed-Stroke Grinding of Hardened Steel with CBN Grinding Wheels
Authors: Duscha Michael ,   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, 19 Steinbachstraße, Aachen 52074, Germany, Klocke Fritz , Wegner Hagen
Published: April 2016

To be competitive, production industry demands efficient, high-quality finishing processes – requirements speed-stroke grinding promises to meet. This paper presents a preliminary residual stress model for speedstroke grinding based on superposition of mechanical and thermal analyses as verified using analogical processes. Comparison showed that results for a residual stress model and grinding experiments correlated well. This model enables robust process control achieving compressive residual stress, itself an important surface integrity feature.