JSME International Journal Series C Mechanical Systems, Machine Elements and Manufacturing
Online ISSN : 1347-538X
Print ISSN : 1344-7653
ISSN-L : 1344-7653
Volume 47, Issue 1
Special Issue on Advanced Manufacturing Technology
Displaying 1-50 of 58 articles from this issue
PAPERS
  • Hisanobu TERAI, Minghui HAO, Koichi KIKKAWA, Yoshio MIZUGAKI
    2004 Volume 47 Issue 1 Pages 2-7
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper clarifies the analysis method for the undeformed chip thickness and the geometric influence of the tool orientation on the ball-nosed end milling. It has been firstly pointed out that the geometric situations on the determination of the thickness are categorized in three cases based on the relationship among the milling parameters. Secondly each corresponding case has been reduced into a comprehensive equation with introducing a coordinate system of tool axis orientation. Then the result of analysis has been shown in graphics. Through the analysis of the equations, the tool axis orientation had directly influenced to the undeformed chip thickness. Besides, the possibility of estimating the machining error or the tool damage using this geometric analysis is pointed out.
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  • Hiroyasu IWABE, Shuji NATORI, Masami MASUDA, Takashi MIYAGUCHI
    2004 Volume 47 Issue 1 Pages 8-13
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper deals with the analysis of the surface generating mechanism of a ball end mill based on deflection. The FEM model of a ball end mill is made out and the cutter deflection due to cutting force is calculated using the model and the cutting edge position is predicted using the behavior of cutting force obtained by the cutting tests and cutting area calculated by 3D-CAD. The shape of the machined surface is predicted by summation of cutting edge positions which are obtained by the cutter deflection and the cutter rotation during machining. The predicted surface is almost coincident to the experimental shape, so the method of calculation for the machined shape is verified.
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  • Kenichi HIROSAKI, Kazuhiro SHINTANI, Hideharu KATO, Fumi ASAKURA, Kazu ...
    2004 Volume 47 Issue 1 Pages 14-20
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Using a binder-less PcBN tool, improvement of processing efficiency was tried in machining of a vanadium-free titanium alloy, Ti-6Al-2Nb-1Ta which was recently applied for a surgical implant material. The tool which is prepared through the direct conversion sintering of h-BN under both high pressure and temperature, exhibits an improved high thermal durability. It was confirmed that a binder-less PcBN tool exhibited lower flank wear and kept sharper cutting edge compared to the tools made of materials such as sintered carbide, conventional PcBN and polycrystalline diamond with Co-based binder, after turning in cutting speed of 4.2m/s, feed rate of 0.15mm/rev, depth of cut of 0.5mm under an application of a high pressure coolant. Also, milling tests were conducted with a radius end mill tool whose tip was made of the binder-less PcBN material. As a result, the possibility of high speed milling at cutting speed of 8.3m/s was found.
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  • Mitsuhiro MURAYAMA, Shigeru NAGASAWA, Yasushi FUKUZAWA, Isamu KATAYAMA
    2004 Volume 47 Issue 1 Pages 21-28
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper reports about the fundamental relationship between tip thickness of crushed cutter and thickness of wedged sheet. By varying the tip thickness of a trapezoidal center bevel cutter, the resistance of cutter indentation and the shared profile of aluminum sheet were investigated experimentally. To discuss the deformation mechanism of aluminum sheet in the necking stage, Hill's solution with slip line theory and finite element analysis with elasto-plastic model were applied to this wedge indentation. The derived results were as follows: the necked height of sheet material varies with the tip thickness of cutter; the occurrence limit of necking deformation exists in terms of sheet thickness; the line force at the deflection point varies with the tip thickness of the cutter, but not with sheet thickness; the residual sheet thickness beneath the cutter tip depends on the thickness of cutter tip.
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  • Jiwang YAN, Kouki MAEKAWA, Jun'ichi TAMAKI, Akihiko KUBO
    2004 Volume 47 Issue 1 Pages 29-36
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Single-crystal germanium is an important infrared optical material. In the present work, single-point diamond turning experiments on single-crystal germanium (100), (110) and (111) planes were conducted in order to examine their ultraprecision machining characteristics. Three kinds of surface textures and chip morphologies were observed during the brittle-ductile transition of the machining mode. The brittle-ductile boundary changed significantly with the crystal orientations of the workpieces. Due to the crystallographic anisotropy, micro-fractures were generated on the workpiece surface in a radial pattern from the rotation center. However, it was possible to produce completely ductile-cut surfaces on all crystal orientations by using undeformed chip thicknesses smaller than a critical value, namely, the minimum critical undeformed chip thickness, which was approximately 60nm under the present conditions. Compared to wet cutting, dry cutting was beneficial for ductile machining on a few specific crystal orientations. The findings in this study provide criterions for determining process parameters for the fabrication of aspherical and diffraction infrared optics using single-crystal germanium.
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  • Toshiro SHIBASAKA, Shin'ichi GORIKI, Toshimichi MORIWAKI
    2004 Volume 47 Issue 1 Pages 37-42
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    One of the problems of current monitoring systems is a lack of flexibility for managing changes in the machining environment. The purpose of this research is to construct a monitoring system that can cope flexibly with changes in the machining environment without sacrificing accuracy of detection. The monitoring system developed involves plural subsystems, and was applied to monitor the chipping at an end mill. The subsystems employ artificial neural networks based on the cutting force signals and the cutting conditions. The flexibility and reliability of the monitoring system were much improved by operating the subsystems in parallel.
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  • Yufeng FAN, Yongbo WU, Masana KATO, Toru TACHIBANA, Katsuo SYOJI, Tsun ...
    2004 Volume 47 Issue 1 Pages 43-51
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    We describe the design of an ultrasonic elliptic-vibration shoe and its performance in ultrasonic elliptic-vibration-shoe centerless grinding. First, the vibration modes of the shoe for the bending and longitudinal directions are discussed and determined from the point of view of fixing the support of the shoe. Then the structure and dimensions of the shoe are determined by FEM (Finite Element Method) analysis. In order to clarify the performance of the produced shoe, an evaluation apparatus is built. The elliptic motions under different applied voltages are investigated using laser vibrometers. Finally, workpiece rotational motion control tests and actual grinding operations are carried out. As a result, it is clarified that the workpiece rotational speed changes linearly with variation of the applied voltage. This indicates that the workpiece rotational motion can be precisely controlled by the elliptic motion of the shoe. In addition, the workpiece roundness was clearly improved from an initial value of 25µm to a final value of 0.64µm after grinding, indicating that the produced shoe performed well in actual grinding operations.
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  • Akira HOSOKAWA, Kazufumi MASHIMO, Keiji YAMADA, Takashi UEDA
    2004 Volume 47 Issue 1 Pages 52-58
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    In this study, a new technique of in-process evaluation of a grinding wheel surface is proposed. Some specific wheel surfaces are prepared as references by the appropriate truing and/or dressing procedure, and grinding sounds generated by these wheels are discriminated by analyzing the dynamic frequency spectrum by a neural network technique. In the case of a conventional vitrified-bonded alumina wheel, the grinding sound can be identified in the optimum network configuration. Therefore, this system can instantaneously recognize differences in the wheel surface with a good degree of accuracy insofar as the wheel conditions are relatively widely changed. In addition, the network can perceive wheel wear because the grain tips are flattened as grinding proceeds and the grinding sound becomes similar to that of a wheel generated with lower dressing feed. The resinoid-bonded cubic boron nitride (CBN) wheel is also discriminable when a grinding sound in a higher frequency range is analyzed.
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  • Shaohui YIN, Hitoshi OHMORI, Yoshihiro UEHARA, Tomoyuki SHIMIZU, Weimi ...
    2004 Volume 47 Issue 1 Pages 59-65
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The 8.2m SUBARU large space telescope in Hawaii requires a mid-infrared high dispersion spectrograph with a resolution of 200000 at 10µm which employs a Germanium Immersion Grating (GIG) element. For this, the GIG element with a large number of sharp and smooth micro V-grooves must be fabricated. Previous studies were focused on the fabrication of a prototype GIG element. The grinding system developed however was not applicable for the fabrication of practical larger GIG element due to insufficient machining space and fast wear of the small grinding wheel used. The ultimate goal of this project was therefore to develop a new grinding system capable of fabricating larger GIG elements for practical use. This paper discusses the results achieved in the first phase of the research, which focused on the principle of the grinding process and grinding system, as well as describes results of micro-truing and micro-grinding experiments using a #4000 metal bonded diamond grinding wheel. Wear variation of the grinding wheel and its effects on the corner radius of micro V-grooves are also discussed. The minimum wheel tip radius of 8.2µm was achieved using this #4000 grinding wheel by micro-truing, and V-groove corner radiuses ranging from 15µm to 25.8µm were also achieved using the same grinding wheel.
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  • Yutang DAI, Hitoshi OHMORI, Yutaka WATANABE, Hiroaki ETO, Weimin LIN, ...
    2004 Volume 47 Issue 1 Pages 66-71
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    In the development of large-scale astronomical telescopes, certain new ceramics such as Silicon Carbides (SiC) and glass-ceramics (Zerodur) are applied for primary mirrors. However, the surface finishing of these ceramic mirrors is very time consuming by traditional polishing processes. In this study, a highly efficient process called ELID (Electrolytic In-process Dressing) grinding was conducted to grind ceramics for lightweight mirrors (CVD-SiC, Sintered-SiC, Zerodur). The dependence of subsurface properties on grinding process parameters was investigated. The subsurface damages on the ground surfaces were observed by AFM. The results demonstrated that crack-free surface could be obtained for CVD-SiC and Zerodur using cast iron bond diamond wheel with grain size of 4µm. The total depth of cut needed was found to be between 13 and 20µm. It was difficult to eliminate the subsurface damages generated on the ground surface of Sintered SiC, even though the depth of cut was as small as 0.1µm.
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  • Nobuhide ITOH, Akihiko NEMOTO, Teruko KATOH, Hitoshi OHMORI
    2004 Volume 47 Issue 1 Pages 72-78
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    In this study, a metal-free electro-conductive resinoid bonded wheel made of carbon as the conductive material was experimentally built to reduce metal ions in the grinding fluid and metal contamination of the workpiece in the aim to develop environmentally-friendly ELID (Electrolytic In-Process Dressing) grinding techniques. At the same time, characteristics of initial electrolytic-dressing and grinding were also investigated. The results showed that the prototyped metal-free electro-conductive resinoid bonded wheel consisted of a layer of oxides with high oxygen level formed on the wheel surface by electrolytic dressing. The layer generated by electrolytic dressing was found to wear more easily than the matrix composition and in addition have a high frictional coefficient. This wheel was also found to have good surface roughness compared to the cast iron bonded wheel generally used for ELID grinding. The obtained surface roughness was about 30nmPV using a #8000 metal-free electro-conductive resinoid bonded diamond wheel.
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  • Koichi KIKKAWA, Keigo NAKAMURA, Yoshio MIZUGAKI
    2004 Volume 47 Issue 1 Pages 79-84
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The objective of this study is to minimize the machining error by selecting the appropriate tool orientation at each cutter location of ball-nosed end mill for 5-axis machining. By the proposed method, the machining error can be estimated with use of a few kinds of geometric properties without any consideration of dynamics of cutting process, hence the estimation algorithm becomes simple. This is significant merit of this method. The equation to estimate the machining error includes several parameters which are determined in the heuristic manner. The prototype of estimation system has been developed based on the equation, and the estimation results can be obtained for various tool orientations. The results represent the tendency of the minimum machining error, but the estimation accuracy should be improved in the future work.
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  • Ryosuke TSUJIO, Takashi MIYOSHI, Yasuhiro TAKAYA, Keiichi KIMURA
    2004 Volume 47 Issue 1 Pages 85-92
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper presents a corrective Cu-CMP (Chemical Mechanical Polishing) method for obtaining higher planarized surface by forming laser aggregation particles on recessed areas of uneven copper surface before polishing. At first, the component analysis and formation condition of aggregated particles were investigated, which is obtained by laser irradiation into the slurry on the copper surface. This result indicated that the aggregated marks were purely made of SiO2 particles contained in slurry and the height of particle aggregation could be controlled by laser irradiation condition. Next, proposed planarization method for uneven surface of copper layer was attempted. As the polishing progressed, the height of aggregated marks was reduced. Then, it was confirmed that the aggregated marks play a role of masks, and no material removal at the bottom surface of recessed areas takes place during the polishing. This process made it possible to realize high planarity on copper surface.
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  • Schubert SOÃRES, Yoshiharu NAMBA
    2004 Volume 47 Issue 1 Pages 93-97
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Float polishing produces extremely flat (<λ/20) surfaces to atomic conformity over large areas. This process was applied to develop robust AT-cut, premium-Q, cultured, crystalline-quartz acoustic oscillators, which are normally highly susceptible to fracture from mechanical shock. The fabrication process was optimized to eliminate sub-surface damage, and to maximize the flexural strength of the crystals. We report premium results of a near-bulk value of stress-fracture threshold of 620 MPa, and a surface roughness of less than 0.2nm rms for 6.35mm diameter, 103.8µm thick samples float polished with colloidal silica. The remarkable surface quality produced by float polishing is combined with a 10-fold improvement in strength over blanks manufactured by the conventional CeO2 process. We also report on the characterization of the surfaces by atomic force microscopy, scatterometry, and photo acoustic spectroscopy where we see that deep 100µm removal eliminates damage from processing prior to the final float polish. These results are a significant improvement over the performance of commercially available resonators in equivalent tests.
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  • Tetsuo OOKAWA, Takashi NISHIGUCHI
    2004 Volume 47 Issue 1 Pages 98-104
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    GaAs wafers have contributed greatly to improve the performance of light-receiving and light-emitting devices. For such applications, a very low level of roughness, of the order of 0.1nmRa, is required on GaAs wafers. If a polishing pad is used for a long time, the polishing rate decreases and the roughness on the wafer increases with increase of polishing time. In this study, the surface morphology of the polishing pad was focused as a dominant factor affecting the polishing rate, and, using an image processing technique, a quantitative approach was tried based on an optical microscope image. For the purpose of increasing the lifetime of polishing pads, a further study was made in which the polishing resistance, which correlates strongly with the polishing rate, was monitored.
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  • Toshiki HIROGAKI, Eiichi AOYAMA, Ryu MINAGI, Keiji OGAWA, Tsutao KATAY ...
    2004 Volume 47 Issue 1 Pages 105-110
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    We propose a new method for cleaning blind via holes after laser drilling of PWBs using oxygen plasma treatment. This report dealt with three kinds of PWB materials: epoxy resin and two kinds of aramid fiber reinforced plastics (AFRP: Technora or Kevlar fiber reinforcement). We observed the drilled holes after plasma treatment using both an optical and a scanning electric microscope (SEM). It was confirmed that adequate etching took place in the drilled holes by plasma treatment. We also compared the hole wall and hole bottom after plasma treatment with ones after chemical etching. It was clear that there was no damage to the aramid fiber tip on the hole wall, and that a smooth roughness of the hole wall was obtained by means of plasma treatment. As a result, we demonstrated that the plasma treatment is effective in cleaning the laser drilled holes of PWBs.
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  • Nobuyuki MORONUKI
    2004 Volume 47 Issue 1 Pages 111-116
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper describes a design procedure of the linear-motion stage that has silicon monolithic structure and flexure beams suspend the stage. Single crystal silicon is appropriate for the structural material of miniaturized mechanism. However, the anisotropic properties and cleavage should be taken into account at the design stage. In addition, the manufacturing process has strong effects on the final strength because silicon is brittle material and sensitive to the flaw such as chipping. The design consideration is concluded as that the cleavage plane, {111} plane, should be arranged apart from the direction of the tensile stress to compromise both the fracture strength and compliance to achieve accurate motion. Also, the crystal direction <100> should be aligned along the tensile stress to obtain long stroke. The prototypes, size of 30×30mm, were prepared with deep reactive ion etching (DRIE) and its compliance was examined.
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  • Osamu OHNISHI, Hiromichi ONIKURA, Akira HATA, Kenichiro YAMAMOTO
    2004 Volume 47 Issue 1 Pages 117-122
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The present paper deals with the fabrication of micro flat drills by precision grinding and their application to the drilling into duralumin and stainless steel without/with ultrasonic vibration on a vertical grinding/drilling machine. It is found from drill fabrication test that, by choosing grinding procedure of workpieces so that the stiffness may be kept as high as possible, the diameters range from 18 to 21µm for a nominal diameter of 20µm, and that precision measurement of the diameter after grinding of drill periphery and the precision positioning enabled us to fabricate a flat drill of minimum diameter 10.8µm. But, web eccentricity must be improved hereafter. From drill life test it is found that, irrespective of the existence of web taper, the drills without back taper showed longer tool life, and that irrespective of back taper, longer drill life was obtained in case of drills with web taper. This fact suggests that the stiffness at the root of a drill is very important for drill life. In duralumin longer drill life are gained without ultrasonic vibration than with ultrasonic vibration, and in stainless steel vice versa. Burr grows significantly with the increase in number of holes, but roundness of drilled holes is roughly good.
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  • Akira KAKUTA, Nobuyuki MORONUKI, Yuji FURUKAWA
    2004 Volume 47 Issue 1 Pages 123-128
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Although there have been some attempts to produce a monocrystalline silicon carbide (SiC) flat surface, the surface properties, such as surface roughness, have not satisfied the required specifications. In this study, we apply a helicon sputtering device to molecular beam epitaxy (MBE) to improve those properties. The helicon sputtering device was used as a molecular beam source for generating a Si molecular beam, where the electric field caused by the helicon coil supplied energy to the sputtered Si molecules. The amount of energy was controlled by the electric power applied to the coil. High-purity acetylene gas was used as the carbon (C) molecular beam source. The substrate was a monocrystalline (111) Si wafer. With the increase of the electric power, that is, the supply of high energy to molecules, the roughness of the surface was improved. A uniform mirror surface of monocrystalline SiC was produced over the entire substrate with a roughness of 1nm (Ra) order.
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  • Hiroyuki NARAHARA, Akihiro YOSHIKAWA, Hiroshi SUZUKI
    2004 Volume 47 Issue 1 Pages 129-135
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Unevenness of the resin liquid surface causes uneven thickness of photo-hardened layers, resulting in reduced precision in stereolithography. Conventional stereolithography machines are equipped with leveling devices to prevent unevenness of the liquid surface. There however exists no system to measure flatness of the liquid surface at present, making it difficult to ensure flatness at all times. This paper proposes a device and method to measure uneven liquid surface. Factors causing measurement errors were analyzed, actual uneven surface shapes were measured, and measuring accuracy was examined to verify feasibility to apply this method to stereolithography. The developed equipment was found to be capable of measuring unevenness up to 6 microns.
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  • Keiichi NAKAMOTO, Keiichi SHIRASE, Hidefumi WAKAMATSU, Akira TSUMAYA, ...
    2004 Volume 47 Issue 1 Pages 136-143
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    For shortening of production lead-time, it is needed to eliminate time and efforts for process and operation planning after product design. However, a conventional NC machine tool has no autonomy and intelligence to achieve direct machining operation or “Rapid Manufacturing”. Because CL data and cutting parameters for machining operation have to be determined precisely in process and operation planning. In this study, in order to realize an autonomous and intelligent machine tool, the digital copy milling system which allows to generate tool paths during machining operation, and the trouble free machining strategy which allows to adapt cutting parameters, have been developed. And, an automatic process and operation planning system has been developed to integrate with the functions mentioned. This planning system works on commercial CAD software, and a prototype of autonomous and intelligent machine tool can achieve direct machining operation or “Rapid Manufacturing” which does not require any effort to prepare an NC program.
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  • Myung-Hoon LEE, Seung-Han YANG, Young-Suk KIM, Yong-Rae ROH, Cheol KIM
    2004 Volume 47 Issue 1 Pages 144-149
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The growing need for higher precision and productivity in manufacturing industry has lead to an increased interest in computer numerical control (CNC) systems. It is well known fact that the cross-coupling controller (CCC) is an effective method for contouring applications. In this paper, a multi-axis contour error controller (CEC) based on a contour error vector using parametric curve interpolator is presented. The contour error vector is a vector from the actual tool position to the nearest point on the desired path. The contour error vector is the closest error model to the contour error. The simulation results show that the CEC is more accurate than the conventional CCC for a biaxial motion system. In addition, the experimental results on 3-axis motion system show that the CEC is simply applicable to 3-axis motions and contouring accuracy is significantly improved.
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  • Atsushi MATSUBARA, Kangkyu LEE, Soichi IBARAKI, Yoshiaki KAKINO, Masay ...
    2004 Volume 47 Issue 1 Pages 150-159
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    In this paper, we propose a simple sliding guideway with a hydraulically operated brake unit, which can control sliding friction force on a feed drive system. The sliding friction force is controlled by the brake force command generated from velocity information of a table and/or a servomotor. The damping control laws of DVFB (Direct velocity feedback) and RVFB (Relative velocity feedback) are analyzed to provide the adequate damping for ballscrew drives. These damping control laws are implemented in the brake force control unit and the dynamic performance of a ballscrew drive is measured. Structural vibration of the ballscrew drive can be successfully controlled by this actively controlled sliding guideway in experiments.
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  • Soichi IBARAKI, Toshihiro OKUDA, Yoshiaki KAKINO, Masao NAKAGAWA, Tets ...
    2004 Volume 47 Issue 1 Pages 160-167
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper presents a methodology to compensate contouring errors introduced by the gravity on a Hexapod-type parallel kinematic machine tool with the Stewart platform. Unlike conventional serial kinematic feed drives, the gravity imposes a critical effect on the positioning accuracy of a parallel kinematic feed drive, and its effect significantly varies depending on the position and the orientation of the spindle. We first present a kinematic model to predict the elastic deformation of struts caused by the gravity. The positioning error at the tool tip is given as the superposition of the deformation of each strut. It is experimentally verified for a commercial parallel kinematic machine tool that the machine's contouring error is significantly reduced by compensating gravity-induced errors on a reference trajectory.
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  • Yasuhiko SUZUKI, Atsushi MATSUBARA, Yoshiaki KAKINO, Kazuhiko TSUTSUI
    2004 Volume 47 Issue 1 Pages 168-174
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper deals with a stick motion compensation system. Stick motion is trajectory error that happens just after a quadrant change in circular motion on NC machine tools. Recently cylindrical machining with an end mill is often executed instead of boring machining with a bore tool. That is why the accuracy with end mill machining is becoming important. Stick motion extremely damages the accuracy and the quality of the circular parts or free form surfaces on workpieces. In the conventional compensation system, tuning parameters for each combination of radius and feed rate is needed. This research proposes a new stick motion compensation system. The new system has a dynamic model that simulates the friction. The simulated friction consists of two components. One is spring resistance in proportion to a reverse distance from a quadrant change. The other is viscous damping friction in proportion to velocity. The system can compensate stick motions suitably for wide range conditions of radii and feed rate.
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  • Javad AKBARI, Mitsuhiro IMAMURA, Tomohisa TANAKA, Yoshio SAITO
    2004 Volume 47 Issue 1 Pages 175-179
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper describes a study on the usage of ultrasound to measure the grasping force components when elastic fingers of a robot grasp an object. The ultrasonic sensor embedded in the soft finger accurately measures the echoes timing lag and amplitude that give information about the amount and directions of the grasping force components. The experimental results indicate good sensitivity of the proposed soft finger to both normal and tangential components of the grasping force.
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PAPERS
  • (Part 1—Static Performances of Colloidal Damper)
    Claudiu Valentin SUCIU, Takuzo IWATSUBO, Shigehito DEKI
    2004 Volume 47 Issue 1 Pages 180-188
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    A novel application of Nano-Technology in the field of Mechanical Engineering, called Colloidal Damper (CD), is investigated. This device is complementary to the Hydraulic Damper (HD), having a cylinder-piston construction. Particularly for CD, the hydraulic oil is replaced by a colloidal suspension, which is consisted of a mesoporous matrix and a lyophobic fluid. In this work, the porous matrix is from hydrophobized silica gel and aqueous solutions (water and antifreeze agents) are considered as associated working liquids. A design solution from a practical point of view of the CD static test rig and the measuring technique of the static hysteresis are described. A synthesis of the CD static performances is presented, i. e., the influence of the mean pore diameter, mean particle diameter, particle architecture, liquid surface tension, working pressure, silica gel quantity, water evacuation and relaxation time is illustrated. Our findings agree with the previously published data.
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  • (Part 2—Dynamic Performances of Colloidal Damper)
    Claudiu Valentin SUCIU, Takuzo IWATSUBO
    2004 Volume 47 Issue 1 Pages 189-198
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    First part of the present work presented the working principle and the static performances of a Colloidal Damper (CD). Second part deals with experimental investigations concerning the CD dynamic performances. Porous matrix is composed from silica gel S3 with labyrinth architecture; water is considered as associated lyophobic liquid. CD dynamic test rig and the measuring technique of the dynamic hysteresis are described. Two design solutions from a practical point of view of the dynamic test rig are proposed: single and double CD. A CD effective only for positive force will be called single; when CD is operative both for positive and negative forces, as in the most actual applications, it will be called double. Considering cycles obtained for pure water and colloidal suspension, and extracting the structural influence, one finds the variation of the CD dissipated energy and efficiency versus working frequency. Our findings agree with the previously published data.
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  • Aneta Nicoleta SUCIU, Takuzo IWATSUBO, Mitsumasa MATSUDA, Takashi NISH ...
    2004 Volume 47 Issue 1 Pages 199-208
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    An experimental investigation upon the durability of the artificial knee joints with PVA hydrogel articular cartilage is presented. PVA hydrogel is manufactured by the cyclic freezing/thawing and annealing methods; femoral component is a disc made in stainless steel. This work is original in the meaning that: a weighting method to differentiate the worn mass from the mass of exuded water for PVA hydrogel is suggested; an original wear test rig, which simulates the anterior-posterior displacement of the knee motion during walking is proposed; wear factor variation against the number of walking cycles (durability curve) for PVA hydrogel is reported. The lowest wear factor obtained is on order of 10-6-10-5mm3/Nm. PVA hydrogel with reduced water content (45-50%) produces the smallest wear factor, for the same polymerization degree. Reduction of the wear factor is on order of 104 when the PVA polymerization degree increases from 1800 to 12300. PVA hydrogel manufactured on a hydrophobic substrate (PTFE) presents a 16-27% lower wear factor than that prepared on a hydrophilic substrate (glass). When layer thickness increases from 2 to 3.6mm, the wear factor reduction is 18%. Influence of the standing interval in start-up conditions on the wear factor is also investigated.
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  • (Micro-Pocket-Covered Femoral Component and Tibial Poro-Elastic-Hydrated Cartilage)
    Aneta Nicoleta SUCIU, Takuzo IWATSUBO, Mitsumasa MATSUDA, Takashi NISH ...
    2004 Volume 47 Issue 1 Pages 209-217
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper presents an experimental investigation upon the wear characteristics of a novel bearing system proposed for the artificial knee joints. Such bearing system is original in the meaning that micro-pockets are machined on surface of the rigid femoral component; a poro-elastic-hydrated layer, called artificial cartilage, covers the rigid tibial substrate. Under compression, the fluid exudes from the artificial cartilage, fills and pressurizes the micro-pockets. In this way, a poro-elasto-hydrodynamic regime of lubrication is developed. Wear tests are performed with different types of artificial cartilages made in PVA hydrogel, articulating against smooth and micro-pocket-covered femoral components. Influence of the number of walking cycles, femoral porosity, depth of the micro-pockets, water content and polymerization degree of the PVA hydrogel upon its wear factor is illustrated. For wear tests performed until 106 walking cycles, in the case of PVA hydrogel with 12300 polymerization degree and 77% water content versus smooth component, the wear factor is on order of 10-6-10-5mm3/Nm; for the same artificial cartilage against a femoral component uniformly covered by identical micro-pockets of 50µm depth, on 15% of its surface, the wear factor drops in the range 10-7-10-6mm3/Nm, i. e., the wear factor reduces with 80%. The highest wear reduction due to the micro-pockets presence is obtained in the case of PVA hydrogel with 77% water content, i. e., for a fluid amount similar to that of the natural cartilage.
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  • Ato KITAGAWA, Liang ZHANG, Takashi EGUCHI, Hideyuki TSUKAGOSHI
    2004 Volume 47 Issue 1 Pages 218-224
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    A mobile robot with a new type of movement called wavy movement is proposed in this paper. Wavy movement can be readily realized by many bars or crosses which are rotating at equivalent speeds, and the robot with simple structure and easy control method is able to ascend and descend stairs by covering the corners of stairs within separate wave shapes between touching points. The principle of wavy movement, the mechanism, and the experimental result of the proposed robot are discussed.
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  • Masayuki NUNOBIKI, Koichi OKUDA, Motoyoshi HASEGAWA
    2004 Volume 47 Issue 1 Pages 225-232
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    We developed an inchworm-type mobile robot. It consisted of only six segments connected by four pitch joints and one yaw joint. Although this robot had neither legs nor wheels, it was able to advance by using vertically undulatory motion of whole body. Even if it became upside down, it was able to move just like normal posture. But if it fell sideways, it was not able to move until returning to normal posture. In this study, we proposed a returning method by which the angular moment around roll axis was generated by twisting itself. To analyze this motion, we developed a mathematical model for this returning motion by considering the robot to be an underactuated mechanical system that consisted of a base frame and two link frames. We confirmed this returning motion was able to equate with a falling down motion of an underactuated two-linked system.
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  • Zheng-Ming GE, Chia-Yang YU, Yen-Sheng CHEN
    2004 Volume 47 Issue 1 Pages 233-241
    Published: 2004
    Released on J-STAGE: September 15, 2004
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    Chaos synchronization and anticontrol of a rotationally supported simple pendulum was studied in this paper. Different kinds of coupling terms are used to synchronize the two identical chaotic systems with different initial conditions. An observed-based scheme is also used to achieve synchronization. The results are demonstrated by phase portrait, Lyapunov exponent, Poincaré maps and synchronization time. Next, in order to analyze the transient behavior of the synchronized systems, Euclidean distance is used to plot a figure with coupling strength versus the distance. The chaotic signals are used to mask the message function in the secure communication system. Finally, anticontrol of chaos is achieved by adding constant term, periodic term, impulse term, time-delay term and adaptive control.
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  • Xiaoyou ZHANG, Tadahiko SHINSHI, Lichuan LI, Akira SHIMOKOHBE
    2004 Volume 47 Issue 1 Pages 242-250
    Published: 2004
    Released on J-STAGE: September 15, 2004
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    The object of this study is to develop a radial magnetic bearing which has nanometer rotational accuracy about a fixed center when rotating at high-speed. To achieve this objective, the vibration of the spindle caused by the unbalance force must be reduced. In this paper, we propose a method of control to reduce the vibration of the spindle. First, the center of inertia is estimated from measured coil currents and the rotational speed of the spindle. Subsequently, the references of the control system are modified on the basis of the estimated eccentricity, so that the spindle is constrained to rotate about the estimated center of inertia. Experimental results show that the spindle has a rotational accuracy of 13.2nm (3σ) at 2000min-1 and that the electromagnetic force synchronized with the rotation is 0.17N, which is 8.9% of the electromagnetic force when rotation is about the center of the profile.
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  • Masataka FUKUNAGA, Nobuyuki SHIMIZU
    2004 Volume 47 Issue 1 Pages 251-259
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The fractional viscoelastic equation (FVE), which is a 2nd-order differential equation with fractional derivatives describing the dynamical behavior of a single-degree-of-freedom viscoelastic oscillator, is considered. Some viscoelastic damped mechanical systems may be described by FVEs. However, FVEs with conventional nonzero initial values cannot generally be solved. In this paper, the prehistory of the unknown before the initial time, referred to as the initial function, is taken into account in order to solve a FVE. Appropriate initial functions are essential for unique solutions of FVEs. Physically, the initial function reflects the process of giving the initial values. If a viscoelastic material is described by a FVE, the behavior of the material of the same initial values depends on the process of giving the initial values. FVEs are solved for some initial functions both by analytical and numerical methods. Implication of the solutions to viscoelastic materials will also be discussed.
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  • Mitsuaki NAKANISHI, Yukinori KOBAYASHI, Gen YAMADA
    2004 Volume 47 Issue 1 Pages 260-267
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper presents a robust method for designing a flexible structure reinforced by fiber-reinforced plastic (FRP) sheets. An FRP sheet has a high ratio of strength to weight and is widely used to reinforce various structures. Vibration characteristics of a structure reinforced by FRP sheets can be easily modified by changing design variables such as the relative volumes of fibers and matrix, the fiber angle and the number of layers. Therefore small variation of the design variables gives rise to drastic change in the vibration characteristics. The focus of this paper is on variation of the modulus of longitudinal elasticity of a structure reinforced by FRP sheets. We propose a constraint that takes into account the variation band of the elasticity of the structure and specifies the total variation of natural frequencies of low-order modes. To maximize the natural frequencies, the design variables are determined by using an optimization technique with this constraint. The validity of the present method is verified by numerical examples and by comparison with results of experiments.
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  • Fumihito ARAI, Toshihiro SAKAMI, Akihiko ICHIKAWA, Toshio FUKUDA
    2004 Volume 47 Issue 1 Pages 268-274
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    It is important to separate a microorganism such as a microbe with high speed and high purity for examination of newly developed or discovered microbes. However, it is difficult and takes much time to separate a single target microbe. Here we designed a new separation chip, with which we can separate the target microbe from the sample liquid which can be supplied continuously. We integrated the laser manipulation and flow control in the microchannel for separation of the target. We fabricated a disposable separation chip by the silicone elastomer poly(dimethylsiloxane) (PDMS) and succeeded in separation of a microbe within 30 seconds.
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  • Liang-An ZHENG, Shinn-Horng CHEN, Jyh-Horng CHOU
    2004 Volume 47 Issue 1 Pages 275-279
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The stability robustness of linear dynamic systems with time-varying elemental uncertainties, norm-bounded uncertainties and delay perturbations is investigated. A sufficient condition in terms of linear matrix inequalities (LMIs) is proposed to ensure that the linear systems with time-varying elemental uncertainties, norm-bounded uncertainties and state-delay perturbations is asymptotically stable. Two examples are given to illustrate the use of the proposed LMI sufficient condition. To see the merit of the proposed condition, Example 1 discusses the case of only both time-varying elemental and norm-bounded uncertainties, for comparison to an existing one reported recently. It shows that the proposed LMI sufficient condition is less conservative than the existing criterion.
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  • Jin-Ho SUH, Masaki YAMAKITA, Sang Bong KIM
    2004 Volume 47 Issue 1 Pages 280-288
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Passive velocity field control (PVFC) was previously developed for mechanical systems which have strong coordination and must interact with the physical environment. Moreover, In our previous researches, the extended PVFC algorithm for multiple manipulator systems is also introduced. The methodology of PVFC and extended PVFC encode tasks using time invariant desired velocity fields instead of the more traditional method of time trajectories and guarantees that the closed loop system behave passively with environment power as the supply rate. This paper addresses an adaptive generation method of the desired velocity field for cooperative mobile robots with decentralized PVFC. Of course, this paper is a method of decentralized control algorithm for cooperative mobile robot systems handling a common object in a coordinated way. The proposed control method for cooperative mobile robots in constructed based on the extended PVFC in this paper. Moreover the stability and the boundedness are ensured using projection algorithm. Finally the effectiveness of proposed control method is examined by numerical simulation for cooperation tasks with two 3-wheeled mobile robot systems to consider our previous research.
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  • Marco Tulio C. FARIA
    2004 Volume 47 Issue 1 Pages 289-296
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper presents a finite element procedure specially devised to analyze the misalignment effects on the behavior of spiral groove gas face seals operating at high speeds. In this study, the seal stationary face is slightly misaligned and the flexibly mounted face is perfectly aligned. Predictions of some steady-state and dynamic performance characteristics versus misalignment angle are presented for spirally grooved gas seals operating under stringent conditions. Curves of dynamic force coefficients versus the static misalignment angle of the seal face indicate that the seal misalignment affects considerably the dynamic response of gas lubricated face seals. At high speeds, the static seal misalignment not only results in increased stiffness coefficients but also leads to negative damping coefficients, which may be a sign of the seal susceptibility to excessive angular motions.
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  • Huinam RHEE, Youngjin PARK
    2004 Volume 47 Issue 1 Pages 297-304
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    A new method is presented for the isolation of resonances from scattered waves for elastic wave resonance scattering problems. The resonance scattering function consisting purely of resonance information of the scatterer is defined. Elastic wave resonance scattering from a water-filled cylindrical cavity imbedded in an aluminum matrix is numerically analyzed. The classical resonance scattering theory and the new method compute different magnitudes and phases of the resonances from each partial wave, and therefore, their total resonance spectra are quite different. The exact π-radians phase shifts through the resonance and anti-resonance frequencies show that the proposed method properly extracts the vibrational resonance information of the scatterer compared to resonance scattering theory.
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  • Jangbom CHAI, Shinchul KANG, Sungkeun PARK, Sungyull HONG, Chanwoo LIM
    2004 Volume 47 Issue 1 Pages 305-313
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper is concerned with the development of data analysis methods to be used in on-line monitoring and diagnosis of Motor-Operated Valves (MOVs) effectively and accurately. The technique to be utilized includes the electrical measurements and signal processing to estimate electric torque of induction motors, which are attached to most of MOV systems. The estimated torque of an induction motor is compared with the directly measured torque using a torque cell in various loading conditions including the degraded voltage conditions to validate the estimating scheme. The accuracy of the estimating scheme is presented. The advantages of the estimated torque signatures are reviewed over the currently used ones such as the current signature and the power signature in several respects: accuracy, sensitivity, resolution and so on. Additionally, the estimated torque methods are suggested as a good way to monitor the conditions of MOVs with higher accuracy.
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  • Choong-Hwi LEE, Jae-Eung OH, Yong-Goo JOE, You Yub LEE
    2004 Volume 47 Issue 1 Pages 314-320
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    The study of the noise reduction of an automobile has been concentrated on the reduction of the automotive engine noise because the engine noise is the major cause of automotive noise. However, many studies of automotive engine noise led to the interest of the noise reduction of the exhaust and intake system. The method of the reduction of the induction noise can be classified by the method of passive control and the method of active control. However, the passive control method has a demerit to reduce the effect of noise reduction at low frequency (below 500Hz) range and to be limited by a space of the engine room. Whereas, the active control method can overcome the demerit of passive control method. The algorithm of active control is mostly used the LMS (Least-Mean-Square) algorithm because the LMS algorithm can easily obtain the complex transfer function in real-time. Especially, Filtered-X LMS (FXLMS) algorithm is applied to an ANC system. However, the convergence performance of LMS algorithm goes bad when the FXLMS algorithm is applied to an active control of the induction noise under rapidly accelerated driving conditions. So, in order to this problem, the modified FXLMS algorithm was proposed. In this study, the performance of an active control using the LMS algorithm under rapidly accelerated driving conditions was evaluated through the theoretical derivation using a chirp signal to have similar characteristics with the induction noise signal and the computational simulation and the control performance of the induction noise under rapidly and suddenly accelerated driving conditions was improved using the modified FXLMS algorithm.
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  • Yong-Goo JOE, Jae-Eung OH, You-Yub LEE, Choong-Hwi LEE, Hyoun-Jin SIM
    2004 Volume 47 Issue 1 Pages 321-326
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Acoustic considerations of axial flow fans become imperative due to regulations and the ubiquitous call for environment-friendly products. This paper suggests a noise reduction method for the engine cooling fan. This engineering model has been developed for the prediction of the noise spectrum of an axial flow fan. The radiated acoustic pressure is expressed as the discrete frequency noise peaks at the BPF and its harmonics and line spectrum at the broad band by noise generation mechanisms. This paper shows a comparison of the measured and calculated noise spectra of the fan for the validation of the noise prediction program. This paper also presents the characteristics of fan noise due to modify the design parameters. Accordingly, design parameter values for noise reduction of the fan were obtained.
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  • Masahiko ITOH
    2004 Volume 47 Issue 1 Pages 327-334
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This paper deals with a control technique of eliminating the transient vibration of a geared mechanical system with backlash. This technique is based on a model-based control in order to establish the damping effect at the driven machine part. The control model of dynamical compensator is composed of a linear reduced-order model related to the velocity control loop and the delay element related to the backlash. The control model estimates a load speed converted to the motor shaft. The difference between the estimated load speed and the motor speed is calculated dynamically, and it is added to the velocity command to suppress the transient vibration of the load. This control model is easily obtained from design or experimental data and its algorithm can be easily installed in a DSP. This control technique is applied to a mechanical system composed of spur gears. Simulations and experiments show satisfactory control results.
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  • Ho PARK, Chang-Su HAHN
    2004 Volume 47 Issue 1 Pages 335-344
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    Using quarter car model, an analytic method for performance estimation of a vehicle suspension system is presented and as the variables of performance estimation, frequency response, RMS response and performance index are considered. From frequency response function, the characteristics of response to the whole frequency range is verified and from RMS response and performance index, sensitivity of ride and handling characteristics are examined. Using full car model, sweet area (stable ride area) are determined and performance sensitivity is estimated according to the change of suspension parameters. In order to estimate the output sensitivity, response curve is displayed using 3-dimensional plot. Design data are suggested for optimal design parameter estimation, which maximize the performance of the given suspension system.
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  • Kevin RUSSELL, Raj S. SODHI
    2004 Volume 47 Issue 1 Pages 345-349
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This work presents a method to design planar five-bar mechanisms to achieve multiple phases of prescribed rigid body path points. Using this method, these mechanisms are designed to achieve multiple phases of prescribed rigid body path points using the same hardware. This synthesis method accommodates one DOF belted, geared and chain driven five bar mechanisms or two DOF five-bar mechanisms. By prescribing the angular positions of one driving link with respect to the synthesized moving pivot positions of the other driving link, the positions of both driving links are timed. The parameters of one driving link and the links to be determined in this mechanism are synthesized using constant length constraint equations given the prescribed rigid body path points. The example problem in this work considers a two-phase moving pivot adjustment (with constant link lengths) of a planar five bar mechanism.
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  • Hong-Sen YAN, Ren-Chung SOONG
    2004 Volume 47 Issue 1 Pages 350-362
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    A novel general approach for designing four-bar linkages that integrates the kinematic synthesis, dynamic design and servo control in one design stage is presented. This approach satisfies kinematic design requirements and also attains trade-off of dynamic balance. By properly designing the speed trajectory of the input link, the balancing parameters of moving links and link dimensions of the given or desired mechanisms, the expected output motion characteristics and dynamic balancing performance are obtained. The input motion characteristics are designed with Bezier curves. The dynamic design is implemented by means of links counterweighing and mass redistribution. Optimization is applied to find optimal design parameters for meeting kinematic and dynamic design requirements and constraints. Examples are given to demonstrate the feasibility of this approach.
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  • Wu-Jong YU, Chih-Fang HUANG, Wei-Hua CHIENG
    2004 Volume 47 Issue 1 Pages 363-368
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    This study describes a novel and complete solution for turning-block and swinging-block design with particular reference to the maximal average mechanical advantage over a specific swing angle span of the output link. The method yields an optimal set of link lengths for the turning-block and the swinging-block mechanisms. The torque was integrated with respect to the crank swing angle that yields a transmission energy form to maximize the average mechanical advantage. The optimal design solution is determined from the stationary value of the transmission energy. Results of this study can provide a valuable reference for efforts to achieve the high precision and high torque required in the mechanical design.
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  • (Modification of the Original Measuring System, Calibration of the Probes and the Results of Dimensional Measurements)
    Toshiya SHIRAMATSU, Kenichi KITANO, Masayoshi KAWADA, Kimiyuki MITSUI
    2004 Volume 47 Issue 1 Pages 369-376
    Published: 2004
    Released on J-STAGE: September 15, 2004
    JOURNAL FREE ACCESS
    In order to facilitate the advancement of micromachine technology and to encourage its use across a wider range of industrial fields, a measuring technology appears to be essential. For the development of micromachines and microfabrication technologies, it is necessary to devise a technique to measure both shape and dimensions of micro-components. Some researchs on measurement methods for micro-boreholes in the micrometer range have been reported. However, general-purpose coordinate measuring machine for both shape and dimensional metrology on micro-system components has not been realized yet. To this end, one of the authors attempted to develop a small three-dimensional shape measuring apparatus which has non-contact probe detecting proximity to the object being measured through the tunneling effect, and the results has already been reported. In this study, measurement of not only shape but also of dimensions of micro-components are attempted. A modified device and the calibration technique for micro-probes are explained in detail, and then several measurement results are shown.
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