bluuebunny/crossref_metadata_2025 huggingface dataset:
New Daylight Panel Design Using Ultra-Precision Machining
Authors: Lin Jian-Shian ,   Mechanical and System Research Laboratories, Industrial Technology Research Institute, Tai Wei-Lun , Lai Chieh-Lung , Takeuchi Yoshimi ,   Department of Mechanical Engineering, Osaka University
Published: April 2016

The daylight panel design we introduce increases inner wall illumination by 20% and improves daytime lighting efficiency. The three panel structures we simulated and manufactured are plain, triangular, and rhombic. Simulation and optical measurement results show that the rhombic structured panel uses daylight most efficiently. Our microstructured daylight panel increases building illumination and uniformity, reduces lighting-fixture glare, and saves energy, making it environment-friendly.
A Machine Tool Spindle Achieving Real-Time Balancing Using Magnetic Fluid
Authors: Nakamoto Keiichi ,   Department of Mechanical Engineering, Osaka University, Mitsuhashi Shinya , Adachi Kazuhiko , Shirase Keiichi ,   Department of Mechanical Engineering, Kobe University
Published: April 2016

A machine tool spindle is a key component affecting the performance of machine tools. Spindle vibration of machine tools causes tool wear prematurely and decreases machining accuracy. The vibration changes depending on the used tooling and the rotation speed during various machining operations. In particular, even small unbalance mass of the spindle makes large whirl in high speed machining. However, real-time balancing of a machine tool spindle has not yet been realized successfully including the influence of the used tooling. In this study, in order to reduce unbalance response of a machine tool spindle and to achieve high accuracy machining, a real-time balancing mechanism using magnetic fluid is proposed. The magnetic fluid is enclosed inside the spindle, and the distribution of circumferential mass is controlled to compensate for unbalance mass in real-time. A test spindle is designed and developed in order to evaluate the real-time balancing mechanism experimentally. It is confirmed that unbalance response of the spindle is significantly improved. Based on the obtained results, a machine tool spindle achieving real-time balancing is developed in this paper. The experimental results proved the feasibility of the proposed real-time balancing mechanism for a machine tool spindle.
Development of a Cutting Tool with a Textured Surface for Dry Cutting of Aluminum Alloys
Authors: Sugihara Tatsuya ,   Department of Mechanical Engineering, Graduate School of Engineering, Osaka University, Enomoto Toshiyuki
Published: April 2016

The demand for dry/near-dry cutting has been rapidly increasing to reduce the environmental impact. However, cutting technologies for aluminum alloys have not actually gained widespread use because the aluminum chips adhere strongly to the cutting edge of the tool, leading to tool breakage. To solve this problem, a cutting tool with a banded textured surface was developed, and a series of face-milling experiments for aluminum alloys showed that the textured surface significantly improves the anti-adhesive and anti-frictional properties at the tool-chip interface under dry cutting conditions.
Sub-Nanometer Positioning Combining New Linear Motor with Linear Motion Ball Guide Ways
Authors: Otsuka Jiro ,   Department of Mechanical Engineering, Faculty of Science and Technology, Shizuoka Institute of Science and Technology, Tanaka Toshiharu , Masuda Ikuro ,   Department of Mechanical Engineering, Toyota National College of Technology,   Shizuoka Institute of Science and Technology
Published: April 2016

A new type of linear motor described in this paper has some advantages compared with the usual types of motors. The attractive magnetic force between the stator (permanent magnets) and mover (armature) is diminished almost to zero. The efficiency is better because the magnetic flux leakage is very small, the size of motor is smaller and detent (force ripple) is smaller than the general motors. Therefore, we think that this motor is greatly suitable for ultra-precision positioning as an actuator. An ultra-precision positioning device using this motor and liner motion ball guide ways is newly developed. Moreover, the positioning performance is evaluated by a positioning resolution, deviational and dispersion errors. As the results of repeated step response tests, the positioning resolution is 0.3 nm, the deviational error is -0.001nm and the dispersion error (3σ) is 0.29 nm. Consequently, the positioning device achieves sub-nanometer positioning. In addition, very large rigidity can be achieved.
Cutting Force Adapted Control Application in Micropositioned Machining
Authors: Hwang Joon ,   Department of Aeronautical & Mechanical Design Engineering, ChungJu National University, Chung Eui-Sik ,   Department of Mechanical Design Engineering, Hanbat National University
Published: April 2016

In the machining process, cutting force is a physical quantity well reflecting the process itself. Measured cutting force is used to identify the tool wear, surface roughness, chip formation, chatter stability and dynamic cutter runout problems. The cutting force linearity is used to measure and control the irregular cutting phenomena and machining process. We applied force-adaptive cutting control technology to evaluate chatter and real-time compensation for dynamic cutter runout. We proposed the concept of force-adaptive cutting control in the angle domain based upon proportional-integral control to control chip-load variation in machining. The micropositioning control of cutting tool or workpiece positioning using a low-friction sliding table and piezoelectric actuator changed the chip-load variation. Our results are expected to provide invaluable information in precision machining technology.
Head-Positioning Control of Hard Disk Drives Through the Integrated Design of Mechanical and Control Systems
Authors: Atsumi Takenori ,   Mechanical Engineering Research Laboratory, Research & Development Group, Hitachi, Ltd.
Published: April 2016

A Hard Disk Drive (HDD) is an inexpensive mass-production product, but the head-positioning control systems of HDDs require nanometer-scale positioning performance. Therefore, we have studied head-positioning control systems of HDD using designs which integrate mechanical and control systems to improve their control performance while curbing cost increases. In this paper, we introduce “disturbance suppression in high-frequency ranges through phase stable design for high-order mechanical resonances” and “high servo-bandwidth design through mode shape design of mechanical resonance” as examples of techniques that have been developed and are easily applied to products.
Development of Axial Encoder to Measure Spindle Axial Motion
Authors: Nomura Mitsuyoshi ,   Toyohashi University of Technology, Kawashima Takahiro , Shibata Takayuki , Murakami Yoshihiko , Masuda Masami , Horiuchi Osamu
Published: April 2016

This paper deals with a newly developed axial encoder to measure spindle axial motion. The axial encoder was composed of a cylindrical rod with circular gratings and an optical encoder head. They were respectively mounted on the spindle nose and the worktable of a vertical milling machine. It has been ascertained by experiments that the prototype can digitally measure spindle axial motion with a resolution of 0.1 μm.
Positioning Accuracy of a Planer Multi-Joint Positioning System and Improvement Thereof
Authors: Fukada Shigeo ,   Department of Mechanical Systems Engineering / Center for Ultra-Precision Technology,
Published: April 2016

In order to discuss the positioning accuracy in a horizontal plane of a planer multi-joint positioning mechanism, we propose a method that uses a reference board on which reference marks are disposed at large intervals in combination with a precision XY stage, and we construct a measurement system that realizes the measurement of positioning accuracy with a resolution of 1.2 µm over the range of 200 × 400 mm. Next, in order to improve the positioning accuracy over a wide range of the planer multi-joint positioning system, we propose a method for calibrating the link length independently of coordinates from the measurements of positioning errors taken on three arbitrarily selected points, and we experimentally verify its validity. Moreover, we show that the positioning error in a local range of 50 × 50mm is mainly a transmission error of the joint drive reducer and experimentally verify the compensation effect for the transmission error. As a result, the positioning bias error is reduced to the same level as that of the positioning resolution over the range of 350 × 150mm.
Unmanned Production Using Intelligent Robots
Authors: Yamafuji Kazuo ,   The University of Electro-Communications
Published: April 2016

Unmanned production using intelligent robots is proposed in this paper. At present even if all direct works in a production environment can be automated, there are needs for supporting personnel who deal with and restore a trouble when it occurs. In order to eliminate such "a human island," the recent results on research and development of intelligent robots can be applied. One of the most serious and frequent troubles is minor stoppage of an automatic assembly line due to parts feeding trouble. Visiting 7 plants at 7 companies, we investigated troubles in parts feeding. Simulation and experiments for unmanned production were conducted on a pilot plant. Then we are confident that the intelligent robots can be substituted for supporting personnel for unmanned production.
Reduction of Consumed Energy and Control Input Variance in Machine Tool Feed Drives by Contouring Control
Authors: Uchiyama Naoki ,   Department of Mechanical Engineering, Toyohashi University of Technology, 1-1 Hibarigaoka, Tempaku, Toyohashi, Aichi 441-8580, Japan, Nakamura Takaya , Yamazaki Kazuo ,   Department of Mechanical and Aeronautical Engineering, University of California, Davis, One Shields Avenue, Davis, CA 95616-5294, USA
Published: April 2016

Contouring control has been widely studied to reduce contour error, defined as error components orthogonal to desired contour curves. Its effectiveness has, however, to the best of our knowledge, only been verified through comparative experiments using industrial non-contouring (independent axial) controllers or conventional contouring controllers such as the cross-coupling controller. Because control performance depends largely on controller gain, these comparisons have problems in showing the effectiveness of contouring control, meaning that similar control performance could be attained if non-contouring controller gain were appropriately assigned. This paper presents contouring controller design for biaxial feed drives that reduces controller gain, rather than contour error, better than conventional independent axial controllers. The contouring controller is shown in experiments to effectively reduce control input variance and electricity consumption on average by 4.5%.
Status Monitoring of Ultraprecision Machining Using Micro Thermo Sensor and AE Sensor
Authors: Yoshioka Hayato ,   Precision and Intelligence Laboratory, Tokyo Institute of Technology, 4259 Nagatsuta, Midori-ku, Yokohama 226-8503, Japan, Hayashi Mamoru , Shinno Hidenori
Published: April 2016

Higher machining accuracy and productivity have been recently required in various manufacturing industry. Machining monitoring requirements have grown increasingly severe. To meet these strict requirements, we developed machining status monitoring system for ultraprecision process combining an original micro thermo sensor and an acoustic emission (AE) sensor. Ultraprecision machining experiments confirmed that the developed monitoring system detects machining status using feature parameters defined relating output signals to machining conditions.
Nano-Mirror Surface Generation for Hardened Steel Using Ultra-Low Pressure Super-Finishing
Authors: Ogawa Sachiko ,   Department of Engineering, Graduate School, Doshisha University, 1-3 Miyakodani, Tatara, Kyotanabe-shi, Kyoto 610-0321, Japan, Aoyama Eiichi , Hirogaki Toshiki , Onchi Yoshiaki , Oku Kentarou ,   Faculty of Science and Engineering, Doshisha University, 1-3 Miyakodani, Tatara, Kyotanabe-shi, Kyoto 610-0321, Japan,   Faculty of Science and Engineering, Doshisha University, 1-3 Miyakodani, Tatara, Kyotanabe-shi, Kyoto 610-0321, Japan,   MIZUHO Co., Ltd., 82 Fukurojiri, Terada, Joyo-shi, Kyoto 610-0121, Japan
Published: April 2016

The fixed-abrasive process has attracted significant attention as an alternative to the loose-abrasive process for the final finishing of precision parts due to the improvement in shaping capability, processing efficiency, and environmental friendliness. Here, a new super-finishing method is proposed that involves fine super-abrasive stones (having a mean grain diameter of 8 μm or less) and ultra-low pressure (<0.1 MPa). The proposed method was implemented using a prototype super-finishing machine which was previously fabricated by the authors. Influences of lower stone pressure and finer abrasive grains on the surface roughness of SUJ2 (JIS) hardened steel were investigated. The following conclusions were obtained: (1) It was confirmed that super-finishing with a processing pressure of 0.02 MPa could be achieved using a fine-grit cBN stone. (2) Approximately half the surface roughness value of that achieved under conventional conditions could be obtained using ultra-low pressure. (3) The surface generation model, which was proposed based on plastic and elastic deformation, provided good agreement with the experimental results.
Robot Vision Technology for Technologizing and Digitalization of Medical Diagnostic and Therapeutic Skills
Authors: Koizumi Norihiro ,   School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan, Tsukihara Hiroyuki , Takamoto Shinichi , Hashizume Hiroyuki , Mitsuishi Mamoru ,   Graduate School of Medicine, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, Tokyo 113-8655, Japan,   Kasaoka Daiichi Hospital, 1945 Yokoshima, Kasaoka, Okayama 714-0043, Japan
Published: April 2016

We have been studying the technologizing and digitalization of skill of the medical professional in the medical diagnosis and therapy. The concept of technologizing and digitalization of medical skills is to extract functions in medical skills, reconstruct and implement those extracted functions in the mechanism/controller of the medical support system. In this paper, we explain a robot vision technology for technologizing and digitalization of medical diagnostic and therapeutic skills for the evaluation system of the post operative pericardial adhesion using cardioechography and remote ultrasound diagnostic system.
Assessment of Mental Stress on Human Operators Induced by the Assembly Support in a Robot-Assisted “Cellular Manufacturing” Assembly System
Authors: Kato Ryu ,   Department of Precision Engineering, School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan, Arai Tamio
Published: April 2016

For the improvement of productivity in “cellular manufacturing assembly systems,” we are now witnessing the emergence of the production support systems in which industrial robots are providing physical support and assistance to the manufacturing operations and also to the cognition of information/instruction to the human operators. In such systems, the human operators still act as the prime players who make the final decision in all facets of the operation, and the adverse effects of the mental stress on these players caused by inappropriate “support” provided by the system must be carefully considered. In view of the above, in this study, we tried to objectively assess the effects of the mental stress caused by such robot-assisted “cellular manufacturing” assembly systems using physiological indices related to cognition and emotion. Our results showed that higher speeds of an approaching robot’s motion and closer distances between human operator and industrial robot increase mental stress related to emotion, while augmenting text instruction with voice guidance and optical pointer increase mental stress related to cognition and emotion. These results provide important knowledge that can be used to formulate design guides and safety standards for reduced-stress production systems that involve human-industrial robot collaboration.
Design of an Automated Container-Handling System in a Seaport Terminal Considering Operating Machine Performance
Authors: Hoshino Satoshi ,   Chemical Resources Laboratory, Tokyo Institute of Technology, 4259 Nagatsuta, Midori-ku, Yokohama, Kanagawa 226-8503, Japan, Ota Jun , Shinozaki Akiko , Hashimoto Hideki ,   School of Engineering, Department of Precision Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan,   Mitsubishi Heavy Industries, Ltd., 3000 Tana, Sagamihara-shi, Kanagawa 229-1193, Japan
Published: April 2016

To provide a highly efficient and automated container-handling system in a seaport terminal, it is necessary to take into account the performance of operating machines, such as quay container cranes, automated guided vehicles, and rubber-tired gantry cranes, in addition to their fleet sizes. In this paper, we introduce these parameters as design objectives. However, this is a serious combinatorial design problem that consists of the objectives presented above. Moreover, it is not always true that a terminal system, in which larger numbers of machines are used with upgraded operation performance, obtains higher throughput. It thus becomes a challenge to identify a design parameter with an impact on the system throughput and to find the most reasonable combination of design parameters. In this issue, we apply a design strategy to this challenge and then modify a previously proposed hybrid design methodology. As a case study for the system design, we determine the combinatorial design solutions to meet given demands. Finally, we show the effectiveness of the system design in consideration of the machine performance.
Assist Control Method Based on Operating Property for Task from Automated Transfer to Manual Positioning of Flexible Parts
Authors: Ohzawa Atsushi ,   Department of Computer Science & Engineering, Graduate School of Engineering, Nagoya Institute of Technology, Gokiso-cho, Showa-ku, Nagoya, Aichi, Japan, Morita Yoshifumi , Suzuki Yosuke , Hara Susumu ,   Denso Corporation, 1-1 Showa-cho, Kariya, Aichi 448-8661, Japan,   Department of Mechanical Science and Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya, Aichi, Japan
Published: April 2016

Industrial production lines combine both autonomous machinery such as industrial robots and operator-machine cooperative power-assist systems. There are a lot of flexible and large parts among assembly parts, because of the weight saving. In efficient switching among machine- and operator-oriented operation, vibration suppression is an important issue. This paper presents operator-based assist control for task from automated transfer to manual positioning of flexible parts. This involves a mode-switching compensator whose control input is continuous and an input-shaping compensator that suppresses flexible-parts vibration. The input-shaping compensator using a notch filter eliminates the vibration frequency component from the operating force signal. Filter gain is adjusted online based on operating properties. The effectiveness of our proposal is verified from (i) maneuverability based on time-response evaluation and task-achievement time, and (ii) operational feel subjectively evaluated based on questionnaires.
Assist Force Control of Smart Suit for Horse Trainers Considering Motion Synchronization
Authors: Kusaka Takashi ,   Department of Electronics and Information Engineering, Hokkaido University, Sapporo, Hokkaido, Japan, Tanaka Takayuki , Kaneko Shun’ichi , Suzuki Yoshihito , Saito Munenobu , Kajiwara Hidekazu ,   Smart Support Technology, Sapporo, Hokkaido, Japan,   Kushiro National College of Technology, Kushiro, Hokkaido, Japan
Published: April 2016

This paper describes semi-active assist control in the form of a smart suit for horse trainers. We have developed a soft and flexible power assist device named “smart suit” for reducing user's physical fatigue. The smart suit is a kind of semi-active and flexible power assist devices. The semi-active assist mechanism consisting of elastic materials and a small DC motor is our original technology. The assist force is basically gained by the elastic force of elastic materials, and it is controlled by adjusting the length of the elastic materials by using DC motor. In this study, we applied the smart suit to horse trainers for reducing their physical fatigue in horse training to prevent their injuries. Moreover we developed an assist force control method based on periodical input control to gain the suitable assist force.
Interaction Approach for Movement-Assist Control Using Neural Oscillators
Authors: Zhang Xia ,   Department of Bioscience and Textile Technology, Interdisciplinary Graduate School of Science and Technology, Shinshu University, 3-15-1 Tokida, Ueda, Nagano 386-8567, Japan, Hashimoto Minoru
Published: April 2016

In this paper we propose a framework of realizing natural assist behavior with a movement-assist suit inspired by human interaction. Since human interaction can be thought as synchronization behavior common in movement assistance between human beings, to achieve human-like movement assistance, synchronization-based control is applied to a movement-assist suit. We use neural oscillators to entrain and synchronize suit movement with that of users. To determine validity and feasibility, we examine the proposal for whether (1) synchronization of action between human and movement-assist suit can be realized, (2) the assist effect can be obtained, and (3) the proposed method is comfortable for users. To determine these points, we simulated movement assistance and conducted experiments with a joint-torque-sensing assist suit. Results demonstrated that synchronized movement was realized and that a movement-assistance effect was implemented. Results of evaluation experiments showed the good usability the suit has as proposed, confirming the proposal's applicability and performance.
Study on Applying Cavitation in Micro Drilling of Austenite Stainless Steel — Control of Burr in Through Hole Drilling —
Authors: Mizobuchi Akira ,   Institute of Technology and Science, The University of Tokushima, 2-1 Minamijyousanjima-cho, Tokushima 770-8506, Japan, Ogawa Hitoshi ,   Tokushima Prefectural Industrial Technology Center, 11-2 Nishibari Saiga-cho, Tokushima 770-8021, Japan
Published: April 2016

Microdrilling is required to produce nozzles for fiber, fuel etc. A problem arising in microdrilling is the need to remove chips to avoid tool breakage. This paper deals with how cavitation affects machining fluid using ultrasonic vibration for chip control. Thrust force, hole shape and burr formation are observed in drilling austenite stainless steel SUS304 with a through hole 0.1mm in diameter. Cavitation-assisted drilling reduces chip adhesion and burr height while drilling number increases, as compared to conventional drilling. During through-hole drilling, cavitation occurs in a blister generated by machining fluid at the hole exit. The burr height in cavitation-assisted drilling is smaller than that in conventional drilling. Tool life in through-hole drilling is the same as in blind-hole drilling. We studied the effect of cavitation on burr removal using B4C powder.
Optical Mold Cleaning Using Carbon Dioxide
Authors: Lin Jian-Shian ,   Mechanical and System Research Laboratories, Industrial Technology Research Institute, 195 Chung Hsing Rd., Sec.4 Chu Tung, HsinChu, Taiwan 310, R.O.C., Lai Chieh-Lung , Lin Hsiu-Jen , Tu Ya-Chun , Takeuchi Yoshimi ,   Department of Mechanical Engineering, Osaka University, Yamadaoka 2-1, Suita, Osaka 565-0871, Japan
Published: April 2016

An optical mold cleaning technique comprised of supercritical CO2 fluids and a CO2 snow particle cleaning process is proposed in this paper. Our results indicate that using supercritical CO2 fluids with cosolvents significantly improves cleaning effectiveness. There is a high degree of cleaning efficiency even when supercritical CO2 fluids are used alone, without any cosolvents. We have also determined that two key factors in controlling the effectiveness of the CO2 snow cleaning process are the density and pressure of the CO2 propellant. Since CO2 cleaning generates much less pollution than current methods, it will be an important cleaning technique in the future.
High-Speed Milling Using a Developed Desktop Machine Tool
Authors: Kato Hideharu ,   Department of Mechanical Engineering, Kanazawa Institute of Technology, 7-1 Ohgigaoka, Nonoichi, Ishikawa 921-8501, Japan, Shintani Kazuhiro , Iwata Kazuo ,   OSG Corporation, 1-15 Honnogahara Toyokawa, Aichi 442-8544, Japan
Published: April 2016

The demand for compact products has raised the need for high-speed machining. In this study, we have designed and produced a desktop machine tool and investigated its high-speed machining performance using a small end mill. The size of the developed machine tool is 300×400×340mm, and the weight is 50 kg. This machine could reach a cutting speed of 25.0 m/s using a 1.7 mm diameter tool. High-speed milling with this machine produced a surface roughness of 0.6 µmRz without tearing. In addition, deformed layers produced at cutting speed of 25.0 m/s was thinner than that at cutting speed of 2.5 m/s. It was confirmed that the thickness of deformed layers at 25.0 m/s was 0.6 µm.
On-Demand MEMS Device Production System by Module-Based Microfactory
Authors: Ashida Kiwamu ,   Advanced Manufacturing Research Institute (AMRI), National Institute of Advanced Industrial and Science Technology (AIST), 1-2-1 Namiki, Tsukuba, Ibaraki 305-8564, Japan, Nakano Shizuka , Park Jaehyuk , Akedo Jun
Published: April 2016

Many micro-scale devices have been developed by applying micro-electro-mechanical systems (MEMS) technology, but MEMS production facilities are large and costly, making it difficult to develop small numbers of trial devices. The novel on-demand MEMS device production system we developed applies two major concepts – that of the microfactory and the introduction of non-MEMS processes in microfabrication. These two concepts have made manufacturing more ecological, economical, agile, and flexible through downsizing, forming an automated production line by connecting standardized unit-processing cells, each of which has a desktop process, a part transfer robot, and a standardized connection interface. These enable any process cell to be connected in any sequence that the target product requires. Four unit-process cells were developed – the micropress cell for fabricating microstructures from thin sheet metal and the miniature aerosol deposition (AD) process cell for fabricating high-performance piezoelectric (PZT) ceramics actuators. The feasibility of the on-demand MEMS production system was demonstrated by the fabrication of a MEMS-like micromirror scanner, proving the potential of on-demand MEMS production in diversified small-lot production.
Advances in the TUT Microfactory Concept Development
Authors: Heikkilä Riku ,   Department of Production Engineering, Tampere University of Technology, Korkeakoulunkatu 6, 33720 Tampere, Finland, Järvenpää Eeva , Tuokko Reijo
Published: April 2016

Microassembly, micromanufacturing and microfactories are currently widely studied around the world. Tampere University of Technology (TUT) has had a strong background on microfactory research since 1999. This paper summarizes the results of the microfactory research accomplished at TUT during the recent projects. The paper introduces the TUT microfactory concept and discusses the demonstrations from the areas of assembly, laser machining and medical applications realized with TUT microfactory concept. It also presents some conceptual ideas for the factory level logistics of microfactory systems.
Online Rescheduling in Semiconductor Manufacturing
Authors: Sugi Masao ,   Research into Artifacts, Center for Engineering (RACE), The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan, Cheng Mingang , Yamamoto Masashi , Ito Hiroki , Inoue Kazuyoshi , Ota Jun ,   Wuxi Paradise Software Co., Ltd., No.2, West Binjiang Road, Jiangyin City, Jiangsu Province, China,   NS Solutions Corporation, 3-1 Minatomirai 3-chome, Nishi-ku, Yokohama-shi, Kanagawa 220-8401, Japan
Published: April 2016

Semiconductor manufacturing rescheduling problems are difficult to solve in real time due to numerous disturbances. We focus on maintaining the existing schedule and propose online semiconductor manufacturing rescheduling. To handle temporary disturbances and obtain a new feasible schedule, our proposal revises the given schedule based on affected operation rescheduling with operation sorting (sorting-AOR) based on schedule stability. To reduce deadline violations, we propose improving schedules two or more days ahead based on a fast local search algorithm for semicritical paths. In problems with 200,000 processes, this handles disturbances and gets new feasible schedules and better revised schedules in less than 1 minute. This is more effective than conventional dispatching-rule-based approaches, some of which have been applied in different facilities because it provides higher schedule stability and fewer deadline violations.
Analytical Prediction of Part Dynamics for Machining Stability Analysis
Authors: Alan Salih ,   Department of Mechanical Engineering, Middle East Technical University, 06531 Ankara, Turkey, Budak Erhan , Özgüven H. Nevzat ,   Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli, Tuzla, 34956 Istanbul, Turkey
Published: April 2016

An analytical procedure is developed to predict workpiece dynamics in a complete machining cycle in order to obtain frequency response functions (FRF), which are needed in chatter stability analyses. For this purpose, a structural modification method that is an efficient tool for updating FRFs is used. The mass removed by machining is considered to be a structural modification in order to determine the FRFs at different stages of the process. The method is implemented in a computer code and demonstrated on different geometries. The predictions are compared and verified by FEA. Predicted FRFs are used in chatter stability analyses, and the effect of part dynamics on stability is studied. Different cutting strategies are compared for increased chatter-free material removal rates considering part dynamics.
Motion Control of a Hyper Redundant Manipulator Built by Serially Connecting Many Parallel Mechanism Units with a Few DOF
Authors: Iwatsuki Nobuyuki ,   Department of Mechanical Sciences and Engineering, Tokyo Institute of Technology, 2-12-1 Ohokayama, Meguro-ku, Tokyo 152-8552, Japan, Nishizaka Norifumi , Morikawa Koichi , Kondoh Koji ,   Komatsu Ltd., 2-3-6 Akasaka, Minato-ku, Tokyo 107-8414, Japan,   Industrial Technology Center of Fukui Prefecture, 61 Kawai Washizuka, Fukui 910-0102, Japan
Published: April 2016

This paper describes the kinematic analysis and motion control of a hyper redundant robot built by serially connecting many units with a few DOF. Each unit of the manipulator is a spatial parallel mechanism with 3 DOF and is composed of 2 stages connected with 3 linear actuators, 7 spherical joints, and a center rod. The forward kinematic analysis of the manipulator based on the forward kinematics of each unit by numerical calculation was carried out. The inverse kinematic analysis, the iterative calculation so as to converge output error while output displacement is distributed into each unit with weighting coefficient, was proposed and formulated. Motion control of the robot was theoretically and experimentally examined based on the inverse kinematics. It was confirmed that a prototype with 3 units could generate the desired trajectories.
Proposal for Abrasive Layer Fabrication on Thin Wire by Electrical Discharge Machining
Authors: Furutani Katsushi ,   Department of Advanced Science and Technology, Toyota Technological Institute, 12-1, Hisakata 2-chome, Tempaku-ku, Nagoya 468-8511, Japan
Published: April 2016

This paper deals with a method of fabricating an abrasive layer on a thin wire by means of electrical discharge machining (EDM). An electrodeposited wire saw is useful for slicing a silicon ingot. However, strong acids are used in the production process and the depositing speed is slow. To overcome these problems, a fabrication process for an abrasive layer on a thin wire by EDM is proposed. The layer deposited by EDM with a green compact electrode is porous under certain electrical conditions so that the layer is composed of abrasive grit, pores and bond. A mixture of WC, Co, and the abrasive was compressed to make the green compact electrode. Two green compact electrodes were placed facing each other and were reciprocally fed during the process. The WC layer was deposited in 1s on an area in a preliminary experiment. The feed rate of 0.12-mm piano wire was set to 50mm/min. Al2O3abrasive powders with a size of 35-50µm were able to be contained in the WC layer on the wire. The deposit containing the abrasive firmly adhered. Because the deposited WC layer was very hard, tight gripping of the grit can be also expected. A copper block was cut with a raw piano wire, with wires with or without the abrasive deposited by EDM, and with electrodeposited or resinoid wire saws available on the market to compare their cutting performance. The initial tension was set to 5N and the cutting load was changed from 5.5 to 9.0N. The average feed speed of the wire was set to 8m/min. After 2000 reciprocating motions, the amounts machined with the deposited wire were larger than those with the wire saw available on the market. The deposited wire endured the same cutting load as the electrodeposited wire saw.
Special Issue on Die and Mold Technology
Authors: Anzai Masahiro
Published: April 2016

Mass-produced items such as cars, consumer electronics, electronic parts, precision instruments, office supplies, and daily necessities are invariably connected to dies and molds – basic manufacturing technology whose quality determines product quality. Die and mold production is difficult due to product complexity and high-precision requirement. Advances in processing and elemental technology such as machine tools and CAD/CAM software determine whether die and mold products are acceptability and the level of production techniques in the country of manufacture.

This special issue focuses on advanced die and mold manufacturing technology. Among the many interesting papers are those on machining and measurement of texture, fabrication of parts using welding, high-speed servo press, CAM system for metal forming, surface inspection system, development of liner motor machining centers, and machine tools. We are certain that you will find this issue both interesting and informative.

We thank the authors for their generous cooperation and the editing staff for their many helpful suggestions.
Estimation of Machining Accuracy by Measurement of Surface Texture Pattern
Authors: Tozawa Kouichi ,   College of Engineering and Design, Shibaura Institute of Technology, 3-9-14 Shibaura, Minato-ku, Tokyo 108-8548, Japan, Toida Naohito , Kobayashi Yoshikazu , Shirai Kenji ,   Makino Milling Machine Co., Ltd., 3-19 Nakane 2-chome, Meguro-ku, Tokyo 152-8578, Japan,   College of Engineering, Nihon University, 1 Nakagawara, Tokusada, Tamuramachi, Koriyama, Fukushima 963-8642, Japan
Published: April 2016

Measuring the accuracy of machining done on machine tools efficiently is always a problem. Measurement in three dimensions is also a problem in terms of the so called “lead time” in the manufacturing process. We propose a new approach that can, in a limited time, use a CCD camera installed in a machine tool for image-processing and precisely measure the machining accuracy of constantly changing texture patterns created by ball-end milling. This paper has led to the development of hands-on measurement of machining accuracy. Its usefulness and reliability are verified by both simulation of machining accuracy and the actual process of measurement.
Basic Study on Laser Forming CAM System for Sheet Material Forming Without Dies or Molds
Authors: Nakamura Toshihiko ,   Department of System Design Engineering, Keio University, 3-14-1 Hiyoshi, Kohoku-ku, Yokohama-shi, Kanagawa 223-8522, Japan, Ishihara Shotaro , Aoyama Hideki , Matsushita Naohisa , Ushimaru Akihiko ,   FUJITSU LIMITED, 4-1-1 Kamikodanaka, Nakahara-ku, Kawasaki-shi, Kanagawa 211-8588, Japan
Published: April 2016

Dies and molds are generally used for press forming and injection molding. However, they are expensive and their production is time consuming, so they are not suitable for prototyping or low-volume production. Laser forming is an effective tool for prototyping and low-volume production because it enables one to form sheet material without dies or molds. Laser forming is the deformation process caused by the thermal stress generated in the sheet by laser irradiation. In this paper, a Laser Forming System is proposed for determining laser irradiation conditions for forming a required shape.
Direct Measurement of Electrode Movement During Electrical Discharge Machining by Means of Automatic Discharge Gap Controller
Authors: Kita Masahiko ,   Department of Mechanical Engineering, Graduate School of Engineering, Osaka University, Yamadaoka 2-1, Suita, Osaka 565-0871, Japan, Ishida Tohru , Takeuchi Yoshimi
Published: April 2016

This study deals with the development of a new method of directly measuring the movement of an electrode during normal electrical discharge machining (EDM) and the movement of an electrode during EDM by means of an automatic discharge gap controller (ADGC) devised by our research group. The ADGC, which mainly consists of a bidirectional actuator using a shape memory alloy (SMA) and an electrode and power supply for EDM, can sustain stable EDMby autonomously and automatically controlling the position of the electrode to keep the discharge gap appropriate. However, the movement of the electrode being controlled by the ADGC cannot be directly measured due to itsminute, high-speed, vibration-like movements inside the working fluid during EDM. This means that there is no way to prove that the ADGC actually controls the position of the electrode so as to maintain a suitable discharge gap for continuing stable EDM. This also means that there is no way to evaluate the movement of the electrode quantitatively and to design or optimize the structure of an ADGC so as to give the ADGC the desired or best performance. Therefore, a method to directlymeasure the electrodemovement by an ADGC is devised in this study. The results obtained in the measurement experiments using this method of measurement prove that the ADGC actually moves its electrode to achieve stable EDM, and they allow the movement of the electrode to be evaluated quantitatively.
Plasma Temperature and Electron Density of Dry µ-EDM on Stainless Steel and Silicon: A Comparison
Authors: Subbian Kanmani Subbu ,   Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Uttar Pradesh, Kanpur, India, Janakarajan Ramkumar , Santhanagopalan Dhamodaran ,   Department of Physics, Indian Institute of Technology Kanpur, Uttar Pradesh, Kanpur, India
Published: April 2016

Fabricating micro/nano-features in devices and largescale production with short lead times is challenging, and many individual and hybrid processes have been developed to meet this challenge. Among nonconventional processes, micro-electric discharge machining (µ-EDM) has many advantages due to the possibility of precise and accurate 2D and 3D machining of complex shapes. Dry µ-EDM is used to process assembled or semi-assembled products. Attempts are being made to improve the µ-EDM process, and further improvement is possible through better understanding the role of discharge plasma in the machining process. We studied plasma and crater characteristics during dry µ-EDM, calculating plasma parameters for different discharge energies using optical emission spectroscopy. Line pair method and modified Saha equations are used to calculate plasma temperature and electron density respectively. Craters were morphologically analyzed using scanning electron microscopy (SEM), and plasma and crater characteristics on stainless steel and silicon were compared.
Electrochemical Spark Micromachining: Present Scenario
Authors: Kulkarni Anjali V. ,   Indian Institute of Technology Kanpur, Kanpur-208016, UP, India, Jain Vijay Kumar , Misra Krishna Avtar ,   HBTI Kanpur, Kanpur-208016, UP, India
Published: April 2016

The electrochemical spark process, alternately known as the electrochemical discharge process or sparkassisted chemical engraving process, is emerging as a viable machining process. Though it emerged accidentally, has been found to be useful in the machining of wide variety of materials. The process has received global attention mainly because of its applicability to electrically non-conducting materials. Many researchers have investigated the process, especially its spark formation mechanism, its hydrogen gas evolution together with its bubble formation mechanism, and its material-removal mechanism. With our intensive experimental research investigations, we have tried to understand the underlying phenomena during the process. With this information, we announce its application to the micromachining of a wide range of materials, including copper, tungsten, molybdenum, glass, quartz, and silicon, among others. With the careful design of the experimental setup, tool material selection, power supply selection, and the in-house development of an automated 5-DOF machine, we have been able to achieve micro-level machining, deposition, and surface modification. These phenomena can be achieved simultaneously or one at a time. Simultaneous surface treatment, micromachining, and copper deposition on a silicon wafer, are achieved using this process. A novel metrology technique based on replica making using polymeric material is devised to measure the depth and width of the microchannels produced using ElectroChemical Spark MicroMachining (ECSMM). This metrology technique is prominent in the study of surface morphology.
Surface Encoders for a Mosaic Scale Grating
Authors: Hosono Koji ,   Nano-Metrology and Control Laboratory, Department of Nanomechanics, Tohoku University, 6-6-01 Aramaki Aza Aoba, Aoba-ku, Sendai 980-8579, Japan, Kim WooJae , Kimura Akihide , Shimizu Yuki , Gao Wei
Published: April 2016

The surface encoder we propose for simultaneously measuring XYZ-directional displacements consists of a XY-axis with a scale grating and an optical sensor head. The XY-axis scale grating size determines the surface encoder’s measurement range in plane - in the X and Y directions. The mosaic XY-axis scale grating we use to expand the measurement range in plane consists of multiple XY-axis scale gratings arranged in plane. We present two optical configurations for the mosaic XY-axis scale grating. To confirm our configurations’ effectiveness, we fabricated two prototypes that we tested in basic experiments using a mosaic single-axis scale grating.
Software Datum Design for Cross-Axis Motion Measurement of X-Stage Based on Least Uncertainty Criterion
Authors: Okuyama Eiki ,   Akita University, Akita 010-8502, Japan, Takahashi Hiroshi , Ishikawa Hiromi ,   Akita Prefectural Office, Akita 010-8570, Japan
Published: April 2016

Cross-axis translational motion of a table on a machine tool is important in ultraprecision processes. Currently, conventional software datums that separate the cross-axismotion fromthe straightness profile of the straightedge by using multiple sensors and/or multiple arrangements are well-known. However, in large sampling numbers, the multiple sensor method tends to propagate random error. In this paper, a novel software datum for cross-axis motion measurement that can reduce the uncertainty due to the datum profile, pitch motion and random error is proposed. The proposed method consists of a weighted addition and inverse filtering. The suitable weight for the weighted addition yielding the least uncertainty is derived by an equation using standard deviations of the datum profile, pitch motion and random error of the sensors.
Surface Shape Measurement for Small Lens Using Phase Shift Shearing Interferometer
Authors: Hanayama Ryohei ,   The Graduate School for the Creation of New Photonics Industries, 1955-1 Kurematsu, Nishi-ku, Hamamatsu, Shizuoka 431-1202, Japan, Ishii Katsuhiro
Published: April 2016

In discussing small-lens surface shape measurement, a shearing interferometer with a plane-parallel glass plate is used to shape a laterally sheared beam from an induced test beam, producing interferogramreflecting wavefront phase distribution. This approach is robust against disturbance thanks to common-path interferometry and to the single solid glass plate. The Degree Of Freedom (DOF) for the shape of targets is high because no reference surfaces are needed. These make our proposal practical for use in the actual factory environment. The phase shift we use to analyze the interference fringe is induced by tilting a shear plate in this configuration, which is far cheaper than conventional equipment using PZT actuators. Our interferometer’s phase distribution shows a differential image of the target wavefront, so detected phase distribution must be integrated to get the original surface shape, as confirmed in the sections that follow.
Micro Cutting of Glass with Multiedge Tool
Authors: Matsumura Takashi ,   Tokyo Denki University, 2-2 Kanda Nishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan, Namiki Tatsuya
Published: April 2016

Glass cutting with a multiedge tool is presented to machine micro-scale grooves at high machining rates in a planning manner. The critical depth of cut at the ductile-brittle transition was measured to design the edge shape in the glass cutting tests. 13 rectangular edges 2 µm wide and 2 µm high were manufactured on a single crystal diamond tool by the focused ion beam. The cutting tests were conducted on a micro/nano-scale cutting machine, which controls the depth of cut of less than 1 µm. The glass cutting process with the multiedge tool is discussed with measuring the cutting force. The cutting force changes with the cutting mode: sliding/ploughing and cutting. Based on the measured cutting force, the compliance of the machine-tool-workpiece system, the friction coefficient of the tool on the glass surface and the specific cutting force are estimated. Then, 13 grooves 2 µm wide 0.3 µm deep were machined simultaneously in a feed of the multiedge tool. The machining accuracy was verified in optical diffraction tests.
A Proposed Ultraprecision Machining Process Monitoring Method Using Causal Network Model of Air Spindle System
Authors: Sawano Hiroshi ,   Precision and Intelligence Laboratory, Tokyo Institute of Technology, 4259 Nagatsuta, Midori-ku, Yokohama, Kanagawa 226-8503, Japan, Kobayashi Ryosuke , Yoshioka Hayato , Shinno Hidenori
Published: April 2016

Future ultraprecision machining systems require inprocess monitoring and intelligent machining control functions. This paper presents a newly developed machining process monitoring method. The method proposed aims at monitoring the ultraprecision machining process using a causal network model of an air spindle system. The results of actual machining experiments confirm that the proposed method can estimate the dynamic and thermal behaviors at the cutting point during machining. In consequence, the process monitoring method proposed can systematically predict the tool wear, the contact condition between the tool and the workpiece, the abnormal machining conditions, and so on.