A ball endmill made of single-crystalline diamond was used for cutting two kinds of mold materials, oxygen-free copper and reaction-bonded silicon carbide (RB-SiC). The cutting performance of the ball endmills was investigated by examining surface roughness and form accuracy of the machined workpiece as well as tool wear characteristics. It was found that micro lens arrays and grooves with extremely smooth surface and high-accuracy profile could be obtained on oxygen-free copper without detectable tool wear. When machining RB-SiC, although ductile cutting was realized, a few fine streaks were observed on the machined surface, which were attributed to the flank wear of the diamond tool. The effects of tool feed condition on cutting performance of a worn tool was investigated by performing micro grooving tests.

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Recently, optical parts are required to be high precision. And the form accuracy becomes under 50nm. The form error, which distributes periodically on ground surface, is named nano-topography. Because the distribution of the nano-topography changes in a poorly-repeatable manner, it is quite difficult to compensate. From previous study, relationship between spatial frequency of the nano-topography and grinding conditions is investigated. And it is found that the spatial frequency of the nano-topography can be controlled by the grinding conditions. In this paper, actual grinding condition is estimated by the distribution of nano-topography. And the grinding condition is compensated so that to optimize the distribution of nano-topography.

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This study presents a novel method to monitor the cutting force in the end milling process by means of an air-driven spindle. This monitoring method is based on the rotational speed of the spindle without the use of dynamometers. A speed difference square method (SDSM) index is computed from the rotational speed difference of the end mill during the process. During the process, the cutting forces are simultaneously observed and compared to the SDSM index. During the cutting process, the correlation coefficient between the SDSM index and the cutting forces is analyzed, and the SDSM index in the process shoes a very high correlation with the cutting forces.

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In order to determine the transient temperature variation of cutting tool in end milling, the temperature response beneath the rake face is measured using a newly developed infrared radiation pyrometer with two optical fibers connected by a fiber coupler. In up milling, the temperature increases gradually during the cutting cycle and reaches the maximum just after the cutting. In down milling, the temperature increases immediately after the cutting starts and reaches the maximum during the cutting cycle. Calculated temperature variation beneath the rake face in up milling and down milling agrees well with the measured temperature variation.

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Milling is one of the most important metal cutting processes. If we measure the cutting force, we can make cutting process optimum, prevent tool breakage, and improve efficiency of process. However in the case of using an end mill with small diameter, it is very difficult to identify whether cutting process is good or not. In this paper, we proposed the cutting force measurement technique by using image processing. In the technique, we captured a image of the end mill during cutting process, determined deflection of the tool and then estimated cutting force. Finally, we can estimate small cutting force with high accuracy.

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This article describes use of Hilbert-Huang Transformation (HHT) in order to detect the damage and cutter tool wear by use of acceleration signal. The successful implementation of this transformation is introduced in this article. The difference between new and severe flute tool damage is clearly obvious in the marginal Hilbert spectra and Hilbert spectra. The tool wear is also obvious from those spectra. The drift into lower frequencies region indicates the cutter tool damage or cutter tool wear. This technique provides the alternative approach to the traditional FFT analysis which was used to the cutter tool detection.

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The purpose of this study is to examine chips adhered to cutting edge and cutting forces for relationship to tool wear in end-milling of Titanium alloy, and reveal possibility of monitoring of tool wear by observation of adhered chip and measurement of cutting forces. As a result of cutting tests and considerations, it was revealed that length of linked chips adhered to cutting edge at tool flank wear smaller than 40μm and maximum value of dynamic cutting force component in feed direction at wear larger than 40μm were effective parameters for monitoring of tool flank wear.

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The acceleration of the spindle in the axial direction was measured when preharden steel was slotted with a square end mill under several cutting conditions. The signal of the accelerometer was stored and processed through digital Fourier transformation on a personal computer. The power spectra had peaks in a distinctive frequency range when chatter occurred. There is a threshold value of the ratio of the maximum intensity in the range to the one at the frequency of interrupted cutting by edges for detection of chatter.

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The goal of "Clean Manufacturing" (CM) is to eliminate waste, aiming at zero waste. by integrating environmental best practices into the manufacturing process. CM is a continuous preventive strategy, which concentrates on resources and manufacturing processes to eliminate waste. Modelling and Simulation of Burr Formation is one of the main topics in contemporary basic scientific investigations. Using state-of-the-art numerical methods, the process of burr-development can be investigated within 2D-simulations and more and more also for 3D-applications. The most relevant methods applied to burr formation modelling and simulation are accurately reported and discussed in the paper.

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The cutting force and the chip flow direction are simulated to reduce burr formation at the backside of the machined plate in an analytical model based on the minimum cutting energy. The curved lips drill is discussed to reduce the thrust and increase the chip flow angle with the orientation and the curvature. The counterclockwise orientation is effective to reduce the thrust and control the chip flow with the small curvature. A curved lip drill is designed with a large radial rake angle at the end of the lips based on the cutting simulation.

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This paper deals with an analysis of the chip area and cutting performance by oval end milling of an inclined surface using a contour path method. At first, the modeling of a cutter, an edge, a rake surface and a workpiece with an inclined surface are carried out using 3D-CAD. Secondly, the chip area is calculated by the interference of the rake surface and the chip volume. The influence of cutting conditions on the behavior of the chip area is shown and the evaluation value Ed for cutting performance is proposed. And also, the theoretical surface roughness by an oval end mill is analyzed and calculated. Values are compared with those of a machined surface.

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An accurate analytical model for the regenerative chatter vibration in the plunge cutting is proposed in the present research. Effects of the cross transfer function and the cutting force ratio on the chatter stability are considered in the proposed model. Equivalent transfer function is defined, which is useful to understand those effects on the chatter stability. It is verified experimentaly that the chatter stability limits can be predicted accurately by the proposed model as compared with the conventional model.

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Life cycle design requires planning of a product life cycle in addition to designing of a product. One of the effective methods to plan the product life cycle is to describe a life cycle scenario, which should be then realized by designing the product and its life cycle processes. This paper proposes an integrated design method to support the life cycle design comprehensively. Especially, we propose a design system that supports a designer to describe the life cycle scenario and to design the product based on the scenario in an integrated manner.

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A product's lifecycle can be described explicitly as a lifecycle scenario, and the product should be designed to realize a scenario that minimizes its environmental load over the entire product lifecycle. This paper proposes a method of modular design that links the lifecycle scenario to appropriate product architecture by modularizing components that are suitable for the same life cycle options such as recycling, maintenance, reuse and upgrade. We also propose an index for evaluating and comparing efficiency in resource circulation for modular products derived from various life cycle scenarios.

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Recently, eco-friendly machining has been drawing attention in manufacturing field. Especially, environmentally conscious cutting process has been developing widely. However, there is few method that achieves low environmental impact in final polishing field. Here, a new polishing method with fixed-abrasives was proposed, and compared with conventional method from a viewpoint of environmental impact. Environmental impact assessment by LCA and energy consumption was compared in manufacturing phase and disposal phase. As a result, it was found that polishing by human work was an eco-friendly process, even if it was compared with desktop size machine manufacturing. Moreover, the effectiveness by using fixed-abrasive process has been clarified in disposal phase.

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Recently, sustainable materials have attracted attention because of the need to alleviate environmental problems. Bamboo, in particular, has attracted attention as a sustainable material because it has the fastest natural growth rate among various renewable natural materials. By a machining center, the self-bonding of bamboo fiber has been enabled by fiber extraction without ruining the bamboo material. Therefore, we propose a sustainable manufacturing system that focuses on bamboo. Additionally, the LCA analytical results of GFRP (Glass Fiber Reinforced Plastics) and bamboo were compared to evaluate the environmental impact of our system.

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Environmentally conscious design or ecodesign is a key methodology to achieve the sustainable society. Manufactures often use ecodesign checklists to improve their products; however, the relationship between individual requirements of checklists and environmental impact is undetermined. This paper proposes a method for assessing ecodesign achievement by developing a weighted checklist from a conventional checklist. The ecodesign achievement is defined as potential environmental improvement, evaluated by the life cycle simulation. An example involving a digital duplicator shows that the proposed method clarifies requirements to be improved. When applying design improvements, the assessment of the product's CO2 emission decreases by 8%.

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Two-dimensional ultrasonically assisted grinding technique is proposed for the machining of monocrystal silicon in order to achieve high material removal rate and high surface quality simultaneously. In this technique, the workpiece is attached on the ultrasonic vibrator produced by bonding a PZT device on a metal elastic body, and the elliptic vibration is generated by the simultaneous creation of the longitudinal and bending vibration of the vibrator. The grinding experiments are carried out and experimental results show that the grinding forces decrease enormously; the surface quality is improved; the dimensions of grinding grooves are significantly smaller; the chip is thicker and shorter compared with those in the conventional grinding.

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This paper deals with the microscopic wear behavior of the grain cutting edges that is the most important factor controlling the grinding ability of cBN wheels. To clarify the self-sharpening phenomenon due to the micro fracture of the cutting edges, the wheel wear process in grinding with cBN vitrified wheel has been observed using three-dimensional (3D) scanning electron microscope with four electron probes and the 3D-profile of worn cutting edge has been evaluated using the attritious wear flat area percentage. In particular, complex behavior of the self-sharpening of the grain cutting edges due to the micro fractures can be quantitatively expressed by the change in the wear flat area percentage.

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This paper describes a development of high-performance vitrified bonded cBN grinding wheel using a new type of ultrafine-crystalline cBN (cBN-U) abrasive grains. Surface plunge grinding experiments using a cBN vitrified wheel made of the cBN-U grains with a mesh size of #80/100 are carried out and its grinding performance is compared with those of cBN vitrified wheels made of representative conventional monocrystalline and polycrystalline cBN abrasive grains. This new cBN-U abrasive grain possesses a higher fracture strength than these conventional cBN grains. Therefore, the cBN-U wheel indicates lower grinding energy and higher grinding ratio than conventional cBN wheels.

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Diamond grains covered by nested carbon nanotubes (CNTs) were constructed using self-assembly techniques for improving the tool life of electroplated tools. The acid-treated CNTs are first adsorbed onto amine-terminated grains, which were chemically functionalized by silane coupling treatments or UV treatments, in N, N-dimethylformamide solution. Then, the drying and readsorption cycle deposited CNT coatings on the grains by CNT-CNT interaction. The CNT coatings on amine-terminated grains treated by UV irradiation had smooth and uniform profiles, and homogeneous structure. The bonding strength of the CNT-coated grains to the Ni matrix was almost twice as large as that of the normal grains.

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In our previous study, a new centerless grinding method using surface grinder was proposed. However, the material removal rate was very small owing to the low worktable feed rate. This paper describes a practical method for increasing removal rate while workpiece roundness is maintained at a high level. In this method, the worktable feed rate is adapted appropriately so that the wheel depth of cut is kept constant during grinding. The actual grinding experimental results showed that the same level of workpiece roundness can be achieved only with a half of grinding cycle time once the worktable feed rate is adapted appropriately instead of the constant feed rate during grinding.

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The present study intends to investigate the comparative micro-grinding performance of BK-7, Lithosil and N-SF14 glass using on-machine fabricated PCD tool. In addition, the effects of cutting conditions on the grinding forces and surface finish of the glasses have been investigated. It has been found that the performance of the three glass materials differ mainly due to difference in hardness and fracture toughness of glass materials rather then cutting condition. It is also observed that the PCD tool performs better in grinding brittle materials, like BK-7 glass with surface roughness around 12.79 nm. However, Lithosil has higher cutting force causing tool rapid blunting and N-SF14 has swarf on its ground surface makes surface rougher.

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Fusion welding is well known as the most promising technique in glass joining, since joining can be accomplished without any intermediate layer and mechanical contact. High precision, small heat-affected zone (HAZ) and small shock-affected zone (SAZ) by ultra-short pulsed laser make it possible to perform the process with minimal damages to the surrounding area. However, there still remained a lot of things to be clarified in this process, since glass materials are very sensitive to temperature gradients and available in different thermal properties. In this study, molten zones created by ultra-short pulsed laser in borosilicate glass and fused silica glass were evaluated. Laser irradiation was carried out inside the glass under various processing conditions. Molten zone was observed visually, and its mechanical strength was measured using three points bending test.

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Pulsed Nd:YAG laser and continuous diode laser were spatially superposed for higher absorption to aluminum alloy. 12-20% increase in bead width and 15-30% increase in weld depth could be obtained by superposition of continuous diode laser and pulsed Nd:YAG laser. Moreover, the unsteady thermal analysis with key-hole effect indicated that the temperature of specimen surface with continuous diode laser could be kept approximately 300K higher than that without continuous diode laser. Therefore, it was clarified that the bead width and depth would increase greatly due to higher absorption of Nd:YAG laser to aluminum alloy by superposition of diode laser.

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The nozzle shape was investigated in order to develop a high performance nozzle for pulsed Nd:YAG laser cutting, and its effect on fine cutting of thin metal plate was also discussed. In the case of 0.5mm throat diameter Laval throat nozzle with an initial expansion zone, the pressure on workpiece increased, and the straightness of gas flow was improved compared to a traditional straight throat nozzle, and the observation using high-speed video camera could reveal the behavior of removing molten metal downward. The experimental results proved that Laval throat nozzle with an initial expansion zone made it possible to reduce the dross height and the kerf width.

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Due to the high functionality of polymer materials, they are widely used in various applications. In this research, firstly the ablation of PMMA using excimer laser was studied. Through simulation and actual experimentation, it is found that the cutting depth was proportional to irradiation pulse number. Therefore, when the laser frequency is fixed, by changing the feed rate of the work piece, the irradiation pulse number and the cutting depth can be controlled. Based on the control of work piece feed rate, the free-form surface machining method of PMMA using excimer laser was proposed.

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Precision micro-machining without crack and with narrow heat affected zone is required in order to use high-performance material. For this purpose, it is expected that higher harmonics of Nd:YAG laser could perform precision micro-machining by its high photon energy. However, even using harmonics of Nd:YAG laser, heat affected zone is inevitable due to the plasma generation. In order to reduce the influence of plasma, it is important to understand the generation mechanism of plasma. Therefore, the laser induced plasma was observed by high-speed shutter camera, and the influence of laser wavelength on machining characteristics was investigated.

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Laser cleaving is used as a technique to separate a thin plate of brittle materials. In this paper, the influence of crystal orientation on crack propagation is investigated experimentally. As a workpiece, a (100) face silicon wafer is used. The pre-crack induced by a Vickers indenter is observed with an optical microscope. Additionally, laser cleaving along the semicircle is performed. The results show the crack propagation with laser cleaving is along the cleavage plane. When the crack propagates along a direction of cleavage plane, the roughness of the fracture surface is very small. When the crack propagates along the direction between two cleavage planes, the fracture surface has the periodic wave.

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The layered manufacturing technique is one of the most effective processes for the manufacture of prototypes, tools and functional end products with metallic powder. In this method the metallic powders are successively melted in a microscopic zone and are clad to the already formed base. In this study, the consolidation characteristics of chrome molybdenum steel (SCM) based powder used to rapid tooling with Yb:fiber laser are described. The density and the strength of consolidated structure were measured under various experimental conditions. As a result, it was revealed that the density of the structures changed under the influence of scanning speed and hatching space of laser beam. The suitable irradiation energy for laser consolidation should be selected to obtain a good shaped structure. The specific cutting force was greatly influenced by the irradiation conditions and its value increasing when the laser condition is optimized.

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This paper deals with design method for structure of injection mold fabricated by Metal Laser Sintering, which is one of the rapid prototyping technologies. This technology provides mold with more sophisticated function and improvement of formability and productivity. To realize structure of mold with these advantages, the method has been developed by following processes : (1) Specifying important structural location by optimization method. (2) Satisfying design specification using the location. It is confirmed as results of numerical experiments that suitable structure with less volume of high-density sintering, in comparison with structure fabricated by conventional process, is obtained.

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This paper proposes a new method for correction of tool run-out on a machine tool using a laser. The laser is irradiated on the tool shank of the attached tool on the machine spindle. The thermal stress caused by laser irradiation at the irradiated part can make a deformation. First, the deformation patterns based on the thermal stress are shown. Second, experiments are carried out in order to investigate the influences of laser irradiation conditions on the deformation. Finally, a few case studies are performed using a cutting tool and succeeded in reducing the run-out to sub-microns.

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This study aims to clarify the influence of surface topography on the photocatalytic function of TiO_2 film surface to support manufacturing high-performance photocatalytic films. In this report, a few textured TiO_2 film surfaces were produced by conducting the anodic oxidation to the titanium plates with micro cutting grooves under various tool feed conditions, and the wettabilty which is one of the photocatalytic functions was evaluated. As a result, it is understood that the wettability of manufactured TiO_2 film is improved with increasing the real surface area, and it is also confirmed that the high-performance TiO_2 films can be manufactured by combination of the microcutting and anodic oxidation, even though further increase in the real surface area is necessary.

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Mask-free and rapid patterning of fused quartz surface is useful for various applications, such as rapid prototyping of optical elements and UV nanoimprint molds. We examined the fabrication of patterned quartz for such applications by ion-bombardment-enhanced etching using buffered hydrofluoric acid as the etching solution.

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UV-nanoimprint lithography (NIL) is high throughput nano-order replication process; thus, this process is promising for next generation lithography and patterned media and so on. But, lifetime or strain of UV-NIL mold has not been studied yet. Therefore, repeatedly UV-NIL were carried out, strain field of Si mold after UV-NIL were observed by Raman mapping image. As the results, UV-NIL causes almost zero strain in the mold.

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Focused ion beam can remove hard materials such as diamond, sapphire, and silicon carbide (SiC). SiC is very useful for glass molding because of high temperature toughness and high hardness, however, fine patterning of SiC is very difficult. Therefore, ion beam machining properties of SiC were investigated and 3D fabrication of SiC using dwell time machining method was also carried out. The machining properties, submicron patterns and 3D patterns of SiC were obtained.

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As one of the core technologies in bioengineering, cloning are frequently used in various fields. As cloning involves a lot of cell manipulations, the manipulation is highly expected to be automated. In previous research, we have developed a vision guided micro-manipulation system to automate the manipulation. In this paper, a path control scheme using potential approach with configuration space and Laplacian potential field is newly proposed to automatically generate the tool path for moving. The scheme is confirmed to enable the manipulator to approach to the target cell without interfering with others in a multiple cells arrangement by simulation.

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Blade dicing by use of diamond blades is the conventional process for separating IC chips, however, encounters many problems including cracks and chippings during the process. On the other hand, Laser machining is expected to be free from these problems. This study aims to develop the ultra-short pulsed Laser cleavage-cutting process by the assistance of chemical reaction to improve process efficiency and process accuracy. In the experiments, single crystal silicon wafers were irradiated by a pico-second pulsed Laser under various conditions, such as TMAH concentration and pulse energy to acquire the fundamental data for precise Laser cleavage-cutting.

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Most of applications are based on two dimensional images. Recently, there are increasing demands of 3D information for new applications. The aim of research is to develop an algorithm for acquisition and configuration of 3D profile by means of binocular stereopsis. In previous research, we have developed the algorithm of acquisition and configuration of 3D data for static image. In this reserach, the 3D data acquisition and configuration are performed on live stereo vision. In the case of live stereo vision, improvement in processing speed is implemented to accommodate to the commercial motion capture systems in the video rate.

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In micro cutting, high efficiency and high precision processing are difficult, because a micro tool has very low strength and stiffness. Thus there is a cutting force measurement as one method to solve this problem. However, the problem of the cutting force measurement in micro cutting is that the cutting force is too small, and the frequency response of the cutting force measurement is required high. Therefore, the cutting force measurement using a conventional dynamometer is difficult. In this study, the problem on the precise measurement of the cutting force in micro end milling using micro tools is solved.

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This paper describes single point micro incremental forming (SPMIF) applied to the fabrication of meso-scale shell structures. The authors have developed SPMIF without using any die and backing plate for flexible micro forming of miniature 3D products in a range of micro meters to sub-millimeters. A desk-top type of CNC milling machine was constructed as an experimental apparatus. Thin aluminum foils of different thickness and thin round tip bars of different diameters were utilized as blanks and forming tools, respectively. Some basic shapes and complex shell structures of micro shell structures were formed in the established SPMIF system. Through the experiments, it was proved that the SPMIF system established in this study can be widely applied to the forming of micro shell structures in various shapes.

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Polydimethylsiloxane (PDMS) is difficult to machine by conventional cutting process because of its low elasticity and high adhesion. We proposed the cryogenic micromachining method assisted by liquid nitrogen cooling for direct fabrication of 3D micro channels on PDMS substrate in short time. In this paper, the cryogenic cutting mechanism is clarified through some verification experiments. Moreover, Pre-Deformation-assisted Cryogenic Micromachining (PDCM) method is also proposed for fabricating the unique shape of channels and its validity is evaluated experimentally. The results of cutting tests show that 3D unique micro channels can be processed precisely and rapidly on PDMS.

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Machining conditions are investigated to improve a tool life in end milling of Cobalt Chromium Molybdenum (Co-Cr-Mo) alloy. First, the machinability of Co-Cr-Mo alloy is estimated by using Difficult-to-Cut Rating (DTCR). To investigate the influence of tool shapes and cutting conditions on material removal rate and volume, cutting experiments are conducted. Experimental results showed that the cutting force increases as the cutting speed increases. Finally, tool life tests are conducted. We experimentally found the machining condition that achieves the material removal rate of 2.16 cc/min and the material removal volume of 391.6 cc or more.

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Inconel 718 is one of a family of nickel-base superalloy. However, Inconel 718 has disadvantageous properties for machining. These properties shorten tool lives. Therefore, it is difficult to increase the cutting speed of Inconel 718. But high-speed and high-efficiency machining is demanded. In this study, the high speed finish-turning of Inconel 718 was conducted. To improve the tool life, the authors proposed the new lubrication method called "Air Jet Assisted (AJA) Machining," in which the compressed air was applied to the normal wet cutting. It was found that this method improved the tool life in comparison with conventional wet cutting.

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To achieve high speed rotary cutting of high hardness super alloys, influences of tool peripheral speed, tool diameter, and tool inclination angle on thermal behavior and adhesions are investigated. Additionally MQL's cooling and lubricating effects are verified. Rotary cutting tests of Inconel718 of HRC45, are carried out using coated carbide tools at up to 500 m/min of surface speed. By employing a larger diameter tool and selecting an appropriate tool peripheral speed so as to reduce the tool-workpiece contact time and frictions, tool temperatures and failures are suppressed. Adhesions are also reduced utilizing the tool inclination angle control and MQL.

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C/C-SiC composite which has recently been developed is C/C composite infiltrated silicon. In this study several endmill cutting experiments for this material were carried out. Cemented carbide, DLC coated and PCD tools were used. The relation between the tool wear and the cutting conditions were investigated. The tool wear progress of the PCD was smaller than that of the DLC coated tool. The cutting tests with cooling air also were carried out in order to clarify the coolant effective. It was found that tool wear was decreased with cooling air.

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Rotational motions of the forearms, called pronation and supination, are applied to various operations of working, daily living, and sports. However, they are not incorporated into digital human models (DHMs) that perform visual and kinematic evaluations for usability of products and workability in workspaces with 3-dimensional CAD data. The forearms in the most of the DHMs are represented by one skeletal frame, even though the real human forearm contains two bones named ulna and radius. The objective of the study is to propose a 3-dimensional skeletal model of the human upper limbs consisting of the upper arms, forearms and wrists, which are applicable to simulation of the rotational motions of the forearms with high fidelity. In particular, emphasis is given to modeling of the inner structures of the forearms including two bones, i.e. the ulna and radius. The right forearms of three healthy male subjects are CT-scanned in every four rotational positions with no rotational torque, in order to analyze in-vivo 3-dimensional kinematics of the ulna and radius. In this study, the rotational axis of the forearms are firstly discussed based on the 3-dimansional images obtained from the CT-data. A 3-dimensional skeletal model is proposed to represent and simulate the motions of the human upper limbs including the rotational motions of the forearms.

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Machine tools are recognized as key components of manufacturing systems, and product quality and cost mainly depend on performances of the machine tools. Much progress has been made in the machine tool technologies, aimed at improving the performances of the machine tools from various viewpoints, such as accuracy, reliability, productivity, and flexibility. The machining accuracy is one of the most important characteristics of the machine tools. From the viewpoints of the design and the manufacturing of the machine tools and their components, one of the important issues is to clarify the relationships between the kinematic motion deviations of the machine tools and the geometric tolerances of the components, such as the guide ways and the bearings. The objective of the present research is to establish mathematical models representing the kinematic motion deviations of the machine tools, on the basis of the geometric tolerances of the components, and to apply the models to theoretical analysis of the kinematic motion deviations of the machine tool components.

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