In actively driven rotary tools (ADRT), the principal cutting force and tool tangential force are measured based on the power consumption of the main spindle and the tool spindle, respectively. In rotary turning, the principal cutting force, amount of chip flow angle change, and chip thickness are almost independent of direction of tool rotation: clockwise or counterclockwise. The high-efficiency reciprocating turning can be carried out done in such a way that the tool tangential force acts in the opposite direction of that of feed force. Furthermore, the cutting conditions where the continuous chip is broken by the chip breaker are also examined via the observation by the high speed camera.

Guaranteeing the machining accuracy of a workpiece is difficult because of various factors. Typical causes of this problem include individual differences between the castings used as materials, tool deformation due to cutting loads, and inconsistencies between machine-tool machining programs. In some cases, these factors overlap. In this study, a mechanism that does not lose shape-data information generated from CAD and CAM before NC program execution is proposed to creates a product as close as possible to the original three-dimensional shape. The problems that can be solved via computerized numerical controller (CNC) are identified and a solution is proposed in the form of a shared database and data model acting as an information sharing basis for the integrated CNC system.

In this study, a new method utilizing the similarity of removal volume to select the most similar machining case data is proposed to realize automated NC program generation. The geometric information of the removal volume, which is extracted by splitting total removal volume, and the cutting conditions associated with the removal volume are stored in database as a machining case data. The proposed method can select the most similar machining case data from database even for the complicated product shape, because each extracted removal volume is geometrically simple. In the case study for the validation of the proposed method, the cutting conditions were successfully determined from the most similar machining case data and an NC program was automatically generated appropriately.

Dry cutting experiments were carried out to investigate the BUL formation process and its influence on the wear of uncoated cemented carbide tool during cutting of Inconel 718. The results show that a thin, stable BUL can form on the tool rake face as a result of the accumulation of workpiece material during cutting of Inconel 718, which can protect the tool. Concerning flank wear and nose wear, adhesive wear is the major wear mechanism, but the adhering layer formed on the worn surface can decrease the tool wear. It is also confirmed that the quick formation and fall-off process of the unstable adhesion has a strong effect on notch wear. In addition, BUL formation mechanism and wear mechanism are also proposed.

Ultraviolet Nanoimprint lithography (UV-NIL) can fablicate nano-scale patterns, and expected as a low-cost and large number of production technique. We have evaluated a transfer durability of a replica mold. Using replica mold is effective technique to prevent a master mold, but pillar shaped replica mold has many defects and adhesion of the transfer resin by repetition transfer. In order to solve these problems, we have improved the UV-curable resin materials. In this paper, we transferred large amount of nano-scale patterns and evaluated of error rate and contact angle of this improved release agent -free hard replica mold. The release agent-free hard replica mold can transfer up to 1200 imprint times.

This study sought to conduct additive manufacturing on a cylindrical object using a wire and arc-based system. As thermal contraction occurs during the cooling process of weld metal, cylindrical objects deform when the additive layers are fabricated along the longitudinal direction on the long thin cylinder side surface. We first focused on the order of four additive layers at 90-degree intervals on the cylindrical surface, investigating the effect of two kinds of layering order on the deformation. The first was a clockwise pattern that layered the second bead to the 90-degree position of the preceding one in sequence. The second was a criss-cross pattern that layered the second and fourth beads in opposition to the preceding ones. We then considered the effects of cylinder surface temperature at the opposite side of the added layer. We found that the final deformation was smaller with the criss-cross pattern than with the clockwise layering pattern. Moreover, deformation decreased as cylinder surface temperature increased.

In recent years, transparent resin organ models created by 3D printing have found application in the medical fields. The inside of the organ model contains diseased parts, blood vessels and so on, but they cannot be seen due to the layered appearance of printed surfaces. To address this issue, an automated system was developed using an industrial robot to replace the manual polishing currently needed. The automated system consists of three aspects: fixturing of the organ model, polishing tool path generation and polishing process conditions. From polishing experiments on a relatively simple shape, it was found that the system has the potential to deliver transparent surfaces on complex resin organ models.

The purpose of this study is to propose a revised instantaneous rigid force model based on oblique cutting model for end-milling operation to eliminate predetermination of cutting coefficients. Although, six cutting coefficients are required for cutting force prediction in the conventional instantaneous rigid force model, the shear angle is only required in our revised force model. The determination of the shear angle is easier than the determination of six cutting coefficients from the cutting test. As a result from a validation, our revised force model can predict the cutting force more practically than the conventional instantaneous rigid force model.

Levelling operations are important during the machine tool installation. For more efficient leveling operations, a model which enables the quantitative evaluation of levelling errors is proposed and verified in this paper. This model considers supports as simple linear springs. The relationships between free length change and preload change is expressed as a matrix. Then, a verification experiment is conducted on a three axis machining center. The result suggests that the free length errors of supports can be obtained from the preload changes using the matrix.

In the development of multi-tasking machines, the speed of development has become faster over the years. To enable the efficient analysis methods, we must enhance design quality by the analysis and design in a short period of time alternately and repeatedly.

In this study, machine bed is set up in the environmental test chamber. Test room temperature can be controlled. We measured thermal deformations of the bed when the environmental temperature changes.

Analysis and experimental results were compared and evaluated. The purpose of this study is to suggest analysis conditions that are simple but highly accurate. Also, the bed's rib structure affects thermal change. This paper investigates the accuracy of analysis of deformation of machine tool bed.

Cutting optical glass bears the problem of severe tool wear, as a result, a stable cutting process is difficult to achieve. Since most optical glasses are composed of silicon oxide, the severe diamond tool wear during glass cutting might be caused by the chemical reaction between silicon oxide and diamond. Thus, reducing the silicon oxide composition might be helpful for glass cutting. This study demonstrates that by using an optical glass without silicon oxide composition as workpiece and using suitable tool geometry, tool wear is greatly reduced and glass can be cut in a ductile mode for a long cutting distance.

The conventional volumetric error compensation for a machine tool is based on the machine's kinematic model, which kinematically formulates the tool center point (TCP) position based on the assumption of rigid-body motion. Particularly in large-sized machine tools, error motions that do not satisfy this rigid-body assumption may have a significant impact on the machine's overall volumetric accuracy. This study proposes a new kinematic model including the influence of three factors; 1) direction- and 2) velocity-dependent error motions, and 3) quasi-static cross-talk between the axes. The paper presents a scheme to assess all the error motions by using a two-dimensional digital scale (cross grid encoder). It is experimentally demonstrated on a large-sized horizontal machine tool.

The turn-mill process to cut the outer side of the hard-to-cut materials is paid to attention in the turn-mill complete machining centers that has both the turning and milling functions. However, it has been said that its process can be used only for roughing because spiral texture is generated on the surface and then the surface roughness is worse. In this research, to apply the turn-mill process to the finishing, cutting texture will be controlled by turn-mill complete machining center and ball end mill that is one of the most basic cutting tools for milling.

Identification method of cutting process is developed with sensor-integrated disturbance observer for general machine tools with multi-inertial feed drive systems. An acceleration sensor is adopted to the developed disturbance observer to eliminate high frequency noise in estimated disturbance force. The developed disturbance observer is also featured that the acceleration signal is processed based on mode decoupling approach. Through a milling test of carbon steel, experimental results verified higher performance of the observer with respect to the conventional observer without sensor integration. By utilizing the developed observer, concurrent identification of milling process and mechanical dynamics is attained successfully.

The objective of this study is to develop a new method for predicting the processing times of workers in cellular manufacturing systems. In our previous researches, a statistical approach was proposed for predicting the processing times of workers. However, the predicted processing times may not always coincide with the actual processing times since there are individual differences of the learning levels for workers and the decrease ratio of processing times of workers. Therefore, the new method uses the individual biological information such as the heart rate variability in workers in order to estimate the individual difference of learning levels of workers.

The stress distribution inside the workpiece under ultrasonic vibration assisted machining (UVM) condition is reported. Many researchers have reported the improvements of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVM condition. In this presentation, stress distribution inside the workpiece was observed by combining the photoelastic method and the pulse laser as light source synchronized with ultrasonically vibrating machining tool. The one shot of pulse laser with pulse width of 15nsec visualizes an instantaneous stress distribution by combining photoelastic method. Assuming that UVM phenomenon has high periodic repeatability for one period of ultrasonic oscillation and sweeping the phase of emission against to ultrasonic oscillation, 362 frames per one period of ultrasonic oscillation are captured. UVM will induced an intermittent cutting condition when vibration speed, which is proportional with frequency and amplitude, is sufficiently greater than feed rate of work, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. Shear angle and amplitude of cutting force change were strongly affected with relation between feed rate of workpiece and tool vibration speed.

Optical glasses are used in a wide range of applications such as lenses in cameras and projectors, medical instruments and window panes. It is highly important to remove cracks in glass in order to prevent breakage, to prolong the lifetime of the glass part and to prevent injury to the user. In this study, the possibility of healing cracks in glass using laser irradiation is presented. Micro-indents, generated under indenting loads, were irradiated using a pulsed laser with a wavelength of 1064 nm using various coating materials at various laser fluences. The results show that laser irradiation greatly decreases the depth of the indents and closes the subsurface cracks. This is due to laser light interaction with glass and coating materials leading to a localized high temperature and the softening of glass.

An assignment problem of cargoes with manufacturing parts to interim storage lanes is addressed, which is a combinatorial optimization model of delivery workload balancing in an automobile assembly plant. The cargo assignment problem has previously been represented as a special case of the unrelated parallel machine scheduling problem of minimizing the makespan, and a heuristic algorithm based on linear partitioning has been presented. In this paper, a modified form of the special case of the unrelated parallel machine scheduling problem with a generalized objective function is considered, and the heuristic based on linear partitioning is extended to the modified form. Numerical experiments are conducted to examine the balancing performance of the extended heuristic algorithm, and the results are reported.

The main machining process for CFRP is hole drilling. Due to the composite structure and high strength of the material, the drilling process counter some major problems such as burrs, delamination and tool life. Therefore, in this study, we aim to realize a hybrid feed mechanism with constant pressure and constant speed feed. This mechanism changes the machining pressure according to the progress of machining without overloading and delamination of CFRP. In addition, by applying ultrasonic vibration, chip transportation is increased and tool friction with chips is reduced. In this paper, we developed a highly accurate CFRP processing machine is equipped with a hybrid mechanism ultrasonic vibration. The efficiency of developed processing machine is evaluated by practical experiment.

X2CrNiMoN25-7-3 duplex stainless steel is suitable for chloride-containing environments such as seawater because it has excellent pitting corrosion resistance. Duplex stainless cast steel is often used to accommodate the complexity of part geometry at joints. However, machining after casting is indispensable. This study evaluated the cutting characteristics of stainless cast steel. Adhesion of the cutting edge was weak at high cutting speeds, but tool wear was large. Diffusion and reactions between the workpieces and the tool edge were investigated. Slight interdiffusion and a reaction phase were observed, but the bondability was low.

This paper presents a design study of an XYZ three-axis micro stage which achieves a size of several cubic centimeters, a millimetric travel range, a nanometric driving resolution and three-axis motion at the same time. In addition, unique leaf springs acting not only as guides for a stage table but also as precision displacement sensors are included in the stage system. The XYZ three-axis micro stage is designed and fabricated. The fabricated stage is designed to have a small size of 25 mm (X) × 25 mm (Y) × 6.5 mm (Z). Furthermore, feasibility of the driving principle of the developed XYZ three-axis micro stage is verified in experiments.

Planetary gear trains (PGTs) are very popular for power transmission and extensively used in various industrial fields such as automobiles. Despite their advantages, negative impacts from noise and vibration on the customer perception of quality are an ongoing issue. In this study, an original full wireless test stand in an anechoic chamber was used to directly measure the sound levels of different numbers of planet gears to consider the noise problem of PGTs. Because the torque capacity changes with the number of planet gears, two conditions were considered: a constant output torque and a constant meshing stress.

Performance of the spindle of the ultra-precision machine tools influences the machining accuracy significantly. Thus, the ultra-precision machine tools use the spindle supported by hydrostatic bearings, in general, aero pressure bearings. A spindle supported by water hydrostatic bearings was developed for ultra-precision machine tool. This paper describes the temperature change of the developed spindle under non-spindle rotation. For example, the water temperature at the upstream and downstream of spindle and the temperature of the spindle body are measured. In addition, the temperature change of the designed spindle is investigated using introduced simplified lumped parameter model of the spindle system. Comparing the experiments and calculations verifies that the introduced model is capable of predicting the temperature increase of the spindle. In addition, the paper indicates that the effectiveness of the water hydrostatic bearings to achieve better thermal stability of the spindle.

This paper presents a new optical angle sensor, in which a mode-locked laser referred to as an optical frequency comb is employed as the light source. Highly-stable carrier frequency of the optical frequency comb is expected to improve the sensor stability. This angle sensor is designed based on laser autocollimation method, and utilizes the chromatic dispersion of an objective lens to detect angular displacement of a measurement target. A detail of the proposed method is described, followed by some experimental results with the developed prototype optical sensor.

This paper presents an optical setup to fabricate a large-area two-dimensional diffraction grating by using a two-axis Lloyd's mirror interferometer. In order to fabricate large-area gratings, a large collimating lens, which generates a large diameter collimated beam, is integrated into the optical setup. In this paper, an evaluation of the intensity distribution of the collimated beam and an exposure experiment are carried out. In addition, the fabricated grating is measured by an atomic force microscope to evaluate the effectiveness of the developed setup with the large collimating lens.

In this paper, a measurement method with a mode-locked laser source for evaluation of grating periods, which is based on the laser diffraction method with the Littrow configuration, is proposed. Optical frequencies of the mode-locked laser, which are referred to as the optical frequency comb, have deterministic mode frequencies with equal intervals in the frequency domain. Since the frequency of each comb mode can be highly stabilized by a high precision external standard, measurement accuracy of the laser diffraction method is expected to be improved. In this study, a prototype optical setup based on the proposed method is developed, and some experiments are carried out to verify the feasibility of the proposed method.

An optical configuration for a confocal microscope employing a mode-locked laser source is proposed in this paper. Due to high illumination efficiency and a highly stable optical frequency of the mode-locked laser, which is traceable with the national standard of frequency and time, the proposed chromatic confocal microscope is expected to achieve a high axial resolution. In this paper, as a first step of research, design study on the optical setup for the prototype chromatic confocal microscope with the mode-locked laser is carried out.

Acrylic resin is employed for optical products because it has a high transparency property. There optical components are required mirror finish to satisfy required optical properties. Acrylic resin is heat weak material because heat affected layer which worse transparency property is generated on machined surface. Hand polishing by skilled worker are carried out to remove heat affected layer generated by milling operation and to finish mirror surface of products surface, however, the polishing consumes long time and has problems that skilled workers are aging and next generation skilled workers are few. In this research, ultrasonic mirror finish machining for acrylic resin were carried to replace hand polishing by skilled worker to solve above problems. Machine tool which equips ultrasonic spindle system was employed the machining experiments to prevent heat affect during milling operation and sphere shape milling were carried out.

In the sheet metal processing, nesting and scheduling are the important factors for the efficient and agile manufacturing. The objective of nesting is minimizing the waste of material, while that of scheduling is optimizing the operational sequence. The relation between them often becomes trade-off. Therefore, they should be considered simultaneously for the efficiency of entire manufacturing. In this study, we propose a Coevolutionary Genetic Algorithm based nesting scheduling method. First, we define a cost function as a fitness value. Then we propose a grouping method that forms groups of gene based on the cutting layout and the processing time. Finally, we validate the effectiveness of the proposed method through computational experiments.

The compensation of friction in the feed drive system is important issue to realize high precision motion. However, feed drive systems consist of several mechanical parts and contact surfaces. Therefore, friction phenomena are complicated. In this report, identification method of friction in the table side and friction in the motor side is suggested. two-inertial model with friction is used for the theoretical analysis. Identification tests were carried out with the feed drive system supported by sliding guideway. The result of identification shows the friction characteristics in the table side and that in the motor side, respectively.

In this study, elastic recovery phenomenon in cutting process of NiTi alloys was investigated with orthogonal cutting experiments under different cutting speed and feed conditions, this phenomenon is expected to be caused by elastic recovery due to the super elasticity property of NiTi alloys. In this elastic recovery phenomenon, cutting forces did not change significantly in all cutting conditions. Furthermore, tool angle change experiments were conducted by using different cutting tools with different rake angle and clearance angle. Results show that cutting tools with negative rake angle deteriorated cutting performance, while increasing clearance angle to 10° can improve cutting performance of NiTi alloys.

In order to machine harder silicon carbide molds precisely, micro milling tools made of single crystalline diamond (SCD) were fabricated by using laser fabrication process. Several cutting edges were fabricated three-dimensionally by a laser beam on the edge of a cylindrical SCD. SiC wafers with a flat face were cut with the developed tool to evaluate the tool wear rate and its life. Some micro aspheric molds of SiC were cut with the tool at a rotational speed of 50,000 min^-1. The molds were cut in the ductile mode. The form accuracy obtained was approximately 100 nm P-V, and the surface roughness was 14 nm Rz.

This paper proposes a new surface form measurement method using a scanning type surface profiler for small roll worlpieces, which are used in many industrial fields. In this method, inclination of a workpiece is required to be aligned precisely. For this reason, this paper also proposes a method of measuring the inclination angle of the workpiece without using any other external sensors but using a scanning probe of the surface profiler. In order to confirm the effectiveness of the proposed principles, a measurement system is developed and some experiments are carried out.

In this study, tool wear in cutting of titanium alloy (Ti-6Al-4V) was investigated when the contact condition of a lathe chuck and workpiece was changed by gripping force of the soft jaw. A workpiece with 90 mm in diameter and 180 mm in length was chucked by cantilever support. Cutting speed was 150 m/min, depth of cut was 0.2 mm, and feed rate was 0.1 mm/rev. Stress distribution of the contact surface of the soft jaws, and static and dynamic stiffness of the main spindle system were also measured to explore the main cause of tool wear variation. The static stiffness of the spindle system increases with increasing into gripping force because by resistivity against bending at the chucking position increases due to the increment of conformity in axial direction between the jaws and workpiece. Accordingly, the modal frequency of the main spindle system increases. Furthermore, the tool wear variation was influenced with this modal frequency of modal vibration.

A novel method is proposed for generating tool swept volumes and estimating the machining errors on machined surfaces caused by errors of multi-axis machine tools, such as geometric errors. The proposed tool swept surfaces generation method derives the tool swept surfaces as a triangular mesh model satisfying the required approximation accuracy by adding approximate tool swept areas. Using the proposed method, tool swept surfaces can be derived for tool self-intersecting motion. In the proposed estimation method, error vectors on machined surfaces are derived by comparing the points on the nominal tool swept surfaces (excluding the machine tool errors) with the triangles on the error tool swept surfaces (including the machine tool errors).

In general, NC data used for machining is made by a CAM software. However, it requires knowledge and skill to judge whether the tool path and tool postures are suitable or not. This study is aiming at developing a system to experience cutting force in 5-axis controlled milling process. In this study, operating the end mill by a haptic device that can manipulate objects in a virtual space, the cutting condition is estimated from the removed voxel, and the force in the cutting process can be calculated. It was confirmed that the experience of cutting force had become possible by force feedback.

Large-area electron beam (EB) irradiation method developed recently, the wide area on metal surface can be simultaneously smoothed due to high energy density of EB on the surface. However, if the workpiece has a hole shape, it is difficult to smooth the hole bottom surface, since the EB concentrates on the entrance edge or inside wall of the hole. In this study, expansion of smoothed area on the hole bottom surface was experimentally investigated by using a magnetic block with a through hole which is placed under the workpiece in large-area EB irradiation. Then, the influence of hole diameter and volume of the magnetic block on the smoothed area was discussed.

A contactless excitation method with a magnetic loading device is investigated for the measurement of dynamic compliance of the tool-holder-spindle system, aiming the real-time simulation of the regenerative chatter with mode coupling. The loading device that can excite in two radial directions of the spindle was developed. This paper reports the basic characteristics of the loading device, which are the static relation between the coil current and the attractive force, the influence of the attracted size of the dummy tool, and dynamic response obtained with swept-sine excitation.

In ultra-precision cutting of polycrystalline material with single crystal diamond tool, grain boundary steps become obvious on the machined surface due to crystal anisotropy between adjacent grains. Therefore, to establish ultra-precision cutting technology, it is necessary to clarify the micro cutting mechanism of single-crystal material. In our past work, we have focused on elastic recovery of single crystal copper in micro groove cutting. However, affected layer were formed at the stage of planar cutting, which was a prior process of groove cutting. It was difficult to observe the influence of crystal anisotropy once the affected layer was formed. Thus, appropriate cutting conditions of prior process are necessary to minimize the affected layer. In this study, single crystal copper (111) plane, one of slip planes, was used as a cutting surface.We defined [112] direction as 0° and conducted prior cutting process at 13 directions ranging from -60° ([211]) to 60° ([121]). Cutting forces were measured and hardness of the finished surfaces were examined. Chips, tools and cutting surface were observed with an electron microscope. The Schmidt factor of each slip system was calculated from the measured three-component forces. Then, we investigated the influence of crystal orientation on cutting mechanism and machined surface in prior cutting. As a result, cutting parallel to [121] direction (60°) generated the best cutting surface. In contrast, cutting parallel to [112] direction (0°) generated the most defective cutting surface. In addition, the finished surface had periodicity of 120° with good surface and defective surface, respectively. Results suggest that the slip systems and its Schmidt factors may explain the periodicity.

Diamond tools wear extremely in single point turning of steels. It is thought that carbon atoms in diamond diffuse into iron. Characteristics of steels can be widely changed by heat treatment and surface modification. In our past work, we have focused on heat treatment and have changed the microstructure to suppress the tool wear. We have found carbides precipitated in α-phase suppress the tool wear. Then, we have studied on carburized steels. Tool wear was examined in comparison with element concentration, hardness, and carbide area ratio of carburized steels. Accordingly, large-size and high-circularity carbides precipitated on grain boundaries were related to increase the tool wear. However, it was not clear which factors may suppress the tool wear. In this study, past experimental data was used to examine relation between tool wear and microstructure of carburized steels. We used 21 sets of data, which contains element concentration, hardness, and carbide area ratio of carburized JIS SKD61 steels. Based on it, a decision tree which explains tool wear was made by using C4.5 classification algorithm. The decision tree revealed carburized steels without carbides whose area is ranging from 1 to 3 μm² and whose circularity is less than 0.5 tend to increase the tool wear. On the other hand, carburized steels with above-mentioned carbides, and with carbides whose area is ranging from 0.07 to 1 μm² and whose circularity is less than 0.5 suppress tool wear the best. Those results suggest that the decision tree can be used to predict microstructure which may suppress tool wear effectively.

Carbon fiber reinforced plastic (CFRP), which is composed of carbon fibers in a resin matrix, is an extremely strong and light composite material that has found use in the aerospace and automotive industries. CFRP boards are very difficult to machine using common machining processes. Various machining artifacts, such as burrs and delamination, occur frequently when machining CFRP. Adequate techniques for machining CFRP have not yet been established. Recently, electroplated diamond wire machining technology has found use in cutting hard, brittle materials such as silicon and sapphire. In this study, we used an electroplated diamond wire saw to cut a CFRP workpiece. We quantified the cutting forces imposed on the workpiece and observed the surface state of the workpiece after cutting. We demonstrated that an electroplated diamond wire tool is suitable for the highquality machining of CFRP boards.

We describe a new method for fabrication of three-dimensional layered structure in large area by a lithographic technique with the Talbot effect. The Talbot effect is three-dimensional phenomena of diffraction and interference of high order diffraction light using a grating mask with sub-micrometer frequency. By using a grating with about 800 nm period, it was successful to fabricate three-dimensional nanostructures on SU-8 photoresist in a millimeter region. The typical nanostructure has 300 x 500 nm x 2 mm hole with three layers. Furthermore, the proposed method using the combination of the Talbot effect and wave-front control was demonstrated for controlling horizontal periodicity.

This paper aims to estimate the compressive characteristics and indentation resistance of the acrylic Pressure Sensitive Adhesive (PSA) sheet subjected to the plane plate compression and/or the wedge indentation. These two compressive loading tests with the acrylic PSA sheet were carried out experimentally and numerically. Through the experimental tests, it was found that the indentation velocity affected the cutting line force and the compressive velocity as the compressive strain rate affected the compressive pressure. In addition, a Finite Element Method (FEM) analysis of those two loading tests was carried out using a linear viscoelastic model. It was revealed that the elastic modulus estimated by compressive test is appropriate to simulate the wedge indentation.

The objective of this study was to investigate the recognition of the cutting state and contact detection by the acoustic emission (AE) technique in ultra-precision turning. To detect the accurate cutting-edge position, the contact limit between the cutting edge and workpiece by the AE technique was investigated. Moreover, to recognize the cutting state, the change of the AE signal detected by changing the cutting condition was investigated. As a result, in the contact detection experiment, the contact between the cutting edge and workpiece was detected with a cut depth of 10 nm. In the cutting state recognition experiment, it was found that the AE signal waveform changed when the cutting state changed. It is therefore concluded that cutting-state monitoring by the AE technique is feasible.

In this study, position and angle commands of each axis when machining the same blade shape with a 5 - axis machining center with different NC were recorded and the influence of NC type and control function on cycle time and velocity fluctuation was investigated. As a result, it was found that the cycle time is greatly shortened by using tool tip point control. In addition, the relative velocity is influenced on NC controller, acceleration or jerk is limited.

It is known that in multi-axis simultaneous control machining of complicated shape parts, machining accuracy may decrease due to synchronous error of the drive axes, and machining time may be longer due to excessive acceleration. In this study, in the machining using 5-axis control machining centers, in order to investigate the difference in machining accuracy and machining time depending on the number of drive axes simultaneously controlled, 4-axis and 5-axis simultaneous machining of a complex shaped blade are compared as a case study. As a result, it is found that the machining accuracy is better in the 5-axis simultaneous machining, but the machining time is shorter in the 4-axis simultaneous machining.

This study deals with the thermophysical properties in the metal powder for additive manufacturing (AM). The thermal conductivity and the laser absorption of SKD61 powder were examined in order to clarify the suitable SKD61 powder for AM. As results, the thermal conductivity of SKD61 powder was influenced by the ratio of particle size rather than the average particle diameter. The thermal conductivity was the principal parameter to affect the building of metal powder, and the atmospheres during the building also have to be considered for the optimization of building conditions. In contrast, the laser absorption of SKD61 powder was not influenced to the average particle diameter and the classification.

This report is proposed a new concept for precise ball end milling used by the tool orientation control. The machining area at the point of the surface generation is changed depend on the tool orientation of the ball-end mill. So the machining error estimation index has been proposed and calculated about three dimensional surface. The machining error distribution of some three dimensional shape by machining test is supported the geometric analysis estimation.

The objective of this research is to construct and utilize a machining error model for elastomer end-milling. In this paper, a framework of machining error in elastomer end-milling is proposed. Workpiece deformation and undesirable chip separation are assumed two dominant phenomena of the machining error in elastomer end-milling. A feasibility of the framework is investigated by evaluating the error model with experimental results. Identified error model with limited machining cases can estimates the machining error of different machining cases. The results indicate that the proposed framework can applicable to a model-based elastomer end-milling by combining a workpiece deformation model and a cutting force model.

This present study describes effect of surface roughness and young’s modulus of stamp on transfer-print and fabricating a prototype of micro-tactile sensor. Micro-roughness in the range of 4 to 110 nm have provide considerably high releasability of Au thin-film to be transfer-printed. A high modulus (8.2 MPa) of stamp allow to perform transfer-printing of Au thin-film with smaller deformation as compared to that low modulus (1.8 MPa) stamp. With the improvement of stamp properties, a capacitive micro-tactile sensor can be fabricated on a polymer substrate by a transfer-print based process. The capacitance is confirmed to be linearly increases with applied force in the range of 0 to 1 N.