bluuebunny/crossref_metadata_2025 huggingface dataset:
Development of a Non-Exoskeletal Structure for a Robotic Suit
Authors: Tanaka Hirohito ,   Shinshu University, 3-15-1 Tokida, Ueda, Nagano 386-8567, Japan, Hashimoto Minoru
Published: April 2016

In recent years, various robots have been developed that can be worn on the body. These can be used to assist elderly people and people with disabilities by either providing extra power or helping themwith walking. These robots usually form an external skeleton around the frame of the body. Although the external skeletal structure has the advantage of supporting the robotic mechanism, an adjustment mechanism to match it to the contours of the wearer’s body is necessary, and this mechanism increases the weight of the robot. In this study, we propose a non-exoskeletal structure which uses the skeletal system of the human body, and we develop a lightweight robotic suit that gives little feeling of restriction.
Evaluation of Metallic Mold Surfaces Polished by an Industrial Robot with Stick Whetstones
Authors: Shibuya Koji ,   Ryukoku University, 1-5 Yokotani, Seta-Oe, Otsu, Shiga 520-2194, Japan, Issiki Shunsuke
Published: April 2016

Our ultimate goal is to develop an automatic polishing system that uses an industrial robot equipped with whetstones. The robot mimics the movements skilled workers make as they polish surfaces manually. This paper, the first step in the development of our system, presents experimental results to prove that our system completely removes the marks, which is the most time-consuming and crucial process for human workers, from the flat surfaces of metallic molds produced through the Electrical Discharge Machining (EDM) process. We build a polishing system that consists of a small 6-DOF industrial robot for material handling. Attached to its wrist is a six-axis force-torque sensor and it employs a whetstone holding mechanism. Before the robot system begins its polishing work, the normal force to be applied to the flat surface can be adjusted to a target value by altering the height of the hand. We adopt two polishing paths for the whetstone, reciprocating and zigzag. We then conduct experiments using the two paths, visually inspect the surface, and measure the surface roughness and shape. Based on the experimental results, we confirm that the system has completely removed the EDM mark layer. Although we find that the zigzag path leaves striped patterns on the polished surface, we are not able to determine their cause. Finally, we test three combinations of the two paths under different conditions to find the most suitable combination.
Effect of Tool Run-Out on Micro-Groove Milling for a Microchannel Die
Authors: Iwatsuka Kenichi ,   Toyama Prefectural University, 5180 Kurokawa, Imizu-shi, Toyama 939-0398, Japan, Maeda Yukio , Yazawa Takanori , Suzuki Shinya ,   Nagasaki University, 1-14 Bunkyo-machi, Nagasaki-shi, Nagasaki 852-8521, Japan,   Nagano National College of Technology, 716 Tokuma, Nagano-shi, Nagano 381-8550, Japan
Published: April 2016

Recently, the use of microchannel chips in micro total analysis systems, which can provide savings of natural resources and energy, has attracted attention in the medical field. Generally, the photolithography technology used in semiconductor manufacturing is used to manufacture microchannel chip dies. However, it involves several processes such as mask fabrication and the application of a photoresist to Si substrate, as well as expensive clean room facilities. In light of this, methods to form a fine groove using a micro-endmill are examined. The effects of the tool run-out of a few micrometers on micro-endmilling, as well as on the groove accuracy of a microgroove, are examined.
Study on Knowledge-Based Product Design Framework for Facilitating the Interaction of Model Based Development and Prototyping
Authors: Nomaguchi Yutaka ,   Department of Mechanical Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan, Mizuta Masashi , Hirooka Masaya , Fujita Kikuo
Published: April 2016

Model-based development is a potential approach to designing complicated mechatronic systems. This paper proposes a product design framework for mechatronic systems, which integrates model-based development with prototyping and focuses on its process of deployment with hypothesis and verification. SysML is adopted as the modeling language for representing the mechatronic system without depending on specific domains, and FMEA is adopted as the method for describing the results of validation by prototyping. The DRIFT framework is used to capture designer’s operations on the design tools of SysML and FMEA and to manage its process. This study defines design concepts and design operations that are extracted from the patterns embedded in design process with SysML and FMEA. A design example of a ball-sorting robot is created using LEGO Mindstorms to demonstrate the proposed framework.
Use of 1DOF Haptic Device for Remote-Controlled 6DOF Assembly
Authors: Kamata Ryoya ,   Department of Precision Mechanics, Chuo University, 1-13-27 Kasuga, Bunkyo-ku, Tokyo 112-8551, Japan, Tamura Ryosuke , Niitsu Satoshi , Kawaharada Hiroshi , Hiraoka Hiroyuki
Published: April 2016

This paper describes a remote controlled assembly using a haptic device. Most haptic devices have six Degrees Of Freedom (DOFs) for a higher sense of reality. However, for assembly operation, the simultaneous motion of parts with only one or two DOFs is required, and force feedback to operators is used only to maintain contact and detect collisions among parts. This leads to the possibility of assembly operations using a haptic device with a small number of DOFs. In this paper, we propose virtual planes to perform remote control of a 6DOF assembly by way of 1DOF user operations. Virtual planes separate the DOFs for user operation and for automatically generated motions that complement the user operation DOF in each assembly operation. A prototype system was developed with a 6DOF manipulator and camera. The system allows an operator to place virtual planes in any position and orientation using a camera image of the workspace. The experiment results showed the effectiveness of the method for remote controlled assembly without geometry information on the parts.
Monitoring and Adaptive Process Control of Wire Electrical Discharge Turning
Authors: Yan Mu-Tian ,   Department of Mechatronic Engineering, Huafan University, No.1, Huafan Rd. Shihding Dist., New Taipei City 223, Taiwan R.O.C., Hsieh Pai-Hung
Published: April 2016

This paper presents a novel pulse discriminating and control system for the identification of spark gap states, process monitoring and control of Wire Electrical Discharge Turning (WEDT). The relation between the proportion of open circuit, normal spark, arc discharge, short circuit to total sparks (defined as open circuit ratio, normal spark ratio, arc discharge ratio and short circuit ratio, respectively), ignition delay time and metal removal rate were experimentally studied and analyzed. A fuzzy logic controller was proposed to control both the arc discharge ratio and ignition delay time at optimal levels by on-line regulation of table feed-rate and pulse off-time for adaptive control optimization of WEDT. Experimental results show that the developed process monitoring and control system results in faster machining and better machining stability as compared with a conventional servo feed control scheme for the WEDT process.
Development of an Innovative Power-Assist Omni-Directional Mobile Bed Considering Operator’s Characteristics
Authors: Ueno Yuki ,   Toyohashi University of Technology, 1-1 Hibarigaoka, Tempaku, Toyohashi, Aichi 441-8580, Japan, Kitagawa Hideo , Kakihara Kiyoaki , Sakakibara Toshio , Terashima Kazuhiko ,   Gifu National College of Technology, 2236-2 Kamimakuwa, Motosu, Gifu 501-0495, Japan,   KER CO., LTD., 215 Yutakagaoka, Toyokawa, Aichi 442-0808, Japan,   Fukushimura Hospital, 19-14 Yamanaka, Noyori, Toyohashi, Aichi 441-8124, Japan
Published: April 2016

In welfare facilities, although wheelchairs are commonly used for transferring patients, there are many cases in which patients are transferred while lying on beds because it is burdensome for caregivers to move a patient from a bed to a wheelchair. However, the task of moving a bed with a patient lying on it is still physically burdensome for caregivers. Hence in this study, we developed a power-assist omni-directional mobile bed to reduce the burden associated with this task. This paper reports a novel prototype of the omnidirectional power-assist bed and describes the prototype’s design, mechanism and control-system configuration. In addition, we report on experiments that were conducted to verify the effectiveness and usefulness of the omni-directional mobile bed, as well as the adaptability of the omni-directional power-assist system.
Feasibility Study on Design of Spindle Supported by High-Stiffness Water Hydrostatic Thrust Bearing
Authors: Nakao Yohichi ,   Kanagawa University, 3-27-1 Rokkakubashi, Kanagawa-ku, Yokohama 221-8686, Japan, Suzuki Kenji , Yamada Kohei , Nagasaka Kohei
Published: April 2016

The machining accuracy of ultra-precision machine tools relies on the performance of the spindle and linear table. The machining accuracy of ultra-precision machine tools is now at the level of several tens of nanometers. In order for ultra-precision machine tools to achieve machining accuracy, a precise spindle system is indispensible. High bearing stiffness is particularly important to minimize displacement due to the cutting force. This paper considers a spindle design supported by high-stiffness water hydrostatic thrust bearings. An objective of this study is to design a precision spindle supported by water hydrostatic thrust bearings with 1 kN/µm bearing stiffness. The bearing restrictors are chosen so that the highest stiffness can be obtained for given bearing parameters. The influences of gap sizes and supply water pressure on the bearing stiffness are presented. Based on the feasibility study done on the design of highstiffness water hydrostatic thrust bearings, the spindle is designed and developed. The influences of the water pressure on the spindle deformation and bearing stiffness are also investigated.
Method to Control Manufacturing Cell by Driving Simulation Model
Authors: Hibino Hironori ,   Tokyo University of Science, 2641 Yamazaki, Noda, Chiba 278-8510, Japan
Published: April 2016

In this paper, a method to Control a Manufacturing Cell by Driving Simulation Models (CMC-DSM) is proposed. The purposes of CMC-DSM is not only to directly operate the manufacturing cell while controlling and monitoring the manufacturing cell based on a simulation model in the manufacturing system execution phase, but also to support the manufacturing engineering processes based on the simulation model. In the manufacturing engineering processes, the simulation model is mixed and synchronized with real equipment and management applications in the case where parts of equipment and manufacturing management applications are not provided in the manufacturing cell. In the manufacturing system execution phase, when the simulation model acts in response to manufacturing system behaviors, the manufacturing system is controlled by synchronizing the simulation model behaviors. In this paper, the Environment required to Control a Manufacturing Cell by Driving Simulation Models (E-CMC-DSM) is proposed. The necessary functions for E-CMC-DSM are defined and developed. E-CMC-DSM consists of a simulator developed to drive simulation models (EMU), a soft-wiring system developed in this study, and a semi-standard industrial network middleware. The validation of ECMC-DSM was carried out through a case study.
Contributions of High-Speed Cutting and High Rake Angle to the Cutting Performance of Natural Rubber
Authors: Takahashi Naoki ,   Yokohama National University, 79-5 Tokiwadai, Hodogaya, Yokohama, Kanagawa 240-8501, Japan, Shinozuka Jun
Published: April 2016

This study investigates the contributions of high-speed cutting and a high rake angle to the improvement of the cutting performance of natural rubber. Orthogonal cutting experiments were conducted at cutting speeds ranging from 1.0 m/s to 141.1 m/s. The rake angles examined were 0°, 20° and 50°. The following results were obtained from the experiments. The cutting ratio is almost 1.0 regardless of the cutting speed and rake angle. The cutting force rises rapidly as the cutting speed increases. High-speed cutting or a high rake angle eliminates tear defects on the machined surface and reduces chipping defects at the entry edge of the workpiece. An uncut portion, however, always remains at the exit edge. The cross-sectional shape of the machined surface becomes concave. Besides, the machined surface comes into broad contact with the clearance face. These degradations in the shape accuracy arise from the large elastic distortion that occurs in the shear zone. Increasing the cutting speed improves the flatness of the machined surface. Although an analysis of the cutting mechanism reveals that the apparent stiffness of the material in the shear zone is enhanced with increasing the cutting speed, a very high cutting speed worsens the shape accuracy because of the development of shock waves. Depending on the rake angle, there is a critical cutting speed that should not be exceeded to maximize the cutting performance of natural rubber.
Effect of Discharge Duration and Pulse Frequency on Surface Characteristics Using Whirling Electrical Discharge Texturing
Authors: Lertphokanont Vitchuda ,   Kyoto Institute of Technology, Matsugasaki, Sakyo-ku, Kyoto 606-8585, Japan, Oi Masahiro , Sato Takayuki , Ota Minoru , Egashira Kai , Yamaguchi Keishi , Yamada Masayoshi , Tomita Yasuo ,   Nissin Manufacturing Co., Ltd., Akasaka-85, Mineyamacho, Kyoto 627-0006, Japan
Published: April 2016

Discharge duration and pulse frequency are studied to determine the optimum conditions for creating a single crater. In addition, the relationships between pulse frequency and surface characteristics using Whirling Electrical Discharge Texturing (WEDT) are determined. It is confirmed that the texture-area ratio and the total removal volume of craters, but not crater diameter or crater depth, can be controlled by adjusting pulse frequency. Moreover, after honing, surface characteristics decrease owing to the removal of protrusions. With honing, the surface roughness of the textured surface leads to a reduced friction coefficient as expected.
Surface Topography of Mini-Size Diamond Wheel in Ultrasonic Assisted Grinding (UAG)
Authors: Fujimoto Masakazu ,   Department of Machine Intelligence and Systems Engineering, Akita Prefectural University, 84-4 Tsuchiya-Ebinokuchi, Yurihonjo, Akita 015-0055, Japan, Wu Yongbo , Nomura Mitsuyoshi , Kanai Hidenari , Jin Masahiko ,   industria Co., Ltd., 2700 Miyadera, Iruma, Saitama 358-0014, Japan,   Depertment of Mechanical Engineering, Nippon Institute of Technology, 4-1 Gakuendai, Miyashiromachi, Minamisaitama, Saitama 345-8501, Japan
Published: April 2016

The objectives of this paper are to describe a quantitative evaluation of mini-size diamond grinding wheel surface topography in Ultrasonic Assisted Grinding (UAG) process and demonstrate the effects of topography on grinding characteristics. In this study, threedimensional (3D) analysis of the wheel working surface was observed using a Scanning Electron Microscope (SEM) with four electron probes (hereafter described as 3D-SEM) in an on-surface UAG process. These results indicated that a good wheel surface maintained in the UAG process is related to the number and the area of cutting edges. Additionally, the resulting topographic features of the grinding wheel surface are closely related to low grinding forces and allow easy manufacturing of a mirror workpiece surface.
Analysis of Energy Consumption Patterns and Climate Effects Using Panel Data
Authors: Uwasu Michinori ,   Center for Environmental Innovation Design for Sustainability (CEIDS), Osaka University, 2-1 Yamadaoka, Suita 565-0871, Japan, Hara Keishiro , Kobayashi Hideki
Published: April 2016

This paper investigates energy consumption patterns using panel data of final energy consumption and economic variables from 1970 to 2010 for more than 100 countries and regions. Although previous economic studies address the role of economic development and income as determinant factors of energy consumption, we examine how physical factors such as climate affects energy consumption level and patterns. By integrating economic and engineering approaches, we demonstrate statistical analyses showing that climate determines not only energy consumption levels, but also the relationship between energy consumption and income levels over time. While climate affects energy consumption patterns, our results suggest that energy technology and price policy are significant in determining whether a country can decouple energy consumption from economic growth.
Simulating the Formation of Urban Mines Considering the Rational Decisions of Distributed End-of-Life Stakeholders
Authors: Komoto Hitoshi ,   National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Naimiki, Tsukuba 305-8564, Japan, Kondoh Shinsuke , Masui Keijiro
Published: April 2016

Stakeholders engaged in the separation and refinement of laptop computers at the end-of-life are indispensable for the recycling of components such as batteries and printed circuit boards. Since the stakeholders are located in various geographical locations, whether they perform the operations or not influences how the urban mines of laptop computers are formed in terms of quantity and location. In this paper, a method for simulating the formation of the urban mines based on the rational decisions of end-oflife stakeholders is proposed. The system can simulate the formation considering the geographical distribution of the stakeholders as well as variations in the material composition of laptop computers across generations. This paper describes the architecture of the system and its data-preparation, simulation, and visualization processes, which are validated with a simulation model prepared with statistical information concerning used laptop computers. The system can simulate the formation of urban mines of various kinds of products if similar types of information presented in the laptop computer example data are prepared or hypothesized accordingly.
Energy Efficiency Improvement of Water Hydraulic Fluid Switching Transmission
Authors: Pham Pha N. ,   Shibaura Institute of Technology, 307 Fukasaku, Minuma-ku, Saitama-city, Saitama 337-8570, Japan, Ito Kazuhisa , Ikeo Shigeru ,   Sophia University, 7-1 Kioicho, Chiyoda-ku, Tokyo 102-8554, Japan
Published: April 2016

This study aims to determine effective methods for improving the energy efficiency of a water hydraulic Fluid Switching Transmission (FST). This paper introduces three methods to reduce energy consumption: lowering the velocity of the electric motor and stopping the motor during the working and deceleration phases, respectively (first method); restricting the working pressure within a certain range by using an unload valve (second method) or using the idling stop method (third method). Next these three methods are analyzed and compared. Experimental results show that by using the proposed methods, the energy and net energy consumption are greatly reduced. The greatest reductions are from 71.5 to 78.3% for energy consumption and from 65.1 to 66.2% for net energy consumption, corresponding to variations in the reference velocity from 600 to 1000 min-1. Additionally, the steady state errors in the proposed methods are slightly decreased in the working phase while the transient responses are almost the same for all cases.
Analyzing the Sustainability of Bimetallic Components
Authors: Ullah A. M. M. Sharif ,   Kitami Institute of Technology, 165 Koen-cho, Kitami, Hokkaido 090-8507, Japan, Fuji Akiyoshi , Kubo Akihiko , Tamaki Jun’ichi
Published: April 2016

This study describes a methodology to evaluate the sustainability of a bimetallic component putting emphasis on energy, material, and component efficiencies. Energy efficiency deals with the direct energy consumptions while manufacturing a bimetallic component. Material efficiency deals with the yield, lightweighting, cost, and CO2footprint of primary material production of the materials used in the component. Component efficiency deals with the degree of alteration of functional properties of the component (surface-finish, strength, and alike). Numerical examples are described based on a case of a bimetallic component made of commercially pure Aluminum and Titanium. It is found that the material efficiency is effective than the energy efficiency in enhancing the sustainability, whereas enhancing component efficiency remains a challenge. The outcomes of this study will help make informed decisions in developing sustainable bimetallic components.
Fabrication of Patterned Ag and Au Inverse Opal Structures Through Repeated Self-Assembly of Fine Particles
Authors: Nishio Manabu ,   Kaneka Corporation, 5-1-1 Torikai-Nishi, Settsu, Osaka, Japan, Moronuki Nobuyuki , Abasaki Minoru ,   Tokyo Metropolitan University, 6-6 Asahigaoka, Hino, Tokyo 191-0065, Japan,   Fuji Electric Co., Ltd., 1 Fuji-machi, Hino-City, Tokyo, Japan
Published: April 2016

This study aims to apply the self-assembly process of particles to the fabrication of inverse opal structures, which improve the fabrication of catalysts and sensors. The process consists of two dip-coating steps. The first one is the production of sacrificial silica particles 1 or 2 µm in diameter. The second one is the fabrication of silver or gold nano-particles. After these processes, silica particles are dissolved to create the inverse opal structure. We demonstrate how changing the diameter of the sacrificial particle varies the size of the pores. Finally, we present how the patterned Ag and Au inverse opal structure can be created using the hydrophobic/hydrophilic patterned substrate.
Deformation Analysis of Silicone Rubber Sheet Subjected to Keen WC Blade Indentation
Authors: Mitsomwang Pusit ,   Department of Mechanical Engineering, Nagaoka University of Technology, 1603-1 Kamitomioka, Nagaoka, Niigata 940-2188, Japan, Nagasawa Shigeru , Kuroiwa Hiroki , Fukushima Yoshio ,   Gunma Industrial Technology Center, 884 Kamesato-machi, Maebashi, Gunma 379-2147, Japan
Published: April 2016

This paper aims to reveal the deformation/cutting characteristics of a stacked silicone rubber worksheet subjected to a keen tungsten carbide blade (WC) indentation. Cutting parameters such as blade geometry, feed velocity and hardness of underlay sheet were varied and investigated. It was revealed that: (i) the use of the high feed velocity caused the increase of the 1st inflection, the peak and the breaking points of cutting line force. Also, the positions of these points were postponed when increasing the velocity. (ii) Under the high velocity condition (V = 0.416 mm•s-1), the geometry of the blade such as tip radius and primary height affected the cutting line force and the bending deformation of the worksheet. (iii) The application of soft silicone underlay resulted in the postponement of the crack initiation and the breaking positions of the worksheet. However, the final cut edge of the worksheet was invariant with the underlay hardness. In addition, an finite elementmethod analysis of the process was carried out using a non-linear elastic Mooney-Rivlin material model. The cutting resistance and deformation of the worksheet was numerically simulated up to the peak cutting line force point using an FEM model, before the occurrence of large cracking.
Fundamental Study on Hole Fabrication Inside a Hole by Means of Electrical Discharge Machining
Authors: Ishida Tohru ,   University of Tokushima, 2-1 Minamijyousanjima, Tokushima 770-8506, Japan, Okahara Yuichi , Kita Masahiko , Mizobuchi Akira , Nakamoto Keiichi , Takeuchi Yoshimi ,   FUJITEC Co., Ltd., Shiga, Japan,   Tokai Polytechnic College, Gifu, Japan,   Tokyo University of Agriculture and Technology, Tokyo, Japan,   Chubu University, Aichi, Japan
Published: April 2016

It is necessary to machine holes of complicated shapes for building pipelines of pneumatic or hydraulic equipment. However, the degrees of freedom of machinable hole shapes are limited, because holes are usually fabricated by drilling. To improve the degrees of freedom of these shapes, the authors have devised a method of fabricating a hole on the inside wall of another hole by means of electrical discharge machining. The method employs a very simple device. The results of the fundamental experiments indicate that this method has the ability to machine such a hole.
Dynamic Thermoelastic Behavior in Sheet Glass Generated by Pulsed Laser Irradiation Using a One-Dimensional Model
Authors: Chiba Akira ,   Department of Mechanical Engineering, Chiba University, 1-33 Yayoi-cho, Inage-ku, Chiba 263-8522, Japan, Hidai Hirofumi , Matsusaka Souta , Morita Noboru
Published: April 2016

The dynamic thermoelastic behavior of a sheet glass subjected to single-pulse laser irradiation is clarified using a one-dimensional model. From the equation of motion for this system, a thermoelastic equation was derived and applied in the analysis. For a 0.1-µs pulse duration, the displacement and thermal stress caused by the thermal expansion within the slab show oscillatory wave characteristics. When thermal stress waves are reflected at the free ends of the sheet glass, the polarity of the stress changes. Alternating stress waves of approximately 0.5-MHz frequency appear in the slab. With cracks propagating in the glass as a result of stress, high-cycle fatigue is possible. We confirm that the dynamic behavior generated by single-pulsed laser irradiation features wavelike properties.
Using Smoothed Particle Hydrodynamics to Examine Influence of Process Parameters on Ultrasonic Machining
Authors: Wang Jingsi ,   Department of Mechanical Systems and Design, Graduate School of Engineering, Tohoku University, 6-6-01 Aoba, Aramaki, Aoba-ku, Sendai 980-8579, Japan, Shimada Keita , Mizutani Masayoshi , Kuriyagawa Tsunemoto
Published: April 2016

The initiation and propagation of cracks generated on a work surface during UltraSonic Machining (USM) were simulated using Smoothed Particle Hydrodynamics (SPH). Different abrasive materials, tool materials, and abrasive sizes were used in this simulation. The distribution and size of the calculated cracks were found to be strongly influenced by different process conditions. According to the simulation results, using tools with a lower yield strength and slurry comprising softer and smaller abrasives decreases the crack size. Experiments were conducted to drill deep blind holes in soda-lime glass by USM and observe the cracks remaining on the machined surfaces. The experimental results agreed well with the simulation results. This work was the first to visualize the crack formation during USM under different process parameters with the SPH method. The results may be very useful for improving the machining performance of the USM process.
Improvement of Chip Evacuation in Drilling of Lead-Free Brass Using Micro Drill
Authors: Kato Hideharu ,   Kanazawa Institute of Technology, 3-1 Yatsukaho, Hakusan, Ishikawa 924-0838, Japan, Nakata Shingo , Ikenaga Noriaki , Sugita Hiroaki ,   OSG Corporation, 1-15 Honnogahara, Toyokawa, Aichi 442-8544, Japan
Published: April 2016

As the miniaturization of integrated circuits has progressed, the penetration holes of bonding jigs have become smaller. However, micro drills have a tendency to break when drilling small holes with high aspect ratios. Moreover, to reduce the impact on the environment, there has been a recent trend towards the use of lead-free brass as jig materials, but these are very difficult to drill. In the present study, small holes are drilled in lead-free brass using a micro drill, and the effects of web thinning, the helix angle, and the nick geometry on chip evacuation are investigated. The results indicate that drills with a helix angle of 15° have the longest tool life. The formation of a nick on the cutting edge is found to help decrease the thrust force during deep drilling. A drill with a relatively shallow nick perpendicular to the cutting edge have excellent chip discharge performance, and its cutting force is stable. Nick treatment effectively decreases the thrust force at a deep drilling position.
Development of a Non-RigidMicro-Scale Cutting Mechanism Measuring the Cutting Force Using an Optical Lever
Authors: Herrera-Granados German ,   Graduate School of Engineering, Chiba University, 1-33 Yayoi-cho, Inage-ku, Chiba-shi, Chiba 263-8522, Japan, Ashida Kiwamu , Ogura Ichiro , Okazaki Yuichi , Morita Noboru , Hidai Hirofumi , Matsusaka Souta , Chiba Akira ,   AMRI, National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Namiki, Tsukuba-shi, Ibaraki 305-8564, Japan
Published: April 2016

A new cutting mechanism for the fabrication of microscale grooves is presented in this study. Based on the control principle of the nano-cutting mechanism using an Atomic Force Microscope (AFM), in the newly developed system, a single crystal diamond tool is mounted at the free edge of a cantilever beam and is used for the removal of material. During the cutting process, the cantilever undergoes a deformation that is required for the implementation of a machining force feedback control. It was experimentally observed that the use of this mechanism enables to maintain the cutting depth of the micro-grooves constant even if they are fabricated on inclined surfaces; this is achieved by maintaining the normal cutting force constant using a feedback controller. For this experimental system, an optical lever is used to measure the angular deformation at the tip of the cantilever, thus providing a better understanding of total cutting force involved in the machining process.
Improving the Properties of Injection Molded Products with Induction Heating and Cooling Molds
Authors: Murata Yasuhiko ,   Department of Mechanical Engineering, Nippon Institute of Technology, 4-1 Gakuen-dai, Miyashiro-machi, Minamisaitama-gun, Saitama 345-8501, Japan, Koike Masayoshi , Pan Song
Published: April 2016

An induction heating and cooling mold that can keep the surface temperature of the entire mold cavity uniform and has a new heating and cooling insert with a gas vent mechanism is designed and produced. The effects of the temperature of the mold cavity surface, of the cavity air during the melt filling process, and of the organic gas generated fromthe melt on the appearance andmechanical properties of an injectionmolded product made of high impact polystyrene are studied. It is found that the heating and coolingmold with a gas vent can suppress molding defects, such as a weld lines and gas burns, and can greatly increase the displacement ratio of molded products obtained in the tensile test. This means that the effects of the gas vent and the surface temperature of the cavity have been quantitatively clarified using this type of mold.
Precision Cutting of Ceramics with Milling Tool of Single Crystalline Diamond
Authors: Suzuki Hirofumi ,   Chubu University, 1200 Matsumoto, Kasugai, Aichi 487-8501, Japan, Okada Mutsumi , Okada Koichi , Ito Yosuke ,   NS Tool Co. Ltd., 2-11 Matsuzakataira, Taiwa, Kurokawa, Miyagi 981-3408, Japan
Published: April 2016

Micro milling tools made of Single Crystalline Diamond (SCD) have been developed to machine micro dies and molds made of ceramics. The milling tools of a cylindrical SCD having many sharp cutting edges are fabricated 3-dimensionally by scanning a laser beam. Flat shape of binder-less tungsten carbide mold was cut with the developed milling tool to evaluate the tool wears and its life. Some micro aspheric molds of tungsten carbide were cut with the milling tool at a rotational speed of 50,000 min-1. The ceramic molds were cut in the ductile mode. By cutting with the milling tool, the form accuracy obtained was about 100 nm P–V and the surface roughness 8 nm Rz.
Development and Control of a Low-Cost, Three-Thruster, Remotely Operated Underwater Vehicle
Authors: Le Khoa Duy ,   University of Tasmania / Australian Maritime College, Maritime Way, Newnham, Tasmania 7248, Australia, Nguyen Hung Duc , Ranmuthugala Dev
Published: April 2016

This paper presents the development of a low cost Remotely Operated Vehicle (ROV) which consists of open source hardware and has three thrusters. First, the hardware of the vehicle, including the actuators, sensors, and control structure, is described. Second, to study the relationship between the thrust forces and the performance of the ROV, a mathematical model of the vehicle in the form of a kinematic and kinetic model is established. Next, a hybrid control algorithm consisting of two components, namely model-based and PID algorithms, is proposed for surge speed, depth, and heading control. The effectiveness of the hybrid control algorithm is then verified by the ROV mathematical model-based simulations. Finally, free running tests for depth control are conducted to verify the robustness and reliability of the control structure and proposed algorithms.
Dexterous Machining of Soft Objects by Means of Flexible Clamper
Authors: Nakamoto Keiichi ,   Tokyo University of Agriculture and Technology, 2-24-16 Naka, Koganei, Tokyo 184-8588, Japan, Iizuka Tomohiro , Takeuchi Yoshimi ,   Chubu University, 1200 Matsumoto-cho, Kasugai, Aichi 487-8501, Japan
Published: April 2016

It is important to establish a new way of creating value-added products, such as craftwork objects or applied arts, different from traditional way of achieving high quality and low price. Such a machining technology that enables (1) extremely complex or small shape generation, (2) machining of hard or soft materials, and (3) machining of difficult-to-grasp or fix workpiece may be called “Dexterous Machining.” Thus, the study deals with the first attempt to create an artistic product shape out of soft objects that have low stiffness and high elasticity. It is generally difficult to machine soft objects precisely because of the deformation caused by not only the cutting force but also the clamping force itself. In order to solve this problem, flexible clamper employing an aqueous solution of sodium acetate is devised to fix a workpiece and to suppress the deformation. The workpiece is placed in a case filled with an aqueous solution of sodiumacetate on a machine tool table. The aqueous solution is crystallized by applying a stimulus, and the solid sodium acetate clamps the workpiece. As a result of experimental machining, it is found that the proposed flexible clamper has the potential of realizing “Dexterous Machining” of soft objects.
FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling
Authors: Wang Jun ,   Department of Microengineering, Kyoto University, Ibaraki Soichi , Matsubara Atsushi , Shida Kosuke , Yamada Takayuki
Published: April 2016

This paper focuses on the deformation of a thin wall during the milling process. Cutting experiments were performed to investigate the influence of the workpiece thickness on its deformation and the cutting force. An FEM-based model was developed to simulate the deformation of a thin-wall workpiece during the milling process. With a tool’s rotation, the cutting force is distributed along the helical cutting edge, and the workpiece deformation can be calculated for a given time interval. The simulated results were compared with those of a simpler model where a constant cutting force is uniformly distributed along an oblique line representing the material removal by a cylindrical tool. Finally, the application of these results to the design of ribs for thin-wall parts during machining was considered.
Development of a New Generation of Independent Metering Valve Circuit for Hydraulic Boom Cylinder Control
Authors: Ahamad Mashruk ,   School of Mechanical and Automotive Engineering, University of Ulsan, Dinh Quang-Truong , Nahian Syed Abu , Ahn Kyoung-Kwan ,   School of Mechanical Engineering, University of Ulsan
Published: April 2016

Recent research on hydraulic systems has mainly focused on energy saving. This is because the efficiency of hydraulic systems is very low even though they have large power-to-size ratios. In mobile hydraulic equipment, conventional hydraulic spool valves with pressure compensators have already been replaced by valve assemblies with four-valve independent metering with electronically controlled pressure compensation. The independent metering concept and microprocessor control have much more potential to save more energy than conventional proportional valve control because of the increased controllability of the system. The primary focus of this study is to reduce the number of Independent Metering Valves (IMV) by introducing one directional control valve. This new model offers two degrees of freedom, i.e., controlling velocity and pressure, just as in conventional IMVs. In the system described here, two of the three independent valves are active during metering. In this paper, the theory behind a new method of flow control based upon load feedback is presented for two of the five distinct metering modes, and its performance is investigated and compared to that of a conventional IMV configuration.
An Innovative Machining Strategy for Efficient Peripheral Finishing of Hard Materials with Highly-Varied-Helix End Mill
Authors: Ito Atsushi ,   Brother Industries, Ltd., Shamoto Eiji ,   Department of Mechanical Science and Engineering, Graduate School of Engineering, Nagoya University
Published: April 2016

Grinding is usually applied to the peripheral finishing of hardened steel since the high specific cutting force and low stiffness of slender end mills often causes chatter vibration. On the other hand, varied-helix end mills have suppressed regenerative chatter vibration successfully in the rough machining of flexible workpieces. In this research, varied-helix end mills are applied to the extremely low radial immersion finishing of hardened steel, and the validity of this application is discussed and verified experimentally in terms of suppression of regenerative chatter vibration. A special varied-helix end mill with an extremely large helix angle difference is developed for this new application, and its performance is compared to that of an ordinarily-varied-helix end mill for the low-radial-immersion peripheral finishing of hard materials.
Configuration Method of Fixing System with 2-Dimensionally Low-Frequency Vibration for Drilling to Decrease Influence from Unintended Displacement of Workpiece
Authors: Burdukovskyi Ivan ,   Department of Mechanical Engineering, Graduate School of Engineering, Saitama University, Kaneko Jun’ichi , Horio Kenichiro
Published: April 2016

Micro deep drilling of hard materials requires introducing of step feed in process that increases machining time. To decrease the machining time by increasing the step feed, we apply low-frequency vibration (∼10 μm, 150 – 250 Hz) to the drilling process by oscillating the workpiece. To cope with the low-frequency vibration-assisted drilling of a curved surface, we have developed a fixing system for 2-dimensional vibration. The Fixing System for 2-Dimensional Vibration (FS2DV) consists of horizontal, and vertical actuators plus spring systems with variable rigidities along the directions of the actuators. A thrust force of 6 – 10 N from the drilling process may induce an unintended displacement of the workpiece. If the rigidities of the horizontal and the vertical spring systems are not balanced, unintended displacement may create diameter error during the drilling process. In this study, a method is proposed for configuring of the FS2DV with balanced spring systems to minimize the effects of the unintended displacement on diameter error. Frequency response function analysis of the vertical and horizontal spring systems is done for successful use of the FS2DV during the low-frequency vibration-assisted 2-axis drilling. Based on this analysis, setting requirements for the FS2DV are proposed for a particular vibration frequency. The behavior of the resultant vibration is evaluated while force is loaded along the intended angle of the drilling process. As a result, the effects of unintended displacement at the FS2DVare decreased for use within the vibration frequency range of 150 – 250 Hz with the vibration amplitude of 10 μm. The system can be used properly with a thrust force of up to 10 N and any angle from 0 to 90° by selecting appropriate rigidities for the spring systems.
Recent Progress in CMM-Based Form Measurement
Authors: Jusko Otto ,   Physikalisch-Technische Bundesanstalt, Neugebauer Michael , Reimann Helge , Bernhardt Ralf ,   Carl Zeiss IMT GmbH
Published: April 2016

Form standards with different profile geometries were measured using 3- and 4-axis scanning on a 3D CMM prototype with a precision rotary table. Physical boundary conditions, including probing force, probe diameter, probe geometry, probe material, and scanning speed, were varied, and then the results were analyzed. Some results were found to be equivalent to those obtained using form measuring machines. Limitations of the current implementation of this technique are discussed.
Quick On-Machine Measurement of Ground Surface Finish Available for Mass Production Cylindrical Grinding Processes
Authors: Ohashi Kazuhito ,   Okayama University, Tan Kazuya , Ashida Tomoya , Tsukamoto Shinya
Published: April 2016

In mass production cylindrical grinding operations, the ground surface finish has never been measured in each grinding cycles because existing surface roughness testers take a relatively long time to measure surface finishes, and the introduction of a surface roughness tester in each grinding cycle would affect mass production processes. Therefore, the surface finish of all parts manufactured in a production lot is generally evaluated based on the measured results of only few parts by sampling checks. We have proposed a unique quick technique for measuring surface roughness. It uses electromotive force based on the slight frictional heat to evaluate the surface finish of cylindrical workpieces rotating on cylindrical grinding machines, and it can do this in a split second just after each grinding cycle, so it does not hamper mass production grinding processes. The proposed quick measurement system can capture the variations in surface finish in a set of repeated cylindrical grinding cycles without dressing. The possibility of accurate judging dressing time by using the quick measurement system in mass production grinding processes is shown experimentally.
Robust Attitude Control and Virtual Reality Model for Quadrotor
Authors: Dinh To Xuan ,   Graduate School of Mechanical Engineering, University of Ulsan, Nam Doan Ngoc Chi , Ahn Kyoung Kwan ,   School of Mechanical Engineering, University of Ulsan
Published: April 2016

This paper introduces an adaptive attitude control based on a backstepping control scheme for a quadrotor helicopter test bed. First, aerodynamics and motion equations are provided to model the dynamics of the quadrotor and a Virtual Reality (VR) model is developed incorporating the dynamic model to the virtual results of simulation. Then, an adaptive backstepping algorithm is applied to the attitude control and this algorithm is adaptive according to Lyapunov-based stability analysis. Finally, the simulation results with many types of reference signals are provided to demonstrate the good tracking performance of the proposed control algorithm.
Investigation on Sensitivity of a Contact-Type Thermal Sensor for Surface Defect Inspections
Authors: Shimizu Yuki ,   Tohoku University, Ohba Yuta , Gao Wei
Published: April 2016

This paper presents an investigation on the sensitivity of a thermal sensor, which will be used as a contact detection sensor for surface defect inspections. In the proposed concept, frictional heat generated at a slight contact between a defect on a measuring surface and the thermal sensor will be utilized to find out existences of defects on the measuring surface. The frictional heat will be detected as a deviation of the electrical resistance of the sensing element in the thermal sensor. According to the principle, the sensor temperature will increase at the contact with defects. However, in the previous research by the authors, the sensor temperature was found to decrease at the contact with the glass-ball probe, whose tip diameter was on the order of several-ten μm. Following the experiments in the previous study, in this paper, further experimental investigation is carried out by employing an AFM probe as a nano-tip probe so that the sensitivity of the thermal sensor as a contact detection sensor for nano-scale defects inspection can be verified. Furthermore, a possible mechanism of the heat flow at the contact interface, which can explain the results observed in these experiments, is also introduced.
Implementation of in Process Surface Metrology for R2R Flexible PV Barrier Films
Authors: Elrawemi Mohamed ,   Mechanical Engineering Department, Elmergib University, Blunt Liam , Muhamedsalih Hussam , Gao Feng , Fleming Leigh ,   Centre for Precision Technologies, University of Huddersfield
Published: April 2016

Thin functional barrier layers of aluminum oxide (Al2O3) that are used particularly in photovoltaic (PV) modules to prevent the possibility of water vapor ingress should be applied over the entire PV surface without any defects. However, for barrier layer thicknesses within the sub-micrometer range (up to 50 nm) produced through the atomic layer deposition (ALD) method, it is common for defects to occur during the production process. To avoid defective barriers from being incorporated in the final PV unit, defects need to be detected during the barrier production process.

In this paper, the implementation of in process inspection system capable of detecting surface defects such as pinholes, scratches, or particles down to a lateral size of 3 µm and a vertical resolution of 10 nm over a 500 mm barrier width is presented. The system has a built-in environmental vibration compensation capability, and can monitor ALD-coated films manufactured using roll-to-roll (R2R) techniques. Ultimately, with the aid of this in process measurement system, it should be possible to monitor the coating surface process of large-area substrates, and if necessary, carry out remedial work on the process parameters.
3-D Obstacle Detection Using Laser Range Finder with Polygonal Mirror for Powered Wheelchair
Authors: Kato Kohei ,   School of Mechanical Engineering, College Science and Engineering, Kanazawa University, Seki Hiroaki , Hikizu Masatoshi
Published: April 2016

Because a large number of accidents with electric wheelchairs are due to operational errors, steering assistance systems for wheelchairs have been studied in a variety of ways. One of the basic systems is 3-D obstacle detection around the wheelchair. One method uses a stereo camera for detecting obstacles by image processing. However, this method is less reliable under varying light conditions. A laser range sensor is another useful device for obstacle detection. However, it requires a complex swinging mechanism for 3-D positioning which makes the measuring time too long. Therefore, this paper presents a 3-D obstacle detection system for electric wheelchairs using a 2-D laser range sensor. We set up only one 2-D laser range sensor over the wheelchair, and attached mirrors around it to reflect the laser light obliquely downwards. Then, we gathered obstacle points while the electric wheelchair was moving and made a 3-D obstacle map to assist steering. We built a prototype device and confirmed by experimentation that it is able to detect obstacles in 3-D.