bluuebunny/crossref_metadata_2025_split huggingface dataset:
Error Analysis by Square 3 x 3 Machining Method for Five-Axis Machining Centers
Authors: Sakamoto Shigehiko , Yokoyama Atsushi , Nakayasu Kazumasa , Suzuki Toshihiro , Koike Shinji 
Published: January 2021

Abstract
The establishment of international standards for 5-axis control machining centers has been supported by the high interest of each country. Internationally, various accuracy inspection methods have been proposed and widely discussed. Accuracy measuring devices for these purposes have also been proposed. In 2014, inspection methods for 5-axis machines were published in ISO 10791-6 and 10791-7.
In this research, we propose a test method to process 9 square faces as a new accuracy evaluation method. We simulate the influence of assembly error by the proposed square 3 × 3 machining method on the machined surface. By processing 9 square faces with different tool angle on the same plane, it was possible to evaluate the influence of assembly errors in the 5-axis machining center on the machined surface.
Nine surfaces machined by the square 3 × 3 processing method cause differences in surface height due to alignment errors. In addition, nine machined surfaces become all diagonal not parallelism. The alignment errors of the 5-axis machining center is identified by evaluating the orientation of the machined surfaces. Specifically, we propose a newly method to measure the height difference of nine surfaces. Then, the possibility of identifying the alignment error of the 5-axis machining center using the measurement results is shown.
Effects of the Size of Built-Up Layer on the Wear of Uncoated Cemented Carbide Tools in Dry Cutting of SUS304 Stainless Steel
Authors: Song Xiaoqi , Takahashi Yukio , Ihara Tohru , He Weiming 
Published: January 2021

Abstract
Built-up layer (BUL) formed on the tool rake face during cutting has the tool protective effect. As BUL can change the shape of tool resulting in variation of rake angle and edge radius during cutting, it also has significant influences on the cutting phenomena such as tool wear, cutting forces and surface integrity. SUS304 stainless steel is very difficult to cut, leading to the rapid tool wear and poor surface quality. It also has a high tendency to form BUL during cutting due to its high work hardening rate and high chemical affinity. To actively and purposely utilize BUL, the effects of the size of BUL on the wear of uncoated cemented carbide tools in dry cutting of SUS304 were investigated using experimental and analytical methods in this study. The cutting parameters were chosen to induce the stable BUL formation. After cutting, the worn cutting tools were analyzed using the laser confocal microscopy and scanning electron microscopy. It was confirmed that BUL can reduce the tool flank wear rate in the steady-state wear when its height is equal to or less than the uncut chip thickness. The results also showed that BUL formed at cutting speed 40 m/min can not only reduce the tool flank wear rate but also induce a significant improvement in cutting forces and surface integrity. Meanwhile, using the obtained experimental results and proposed model, simulation was conducted to evaluate the effects of the size of BUL on the tool flank wear formation. It was confirmed that BUL, especially when its height is close to the uncut chip thickness, which reduces the real rake angle to negative, can reduce the normal stress on the tool flank face and lead to a decrease in the tool flank wear rate.
Measuring Optical Properties of Advanced Nano/Micro-Periodic Structures Fabricated by Multi-Exposure Interference Lithography
Authors: Masui Shuzo , Michihata Masaki , Takamasu Kiyoshi , Takahashi Satoru 
Published: January 2021

Abstract
Functional optical elements based on nano/micro-periodic structures have attracted much attention. Since the fabrication of these dual-periodic structures requires precise control of periodicity, the semiconductor process such as an electron beam lithography has been mainly employed. However, these techniques have problems with expensive and low throughput for industrial applications. Therefore, there remains a need for low cost and high throughput fabrication methods of dual-periodic structures. Then we developed a multi-exposure interference lithography (MEIL) system using rotational Lloyd’s mirror interferometer to overcome these problems. The advantages of interference lithography are a large processing area and low cost. Our developed rotational Lloyd’s mirror setup enables us to a highly precise superposition of multiple interference fringes by multi-exposure. Furthermore, we developed a measurement setup for reflective diffractive elements using a two axial rotating stage and measured the diffraction properties of the fabricated dual-periodic diffraction gratings. In this paper, as a demonstration, we succeeded in the fabrication of high-dispersion diffraction grating with an enhanced diffraction efficiency of the −3rd order light. The fabricated shapes have a periodicity of 1997 nm and 665 nm. Furthermore, it was confirmed that the intensity of the −3rd order light was enhanced by about 10 times compared to the single periodic grating.
Measurement of Rake Face Temperature in Cryogenic Machining of Titanium Alloy
Authors: Sato Masahiko , Kamoto Masashi 
Published: January 2021

Abstract
Titanium alloys are widely used as mechanical components, since they have superior properties such as high strength-to-weight ratio. They are regarded as difficult-to-cut materials. Their low thermal conductivity increases the temperature near the cutting edge, which causes excessive tool wear during cutting. Recently, many studies on cryogenic machining have been conducted. Cryogenic machining has emerged as an environmentally friendly alternative to traditional emulsion coolants. In this study, the rake face temperatures of cutting tool in the turning of titanium alloy under dry, soluble coolant, cryogenic carbon dioxide coolant and liquid nitrogen coolant conditions were measured to clarify the effect of coolant on cutting temperature. Turning tests were performed using a precision lathe. Tool insert was made by a translucent alumina. A small hole was drilled into the tool insert. An infrared radiation pyrometer with an optical fiber was used. The optical fiber was inserted into the hole. During chip formation, the infrared rays, radiated from the tool-chip interface and transmitted through the cutting tool, were accepted and transmitted by the optical fiber. The effects of cryogenic coolant on the rake face temperature were investigated. The rake face temperatures under carbon dioxide cooling and liquid nitrogen cooling were approximately 60 °C and 90 °C lower than that in dry cutting, respectively.
Investigation of Fracture Behavior of Piezoelectric Ceramics Embedded in Metal Matrix
Authors: Iijima Karin , Yanaseko Tetsuro , Kuboki Isao , Sato Hiroshi , Asanuma Hiroshi 
Published: January 2021

Abstract
In recent years, there is considerable interest in the Structural health monitoring. This is a technique to diagnose and evaluate the damage and deterioration of a structure by attaching sensors to the structure, and is useful for judging whether building can be reused or not at that time of a disaster such as an earthquake. There are several types of sensors such as piezoelectric type, optical fiber and strain gauge type and piezoelectric sensors are very suitable for this purpose because they do not require an energy source considering that they produce electrical power by themselves. However, the application range of piezoelectric ceramics used for piezoelectric sensors is narrow because of its fragility. Then, the researches and developments of the piezoelectric ceramics embedded in the matrix that has excellent mechanical strength are carried out. The metal-core piezoelectric fiber/aluminum composite was developed by Asanuma et al. to overcome the problems associated with piezoelectric ceramics, such as poor mechanical properties, reliability; brittleness and low fracture strain. The fracture strain of piezoelectric ceramics fiber significantly improved due to residual compressive stress caused by difference of coefficient of thermal expansion between the ceramics and the matrix during embedding process. However, there is few statistical data on the mechanical properties of piezoelectric ceramic fibers, and the improvement in the properties due to the embedding has not been quantitatively evaluated. In this study, to overcome this problem, the simplified model of metal matrix piezoelectric composite was fabricated and used to compare strengths before and after embedding by 3-point bending test. As a result, it is found that Weibull parameters of piezoelectric ceramics are improved by embedding in the matrix.
Precision Coating of ta-C Films on Quartz Surfaces
Authors: Kawai Kotaro , Hirata Yuki , Akasaka Hiroki , Ohtake Naoto 
Published: January 2021

Abstract
Diamond-like carbon (DLC) films have excellent properties such as high hardness, low friction coefficient, high wear resistance, chemical inertness and so on. Because DLC film is considered as an effective coating material to improve their surface properties, this films are used in various applications such as parts for automobiles engines, hard disk surfaces, cutting tools and dies, and so on. DLC films consist of a mixture of sp2 bonded carbon atoms and sp3 bonded carbon atoms. Among them, ta-C film is known as the hardest and strongest film since it mainly consists of sp3 bonded carbon atoms. One of deposition methods to form ta-C is Filtered Cathodic Vacuum Arc (FCVA). The characteristic of this method is that it is possible to remove the droplets and form a high-quality film.. However, even though lots of mechanical components which require ta-C coating have three-dimensionally shapes, it is difficult to coat ta-C film three dimensionally by using FCVA process. At present, researches on 3D deposition of amorphous carbon films on three dimensional components is still insufficient, and investigation reports on the deposition mechanism and characterization of the deposited films are even more limited. In this study, we tried to deposit films on 3D components by the FCVA method and evaluated the microstructure and surface morphologies of films. Although films were coated successfully in the entire surfaces, different properties were showed depending on the location of components. These properties were investigated by Raman spectroscopy and laser microscope.
Development of Curved Hole Electrical Discharge Machining Method: Automatic Generation of Device Operating Command in Consideration of Realizing the Machining
Authors: Ishida Tohru , Kaide Yusuke , Mizobuchi Akira , Takeuchi Yoshimi 
Published: January 2021

Abstract
Aiming to enhance the degree of freedom of hole shapes which can be realized by machining methods, our research group has developed a new device that can fabricate curved holes by means of electrical discharge machining. The previous studies have shown that the device has the ability of fabricating curved holes and have developed the manner for fabricating curved holes with desired shapes by use of the device. This manner is built on the basis of the teaching playback method. So, the manner contains the teaching process for generating the operating commands that can make the device fabricate desired curved holes. However, the teaching process just built needed troublesome manual works. Not to need such works, the last study has devised the manner for automatizing the teaching process. Contrary to our expectation, however, the operating command generated by the automatized teaching process could not fabricate a desired curved hole due to the lack of the consideration to the motion capacity of the device and so on. To overcome this problem, this study has improved the algorithm to generate the operation command. The machining experiment employing the operating command generated by using the improved algorithm can fabricate the desired curved hole. This proves that the improved algorithm is effective to the fabrication of desired curved holes by means of the device.
Surface Texturing Process by High Speed Ultrasonic Turning to Obtain Low Friction Surface
Authors: Hara Keisuke , Isobe Hiromi 
Published: January 2021

Abstract
Tribological properties such as lubrication, friction and wear resistance are important to improve machine operating efficiency, machine performances and machine life. To improve tribological properties of sliding surface, scraping is available. Scraping fabricates many small depression on target surface evenly, the depression will function oil hole which promote lubrication of flat bearing surface. Many researchers have reported the surface texturing method which aim is similar to scraping. For example, the techniques fast tool servo turning with diamond insert tool and turn mill processing by dual spindle turning center were reported to fabricate periodically micro dimple. However, these techniques employ expensive high precision machine tools. This paper introduces a more cheaply and rapidly surface texturing technique which employs ultrasonic vibration turning to obtain low friction surface and improve tribological properties. In ultrasonic turning, cutting tool tip is vibrated in principal direction and radial direction simultaneously origin from poisons deformation of ultrasonic transducer. The radial direction tool vibration functions to squeeze workpiece surface in workpiece radial direction periodically, textured surface will be obtained. The results of ultrasonic turning experiments, textured surfaces were obtained. In order to evaluate the tribological performance of the turned surface, friction coefficient between stainless steel pin and turned surface were measured under oil dipping condition. It was confirmed that friction coefficient of ultrasonic turned surface is drastically reduced compared with ordinary turned surface. And proposed technique is available to perform surface texturing for several materials.
Development of the cBN Electroplated End-Mill for High Precision Machining of CFRP
Authors: Yamashita Shinnosuke , Furuki Tatsuya , Kousaka Hiroyuki , Hirogaki Toshiki , Aoyama Eiichi , Inaba Kiyofumi , Fujiwara Kazuna 
Published: January 2021

Abstract
Recently, the demand of carbon fiber reinforced plastics (CFRP) has been rapidly increased in various fields. In most cases, CFRP products requires a finish machining like cutting or grinding. In the case of an end-milling, burrs and uncut fibers are easy to occur. On the other hand, a precise machined surface and edge will be able to obtain by using the grinding tool. Therefore, this research has been developed a novel the cBN electroplated end-mill that combined end-mill and grinding tool. In this report, the effectiveness of developed tool was investigated. First, the developed tool cut the CFRP with side milling. As the result, the cBN abrasives that were fixed on the outer surface of developed tool did not drop out. Next, the end-milled surface of CFRP was ground with the developed tool under several grinding conditions based on the Design of Experiment. Consequently, the optimum grinding condition that can obtain the sharp edge which does not have burrs and uncut fibers was found. However, surface roughness was not good enough. Thus, an oscillating grinding was applied. In addition, the theoretical surface roughness formula in case using the developed tool was formularized. As the result, the required surface roughness in the airplane field was obtained.
Study on Forming Behaviour of Friction Stir Welded Blanks During Single Point Incremental Forming (SPIF) Process
Authors: Marathe Shalin , Raval Harit 
Published: January 2021

Abstract
The automobile, transportation and shipbuilding industries are aiming at fuel efficient products. In order to enhance the fuel efficiency, the overall weight of the product should be brought down. This requirement has increased the use of material like aluminium and its alloys. But, it is difficult to weld aluminium using conventional welding processes. This problem can be solved by inventions like friction stir welding (FSW) process. During fabrication of product, FSW joints are subjected to many different processes and forming is one of them. During conventional forming, the formability of the welded blanks is found to be lower than the formability of the parent blank involved in it. One of the major reasons for reduction in formability is the global deformation provided on the blank during forming process. In order to improve the formability of homogeneous blanks, Single Point Incremental Forming (SPIF) is found to be giving excellent results. So, in this work formability of the welded blanks is investigated during the SPIF process. Friction Stir Welding is used to fabricate the welded blanks using AA 6061 T6 as base material. Welded blanks are formed in to truncated cone through SPIF process. CNC milling machine is used as SPIF machine tool to perform the experimental work. In order to avoid direct contact between weld seam and forming tool, a dummy sheet was used between them. As responses forming limit curve (FLC), surface roughness, and thinning are investigated. It was found that use of dummy sheet leads to improve the surface finish of the formed blank. The formability of the blank was found less in comparison to the parent metal involved in it. Uneven distribution of mechanical properties in the welded blanks leads to decrease the formability of the welded blanks.
A Hybrid Physical Model Based Artificial Neural Network Approach to Predict Surface Texture in the Honing of Engine Cylinder Bore
Authors: Afzel Burhan , Zhang Xueping , Srivastava Anil K. 
Published: January 2021

Abstract
This study proposes a hybrid model that utilizes a physical model and Artificial Neural Networks (ANN) approach to predict surface roughness during cylinder bore honing with an improved prediction efficiency of 90% compared to the standalone physical model. As a critical component of internal combustion engine technology, improvement in the surface roughness of cylinder bore can significantly reduce friction, wear and oil consumption, resulting in improved engine performance. Desired surface roughness in cylinder bore is imparted by honing, which serves as the terminal process in cylinder bore manufacturing. The cylinder bore honing process consists of rough honing, fine honing, and plateau honing stage. Each stage further involves variables such as honing stone geometry, grain size, grain concentration, honing speed, pressure, feed, over travel, number of strokes, etc. In literature, different approaches have been proposed to determine the influence of process parameters on the surface roughness of the honed cylinder bore. However, these approaches have their limitations. Experimental based studies are limited by the number of parameters that can be considered, analytical analysis methods involve extensive calculations resulting in reduced computational efficiency and accuracy, while machine learning approaches require a large amount of data. To overcome these limitations, this study employs a hybrid model to investigate the evolution of roughness at the rough and fine stage of the honing process. A two-phase approach is employed; first, a physical model is used to determine the surface roughness using various parameters. Secondly, these results are applied to train the ANN that can predict surface roughness for new parameters with a difference of less than 10% from the physical model.
Expulsion Intensity Monitoring and Modeling in Resistance Spot Welding Based on Electrode Displacement Signals
Authors: Xia Yu-Jun , Shen Yan , Zhou Lang , Li Yong-Bing 
Published: January 2021

Abstract
Weld expulsion is one of the most common welding defects during resistance spot welding (RSW) process especially for high strength steels (HSS). In order to control and eventually eliminate weld expulsion in production, accurate assessment of the expulsion severity should be the first step and is urgently required. Among the existing methods, real-time monitoring of RSW-related process signals has become a promising approach to actualize the online evaluation of weld expulsion. However, the inherent correlation between the process signals and the expulsion intensity is still unclear. In this work, a commonly used process signal, namely the electrode displacement and its instantaneous behavior when expulsion occurs are systematically studied. Based upon experiments with various electrodes and workpieces, a nonlinear relation between the weight of expelled metal and the sudden displacement drop accompanied by the occurrence of weld expulsion is observed, which is mainly influenced by electrode tip geometry but not by material strength or sheet thickness. The intrinsic relationship between this specific signal feature and the magnitude of expulsion is further explored through geometrical analysis, and a modified analytical model for online expulsion evaluation is finally proposed. It is shown that the improved model could be applied to domed electrodes with different tip geometries and varying workpieces ranging from low carbon steel to HSS. The error of expulsion estimation could be limited within ±20.4 mg (±2σ) at a 95% confidence level. This study may contribute to the online control of weld expulsion to the minimum level.
On Transfer Learning of Traditional Frequency and Time Domain Features in Turning
Authors: Yesilli Melih C. , Khasawneh Firas A. 
Published: January 2021

Abstract
There has been an increasing interest in leveraging machine learning tools for chatter prediction and diagnosis in discrete manufacturing processes. Some of the most common features for studying chatter include traditional signal processing tools such as Fast Fourier Transform (FFT), Power Spectral Density (PSD), and the Auto-correlation Function (ACF). In this study, we use these tools in a supervised learning setting to identify chatter in accelerometer signals obtained from a turning experiment. The experiment is performed using four different tool overhang lengths with varying cutting speed and the depth of cut. We then examine the resulting signals and tag them as either chatter or chatter-free. The tagged signals are then used to train a classifier. The classification methods include the most common algorithms: Support Vector Machine (SVM), Logistic Regression (LR), Random Forest (RF), and Gradient Boost (GB). Our results show that features extracted from the Fourier spectrum are the most informative when training a classifier and testing on data from the same cutting configuration yielding accuracy as high as %96. However, the accuracy drops significantly when training and testing on two different configurations with different structural eigenfrequencies. Thus, we conclude that while these traditional features can be highly tuned to a certain process, their transfer learning ability is limited. We also compare our results against two other methods with rising popularity in the literature: Wavelet Packet Transform (WPT) and Ensemble Empirical Mode Decomposition (EEMD). The latter two methods, especially EEMD, show better transfer learning capabilities for our dataset.
Data-Enabled Modeling and Performance Evaluation of Multistage Serial Manufacturing Systems With Quality Rework
Authors: Zhu Cheng , Yu Tian , Chang Qing , Arinez Jorge 
Published: January 2021

Abstract
In a multistage serial production line, products with defect can be repaired or reworked to ensure high product quality. This paper studies a multistage serial manufacturing system with quality rework loops. Rework is the activity to repair or repeat the work on the defect parts during manufacturing processes, and it adds to cost and cycle time. This paper introduces an event-based data-enabled mathematical model for a stochastic production line with quality rework loops. The system performance properties are analyzed and permanent production loss due to quality rework loops is identified. The mathematical model and system performance identification methodology are studied analytically through numerical case studies.