bluuebunny/crossref_metadata_2025_split huggingface dataset:
Experimental Analysis of the Power Consumption of Feed Drive Systems Driven by Ball-Screw
Authors: Rigacci Massimiliano , Sato Ryuta , Shirase Keiichi 
Published: January 2021

Abstract
This study presents an experimental analysis of the power consumption of feed drive systems. The relevant system components from the power consumption point of view are the motor, bearings, ball-screw and linear guides. The electric power consumption of the motor is investigated experimentally acquiring the inputted voltage and the current; then, through the study of its efficiency, it is shown that the electric efficiency of the motor heavily depends on the angular velocity and the supplied torque. The mechanical power consumption of each component of the feed drive is investigated showing that the component that affects the most the consumption is the ball-screw. Thus, four kind of ball-screws differing for the lead of the screw and the preload of screw-nut are investigated; it is clarified the relation between the mechanical power consumption and several system characteristics such as the lead of the screw, the preload condition, and the table working velocity. Finally, the advantages and disadvantages of each mechanical configuration of the feed drive are discussed, emphasizing that the most important driven factor of the power consumption is the angular velocity due to the trade-off between the motor efficiency and the mechanical power loss of the system components cause friction.
Light Environment Design Support System Using Light-Guiding Plate With Decorative Cut Surface: Effects of Stripe Pattern Decorative Cutting on Plates Made From Transparent Resin
Authors: Imada Takumi , Ogawa Keiji , Tachibana Takuya , Sera Tetsuya , Okabe Toru 
Published: January 2021

Abstract
To increase the transmission efficiency of incoming and outgoing light on the side of a transparent resin light guide, such as an acrylic plate, we created a machined surface that does not become cloudy and transmits visible light well by cutting it with a single crystal diamond tool. When light is guided to this mirror-finished acrylic plate using an LED light source, its uneven brightness or illuminance distribution may be noticeable, depending on the application. To suppress the uneven distribution, attempts have made the luminance distribution uniform by a decorative cut on the acrylic plates for a fine pattern shape. Our research is developing a light environment design support system using an acrylic light-guiding plate with a decorative cut surface. This system consists of a rapid decoration pattern design technique with optical simulation, a decorative cutting technique to satisfy the demanded optical characteristics, and a technique to maintain machining quality. We implemented decorative cutting tests for various stripe patterns by adjusting the cutting conditions for the acrylic plates. Estimation of the decorative shapes was based on the shape of the tool cutting edge and its trajectory. We controlled the decoration shape and dimensions. The tendency of luminance distributions estimated by optical simulation were corresponded with the actual distributions.
Machining Vibration Suppression of a Cylindrical Part by a Point-Contact Support
Authors: Matsubara Atsushi , Mori Kotaro , Kono Daisuke 
Published: January 2021

Abstract
Aircraft engine cases employ a thin-walled cylindrical structure for the reduction of fuel consumption. The machining of such parts requires support systems as cutting forces generate shell mode vibrations. There has been much research on the design of vibration suppression devices such as mass dampers, tuned mass dampers, active dampers, and fixturing stretch. Although such devices can offer excellent performance in vibration suppression, cost, and time for manufacturing and setup with tuning are problems. In this paper, the test results of a simple support system that suppresses the vibration modes of a cylindrical part are reported. A support element employs two-contacts in the curved surface. Multiple support elements are arranged according to the number of antinodes of shell modes. Each support has two rollers with a rotating head; the roller contact aligned in the curved surface. For the decision of the number of the support elements, modal analysis was carried out for a cylindrical part. An excitation test was carried out to evaluate the frequency response of a supported cylinder, and several peaks in frequency response were found to be suppressed. A cutting test with an endmill was carried out to evaluate the vibration levels. The experimental results show that the support can suppress forced vibration during machining.
Precise Identification of Principal Stress Directions Induced in Laser Cleaving Process
Authors: Zhang Duo , Yamada Keiji , Nakajima Yuki , Tanaka Ryutaro , Sekiya Katsuhiko 
Published: January 2021

Abstract
Crack propagation is induced by thermal stress in the laser cleaving process, which is a prospective technique for dividing the substrates of hard and brittle materials such as glass, ceramics, and some semiconductor materials. Because the control of thermal stress distribution is essential for achievement of high accuracy in the process, various models have been developed for theoretical analyses to predict the stress distribution and estimate the effect of it. Besides, authors have developed a photoelastic observation technique for stress distribution in the laser cleaving process. In the present paper, the authors propose a procedure to compensate the distribution of stress direction within the substrates in order to apply the observation technique for the laser cleaving of single crystalline substrates which exhibit anisotropic photoelasticity. Single crystalline sapphire substrates are used as specimen in experiment to confirm the proposed procedure. Obtained results show the discrepancies between the principal stress direction and the birefringence direction of observation light in plane polariscope. And, the discrepancy depends on the crystal orientation with respect to the vibration plane of polarized light of the polariscope. This result is used to compensate the distribution of principal stress caused within the sapphire substrates during the laser cleaving process.
Lubrication Effect of Smeared Oil on Workpiece Surface in Intermittent Cutting With Very Short Cutting Duration
Authors: Nakamura Yoshiki , Itoigawa Fumihiro , Hayakawa Shinya , Maegawa Satoru , Liu Xiaoxu 
Published: January 2021

Abstract
In the metal cutting, generally, application of lubricant to a cutting edge is one of the methods in order to suppress temperature rise of the cutting edge by reducing frictional heat. However, the reduction in friction with lubricant disappears at higher temperature environment because of the loss of lubricant oiliness associated with temperature rise. Conversely, this reduction effect might work only in the initial stage immediately after cutting edge /work engagement because the temperature is not so high. Therefore, if the cutting duration of each blade of end-mill is shorten by limiting the cutting length per once, the cutting temperature can be suppressed to be lower than the moderate magnitude for lubrication. On the other hand, Ti-alloys with low thermal conductivity would experience quite high temperature increase during the high-speed cutting process. Therefore, it is thought that lubricant cannot be used properly with conventional cutting methods. In this study, the high-speed milling method mentioned above was used to implement the machining of Ti-alloys, and the lubricant effects of different types oils were compared from two aspects as tool wear and cutting force. As a result, when using low-viscosity synthetic ester oil, the damage to the cutting edge was suppressed most. At the same time, there was no fluctuation in cutting force by repeated machining. From this result, it was suggested that the lubricant performance, in intermittent cutting with very short cutting duration, depends on the heat resistance and permeability of the oil.
Development of Tool Path Generation Method for Complex Deep Groove Shape With Simultaneous 4-Axis Machining
Authors: Ichikawa Kohei , Nakamura Takayuki , Kaneko Jun'ichi , Hasegawa Masanobu , Abe Takeyuki 
Published: January 2021

Abstract
In recent years, aero engine parts with complex shapes are increasing due to demand on improved performance and weight reduction. In one example, some of those parts have groove which are deep, narrow and complex surface. They are processed by Simultaneous 5-axis machining with small ball end-mill. However, its complex groove shape cause greatly move of tool posture, thereby it cause greatly and discontinuous move of rotational and tilting axis of machine tool. As a result, actual feed speed cannot follow the commanded feed speed, so low process efficiency is problem. It can be considered simultaneous 4-axis machining which with fixed tilting axis as countermeasure. However it is difficult to generating tool path of simultaneous 4-axis machining by commercial Computer Aided Manufacturing (CAM) software for these deep groove shapes because of its tool collision avoidance algorithm. In this study, we developed method of generating tool path that can be machining simultaneous 4-axis machining while avoiding collision of workpiece and tool as an aim of increasing process efficiency. Furthermore, In order to effect of further improve the feed speed, we studied about posture planning way with possible to continuous moving of rotational axis, and we conducted verification test of increasing of feed speed with proposed method.
Tool Posture Planning Method for Low Rigidity Workpiece Considering Elastic Deformation Caused by Cutting Force
Authors: Kaneko Jun'ichi , Okuma Yuki , Sugita Shumpei , Abe Takeyuki 
Published: January 2021

Abstract
In machining process for a workpiece with low rigidity such as a blade shape, it is required to consider elastic deformation of the workpiece shape itself due to cutting force. Conventionally, reduction of the cutting force in machining process is achieved by optimization of feed rate value in NC program. On the other hand, since a decrease in the feed rate causes an increase in machining time. So, other optimization algorithm is required.
In this paper, a new method to suppress the elastic deformation of the workpiece by changing tool posture in multi-axis controlled machining is proposed. The proposed method is intended for finish machining process for blade shape with a ball end mill. In the proposed method, first, the cutting force loaded on the workpiece surface in a certain posture candidate is predicted, and an instantaneous cutting force at the moment when the machining surface is generated is estimated by model-based computer simulation. Based on this results, the amount of elastic deformation on the machined surface is estimated by FEM. This process is repeated at each cutter location and tool posture candidate, and the new tool posture that can minimize machining error caused by the elastic deformation is determined at each cutter location.
Effects of Alpha-Cellulose Supply on the Working Life of MCF Slurry in MCF Polishing
Authors: Nonaka Yuta , Nomura Mitsuyoshi , Fujii Tatsuya , Suzuki Tsunehisa , Wu Yongbo 
Published: January 2021

Abstract
High precision surfaces exhibit prominent capabilities for enhancing the imaging quality, expanding the visibility of equipment, simplifying structures, and reducing total costs of optical systems. Hence, they are regarded as essential optical surfaces for replacing traditional elements to modify optical systems, including space systems, optical inspection systems, and smart devices.
Single point diamond turning (SPDT) and ultra-precision grinding have been adopted preliminarily to manufacture high-quality elements. However, these processes create sub-surface damage and tool marks on the work surface. To meet performance requirements, polishing is critical for post-processing to improve the quality of the products.
MCF (Magnetic Compound Fluid) polishing, which is one of polishing methods using magnetic fields, is a processing method for finishing hard and brittle materials with high accuracy. Previous research has shown that MCF polishing is effective for hard and brittle materials. However, despite the high cost of the magnetic fluid that is a component of the MCF slurry, the MCF slurry used for polishing has been discarded. Another major issue was that unused MCF slurry could not be used due to drying. The purpose of this study is to recycle MCF slurry to solve this problem, and to develop high precision finishing technology. Therefore, in this study, a novel MCF polishing method using ultrasonic atomization is proposed, and the effects of α-cellulose on the MCF polishing are investigated. In addition, in order to make it possible to reuse the MCF slurry, In addition, experiments are conducted to enable reuse of MCF slurry.
Effects of Cold Air Supply on Cutting Characteristics in Small Hole Drilling of PEEK
Authors: Ito Shogo , Nomura Mitsuyoshi , Fujii Tatsuya , Suzuki Tsunehisa 
Published: January 2021

Abstract
A polyetheretherketone (PEEK) is one of the thermoplastic resins. The material is superior in mechanical strength, heat resistance and chemical resistance. Therefore, it is suitable for industrial components such as automotive parts, machine parts, electrical and electronics parts. Particularly, it is used for an inspection socket of a connector and the semiconductor package in the field of electronic components. Consequently, a demand of the high efficiency machining in small drilling for the PEEK increases with a miniaturization and diversification of the industrial equipment. However, PEEK, which is a thermoplastic resin, has a problem that the hole accuracy is lowered due to the cutting heat.
The objective of this study is to achieve high precision and high efficiency machining process for industrial components of the PEEK such as an inspection socket of a connector or the semiconductor package. In order to solve these problems, this study carries out cooling workpiece by cold air supply. This paper describes the investigation result of the effect of cold air cooling on hole accuracy and cutting state in the small hole machining of PEEK. As a result, it was found that cooling the workpiece is effective to suppressing the cutting heat and improve hole accuracy. Within the experimental conditions, the combination of non-step drilling and cooling enables high-precision drilling with approximately the same accuracy as step drilling.
Experimental Investigation of Plastic Injection Molding Heating System Using Hydrogen Absorbing Alloys
Authors: Fukushima Yoshio , Kosaka Masataka 
Published: January 2021

Abstract
Much focus from various fields is being placed on the hydrogen and utilizing the technique. Nowadays, the applied researches of hydrogen energy have been trying as one of an alternative energy source for fossil fuel. And, since we could not think lightly of consumed energy by machine tools and industrial machinery, Eco-friendly manufacturing is going to be achieved by hydrogen energy. In this study, to prevent the weldline that is a representative defect in the field of plastic injection molding, heat & cool technology using hydrogen energy, LmNi4.90Mn0.10 hydride, is applied to the mold. This method can achieve heat & cool technology by using only hydrogen energy. So, since electricity and warm/cool water that are for heating/cooling the mold are not necessary, this method should thus be at an engineering advantage in terms of eco-friendly manufacturing. After manufacturing the hydrogen-used-prototype-mold that is dedicated to preventing the weldline, the comparison between the experimental data and numerical simulation was carried out. As result, using this approach, the mold surface temperature difference from initial temperature was rapidly increasing to 40 K, in 18 seconds from the beginning of hydrogen-absorbing and the maximum temperature difference ΔT in this experiment has become 48 K.
Generation of Micro Texture Including Calcium and Phosphorus Elements on Titanium Alloy for Improvement of Biocompatibility With Laser Induced Mist Surface Treatment
Authors: Ezura Atsushi , Katahira Kazutoshi , Komotori Jun 
Published: January 2021

Abstract
Titanium alloys are widely used for the hard tissue substitute implants. However, it is necessary to improve interfacial biocompatibility for reduce adhesion period. For improvement of biocompatibility of titanium alloys, texture and chemical composition on contact part with biological tissue play very important roles. In this research, mist of glycerophosphoric acid calcium aqueous solution was applied on the laser irradiated area. As result, micro texture including Ca and P elements was generated on the Ti-6Al-4V-ELI alloys surfaces. When laser was irradiated, glycerophosphoric acid calcium aqueous solution applied as mist flowed on the test pieces as droplet. The velocity of droplet fluid was relatively fast, so that laser irradiation was unhindered access to the surface of specimens and the treatment was stable. In order to estimate biocompatibility of treated surfaces having micro texture with Ca and P element, culture assays using osteoblast cells were conducted. As result, it was clearly that biocompatibility of the specimen treated by laser with glycerophosphoric acid calcium aqueous solution mist more improved than treated specimen soaked in glycerophosphoric acid calcium aqueous solution.
Energy Consideration in the Micro-Extrusion of Aluminum Alloy 6063
Authors: Sucharitwatskul Sedthawatt , Mahayotsanun Numpon , Bureerat Sujin , Dohda Kuniaki 
Published: January 2021

Abstract
This paper investigated key factors influencing energy consumption in the micro-extrusion process. The considered factors were: extrusion ratio (ER), die angle (α), billet length (BL), bearing length (LB), coefficient of friction (COF), and die shift (DS). The finite element simulation was carried out to determine the extrusion energy required to complete one extrusion cycle. The simulation results showed that the increased values of all the considered factors (except the die shift) led to increased extrusion energy. The results also provided percentages of energy variation in steps, which helped evaluate the energy savings with regards to the crucial other production considerations. The percentage increase in energy consumption in the lower ER values was considered higher than those of, the higher ER values. Increasing die angle (α) from 60° to 90° barely affected the consumed energy. The highest increase percentage of extrusion energy was found while increasing billet lengths (BL) from 3.00 mm to 4.00 mm. The lower bearing length (LB) values offered lower consumed energy. The consumed extrusion energy linearly increased with COF. The die shift (DS) did not affect the extrusion energy, but the final part geometry (curved pins). The results and analysis from this study could be used to potential energy savings and overall production costs of the micro-extrusion process.
Effect of Insert Material on Microstructure and Strength of Aluminum Alloy to Zinc-Coated Steel Dissimilar Metal Weld
Authors: Walker Luke , Lu Ying , Hilla Colleen , Zhang Wei , Ou Byoung , Hunter Scott 
Published: January 2021

Abstract
Ultrasonic interlayered resistance spot welding (Ulti-RSW) is a recently developed method for dissimilar metal joining of aluminum alloy to advanced high strength steel. It makes use of a thin insert (or interlayer) which is first ultrasonic spot welded to one of the two sheets. The second sheet is then resistance spot welded to the insert side of the first sheet. In the present study, two inserts were tested, 0.3-mm-thick AA3003-H14 and 0.25-mm-thick stainless steel 316, for joining 0.8-mm-thick Zn-coated (galvannealed) dual phase steel 590 to 1.2-mm-thinck aluminum AA6022-T4. The joint with the aluminum insert achieved a peak tensile-shear strength of 4.1kN and a fracture energy of 1.7J, while the joint with the stainless steel insert achieved a peak strength of 4.5kN and a fracture energy of 2.6J. Both welds were much stronger than a direct resistance spot weld between the two sheets which had a strength of 3.3kN and an inferior fracture energy of 0.87J. The increase in strength and fracture energy achieved using stainless steel insert over aluminum insert was discussed based on the nugget diameter and the interface microstructure.
Simulation of Complex Plastic Flows in Machining of Metal Polycrystals Using Remeshing
Authors: Salilkumar Vandana A. , Sundaram Narayan K. 
Published: January 2021

Abstract
The simulation of machining of soft metals at the 100 microns-few mm length-scale requires capturing complex flow physics induced by the high ductility and polycrystalline aggregate nature of these metals. This work presents a remeshing and mesh-to-mesh transfer approach that can successfully simulate complex flows including highly sinuous flow with surface folding in polycrystalline aggregate cutting. The meshing scheme is both graded and adaptive, with the ability to automatically refine regions such as self-contacts. Notably, the presence of microstructure makes these simulations far more complex than their homogeneous counterparts, with several additional constraints on the remeshing algorithm. The approach is general, with no limitations on rake angle, grain-size, or friction coefficient, and does not use an artificial, predefined separation layer. The scheme accurately tracks individual grains and allows grain splitting in a manner consistent with imaging experiments. The plastic strain field, cutting-force evolution, and deformed grain shape from several annealed-copper cutting simulations are presented, representing a range of rake angles and friction coefficients as high as 0.5. The simulations accurately capture the thick chips, high cutting force, and highly undulating streaklines of flow that characterize sinuous flow, as well as the experimental observation that the sinuous flow is suppressed on using a high rake-angle for the cutting. Moreover, in grains that are split between the chip and residual surface, we can accurately capture the extreme grain stretching that is observed prior to splitting in imaging experiments. Remeshing also provides a way to accurately capture the residual surface plastic strains and strain gradients. The latter are particularly steep, with the strain falling from a value greater than 10 to 2 within a distance of 30 microns. The use of remeshing has numerous advantages over a predefined separation layer, including the fact that one can parametrically explore the effect of variables like the extent of yield stress inhomogeneity on the flow pattern with no limitations. Interestingly, the technique allows us to find the actual line of material separation in such cutting processes: As opposed to a horizontal line, this is typically an undulating curve with a deviation of about 0.06 of the undeformed chip thickness on either side of the horizontal. This fraction increases with the extent of sinuous flow. A simple, pseudograin model with spatial inhomogeneity in flow stress is used to represent the microstructure in the present work, but the present scheme can easily be used with more complex microstructural models as well.