Discussed in this report was the difference in material removal mechanism below and beyond its static plastic propagation speed. It was found that when the cutting speed exceeded the propagation velocity of material the workpiece became "brittle", resulted in the reeducation in plastic flow/deformation and work hardening, and thus the improvement in finished surface integrity. At such ultrahigh cutting speed, the ductile metal behaved much like the brittle materials. Based on these findings, the authors further proposed and developed a new concept of novel grinding machine of 600m/s speed and 10mm/step positioning capability, in order to achieve both high productivity and high accuracy at the same time. This study particularly investigated the cutting speed effect on ground surface of aluminum alloy (5056).

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The cutting process is one of the most basic machining processes widely used in manufacturing industries, and therefore consciously required to improve its performance in quality and productivity. In this research the ultra sonic cutting (USC) was studied to reduce the plastic flow, which is seen as the cause of the geometric error and residual stress. The experimental results of USC, compared against to the results of conventional cutting, led to the now findings of reduction in 1) the surface roughness by 70%, 2) the depth of plastically deformed layer by 50%, and 3) the working hardness by 30%.

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In this paper, the result of nano-scale cutting of single crystal silicon by using friction force microscope is described. The (100) surface of single crystal silicon was etched by KOH solution after nano-scale cutting of 15μm×15μm area. It was found the etch rate was extremely different between the cut area and non-cut area. The cut area remained as it was little being etched. Dependence of remaining height on normal cutting force and cutting velocity and KOH solution concentration was examined. The new processing technique of micro-structure was proposed by applying the above-mentioned experiment result.

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Atomic scale mechanical processing of superlattice films deposited by RF sputtering was performed using an atomic force microscope (AFM). To realize high density memory, possibility of tribo memory which is consistent with nanometer scale mechanical processing of superlattice films was suggested, and processing properties of superlattice films by diamond tip of atomic force microscope were studied.

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In this study, we evaluated the atomic scale processing of a material with a layered crystal structure, based on topographic changes caused by sliding. Materials with layered crystal structures, such as molybdenum disulfide, graphite and muscovite mica, have basal planes with weak interaction; therefore, the surface of these materials is easily cleaved and observed on the atomic scale. Processing mainly occurs to a depth of about one nm in the mica surface, corresponding to the depth from the surface of one cleavage plane to the surface of the cleavage plane immediately beneath it. By applying this mechanism, high-precision processing such as line and space and cross grooves can be performed in a period unit of a multilayered crystal material which has periodic weak van der Waals bonds.

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In order to clarify friction phenomena generated in the surface observation processes by atomic force microscope (AFM), several molecular dynamics simulations have been performed. In the simulations, a 3-dimensional simulation model is proposed where the specimen and the probe are assumed to consist of mono-crystalline copper and rigid diamond, respectively, and the effect of cantilever stiffness of AFM is also taken into consideration by connecting the springs with the probe in 3-axis directions. The friction process without wear on a well-defined copper {100} surface by a diamond probe is simulated. From the simulation results, atomic-scale stick-slip phenomenon just like observed in the AFM surface observation is realized. Generation of the 2-dimensional friction process even in one-dimensional sliding simulation is confirmed. Influences of the point defect in the specimen surface and the probe tip shape on observed surface image are also evaluated. These results indicate that the molecular dynamics simulation has an advantage in estimating the various phenomena in AFM surface observation.

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This paper describe a new application of stereolithography using LCD mask. Rapid Prototyping (RP) has been developed as the key manufacturing process for fabricating solid model from a computer aided design (CAD). In this paper, we propose a new RP process for micro manufacturing, namely stereolithography using liquid crystal display (LCD) mask. The stereolithography using LCD mask employs the mask method for fabricating 3-dimensional object precisely. This process is characterized by the exposing method and the nonlaminate 3-D constructing process. Several experiments were performed to verify the proposed method. Both a micro gear with a tooth width of about 80 E m and pyramidal shape 1.5mm in height can be fabricated in a few seconds without lamination.

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The aim of this work is the development of a photoforming process for fabricating microparts used in a micromachine system. The high precision photoforming system is constructed, in which variations of machining parameters, such as UV laser power, laser scanning velocity and laser beam radius, that affect the accuracy of microparts are controlled as small as possible. It is confirmed that simple shaped micro-structured parts, such as a cube and a cylinder in the order of 100μ m in size, can be fabricated with the accuracy of the order of a few μ m using this system. Furthermore, a new method for solving the problem that solidified objects adhere to a window is proposed and by applying this method to this photoforming process a micro-gear (PCD 3mm) is successfully fabricated.

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For the production of dicing blades using thermal selling resin binder, several hours for curing process in which thermal deformation induced by thermal shrinkage results in accuracy deterioration are usually required and the lapping process for modifying the blades has been the neck in cost reduction. Dicing blade with UV-resin binder has been developed to solve this problem. On the other hand, higher accuracy and efficiency are required in the dicing process of various hard-and-brittle materials. Thus the opposite demands, increasing the dicing efficiency and reducing the occurrence of chipping, are to be met simultaneously. Based on the feature of UV-resin that is easily to produce a multi-layer structure, we have developed a new type of dicing blade which has a three-layered structure consisting of a inner layer including coarse abrasive grains, and two outer layers of fine abrasive grains. In comparison with the traditional dicing blades, the new type of blade has shown higher dicing efficiency and better cutting quality.

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In order to realize the actual use of micro machines, it is important not only to make machine elements consisting of micro machines precisely but also to establish manufacturing process for micro machine elements having sufficient functions. From such a viewpoint, this study aims to consider the manufacturing technology for micro machine elements and to propose a new concept for micro machine elements. As the first stage of this study, a manufacturing technology of micro size bolts as a machine elements widely used is considered. In order to discuss the manufacturing technology of bolts less than 1mm, performances test of ordinary size bolts are carried out. On the other hand, a small size NC lathe for micro bolts is developed.

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In 1999,our research group in MEL designed a prototype microfactory which consists of three miniature machine tools and two manipulators. Three machine tools are the micro lathe which was developed in 1996,the micro press machine and the micro milling machine. The paper first mentions the effort to develop the microfactory and it's components that potentially reduces energy consumption and space occupied by the manufacturing system for micro mechanical fabrication. The paper also describes a robust design procedure for machine tools, combining the form-shaping theory with the Taguchi method. The study applies the procedure that can estimate the machine tool performance without prototyping, to the miniature machine tools designed for the microfactory. It analyzes the effect that the local errors, the design parameters and the design concept of the miniature machine tools have on its machining performance. The results lead us to conclude that the procedure is a powerful tool to get design suggestions enable better tolerances.

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The microfactory is the downsized manufacturing system, which consist of the miniature machine tools and the micro manipulators, and it has a potential to reduce the energy consumption, to save occupied space and to increase the flexibility for changing products. This paper describes the development of the micro press machine, which can works as one of the components of the machining desktop-type microfactory. The key of the development is to downsize the mechanisms according to the required press force. From this point of view, firstly, the experimental micro press system was constructed and measured the press force. then, considering the result, the micro press machine has been developed, which has a small progressive die and a compact roll feed device. Its dimension is only 111mm wide, 66mm deep and 170mm high, but is has the maximum press force of about 3 kN. The micro press machine can process from the metal strip of 120μm thick to housing cover of the miniature bearing using four blanking and two bending included in single die set. These results can prove the usefulness of the micro press machine for actual production of small mechanical parts.

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This paper presents a machining system for generating two-dimensional angular grids, which are used in a newly developed multi-degree-of-freedom position detection method. This position detection method basically consists of a two-dimensional angle sensor and an angular grid, on which two-dimensional sinusoidal micro-patterns are generated. The wavelength and amplitude of the sinusoidal micro-pattern are typically 300μm and 200nm, respectively, A fast-tool-servo (FTS) based precision diamond turning system was constructed to generate the angular grid. Since the accuracy of position detection is greatly affected by that of the profile error of the angular grid, the angular grid needs to be generated accurately. In this paper, techniques of improving the accuracy of generating the angular grid are described.

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This paper deals with the development of a new type machining system for ultra-precise micro-aspherical parts, which is assisted with electrorheological phenomenon. Now, it is trying to machine the small parts utilizing a micro-grinding and -polishing with the same tool as a series of processes. As a diamond micro-quill for the grinding/polishing processes has a small diameter (0.1-1.0mm), an on-machine truing of the quill is very difficult and a tool life becomes short. A new method is developed, which is named an electrorheological fluid assisted polishing. In this process, polishing slurry is mixture of fine abrasive (diamond, GC or WA) and electrorheological fluid. A strong electric field (0-4kV/mm) is applied between a very sharp tool like a needle (negative electrode) and a fixed electrode on the workpiece surface (positive electrode), and viscosity of the polishing slurry is increased. The abrasive particles gather around the tip of the tool, and are softly held. The necessary instrumentation and control system have been designed and built. The machine has NC controlled 2-axis slide tables driven with ultrasonic linear motors and ultra-precision air spindles. Basic motion errors of the machine were investigated.

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This paper deals with the precision glass molding for micro optical components. A new glass molding process was developed. In the glass lens molding process, the lens surface was deviated because the lens core layer would be cooled and harden finally. In the proposed process, the lens deviation profile was measured and a shape of the molding die was compensated by diamond grinding with regard to its lens deviation profiles.

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Device which has a high precision and a ultra-micro structure is highly important in the product of the digital-network. In the field of optical device, a micro V-groove which the size of width is micron meter size is required. The authors had developed a micro grinding method for the micro V-grooving that the tool is trued to the sharpened cone shape by the micro EDM process on the same machine. We describe the application this method to make V-groove on the three dimensional surface mold which is the electroless nickel plated for an aspherical lens and show some results of examples.

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In an assembly system for part recycling, a robotic arm selectively picks reusable parts and new parts from part feeding devices and moves them to an assembly place. The movement time of the robotic arm between the part feeding devices and the assembly place is a function of the configuration of the system in terms of the layout of the part feeding devices and the assembly sequences. This paper evaluates the throughput of the part feeding devices and the assembly sequences in various situations. From computational and experimental results, it is shown that a certain combination of zigzag line part feeders and assembly sequence results in the shortest route in every matched parts selection. This is applicable to assembly systems for part recycling.

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The study deals with the automatic chamfering with an industrial robot. Although the automation system with an industrial robot has been introduced, the chamfering and the deburring are still out of automation. Chamfering paths need to be generated, considering the depth of cut on the basis of CAD data of workpiece. However, the matching error will occur between the model coordinate system and the robot coodinate system. The aim of the study is to develop an intelligent holder and automatic chamfering to cope with the problem. The intelligent holder could correct position errors by perceiving the contact force and comparing it with the theoretical one. As the original intelligent holder had some problem, an improved intelligent holder is designed. This system is experimentally found to be effective in chamfering.

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We described the mechanisms and characteristic performances of the following compliance robot hands on the assembly works. In order to achieve automatically interpositioning the objects we have applied such kind of remote center compliance hands as the spring mechanisms through the feed back of the sensing load. These test results have been evaluated in practical use.

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This paper describes the efficient measuring method of 3-D edge profile with high accuracy for free form surface including die and mould model shapes. We propose a new method of the 3-D edge profile measurement technique by means of optical ring image sensor. The two-step measurement strategy for measuring the edge profile is proposed. In the first step, the edge area for re-measuring is extracted by rough measurement and the measuring path of the sensor is decided. In the second step, the edge positions are estimated, namely the edge profile is measured by fine measurement along the measuring sensor paths. Measurement results of hole edge on a cylindrical surface show the validity of out method.

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To satisfy industrial requirements for a table system, such as high speed drive and accurate positioning, linear motor driven aerostatic table systems are increasing. In this paper, to realize nanometer order tracking accuracy and high speed feed drive of a table system, an application of a learning control method was investigated. And through a series of driving experiments, it was proved that a leaning control method can restrain tracking error caused by many factors such as force ripple of the linear motor.

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To improve the quality of cylindrical roller bearing, e.g. seizure-proofing, one of the most important factors is edge quality of the end of a roller. It is required that rolling surface and end surface connect with chamfer with a large radius of curvature. To form such a profile, we proposed a machining method by means of water jet technology. First, a profile is formed in rough machining process with one of machining characteristics of water jet, that is, distribution of machining capability within a cross section of a water jet. Next, required surface roughness is realized with using smaller particles with polishing mechanism.

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The purpose of this research is to machine a shape on the object having curved surface. The shape, position and attitude of the object are recognized by measurement on 5-axis controlled machining centre (MC), with that we can machine on the curved surface without detaching the object from machine tools. In this report we would like to show the process to derive the geometry data of curved surface by using a laser displacement instrument which is set on spindle nose of 5-axis controlled MC, and to examine shape machining to curved surface on 5-axis controlled MC.

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Problems relating to air flow generated by rotating chuck of CNC lathe or TC, e.g., cutting chip scattering, cumulating, twisting around workpiece, coolant oil scattering and leaking, have become to elicit in connection with recent higher spindle speed. This paper presents visualization results within a machining space of high-speed CNC lathe and proposes hints of how to design a cover panel structure in order to prevent problems mentioned according to the visualization results. Concretely speaking, visualization results show that there are three characteristics; (1) air flow separation from cover panel, (2) air flow encounter with cover panel and (3) air flow circulation in machining space. It has been found that (1) and cutting chip cumulating, (2) and coolant oil leaking, (3) and cutting chip/coolant oil scattering have a strong relation each other respectively.

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This paper describes a basic study to develop a sensor for detecting the cutting force in milling processes by utilizing the Villari effect of ferromagnetic material. The cutting force is detected using the three force components in the x, y, and z directions and torque. Basic experiments were conducted to quantitatively investigate the characteristics of the Villari effect, namely the change in the magnetic permeability caused by the force applied on the ferromagnetic material that can be detected as inductance change in the coil. The results clarified that magnetic permeability is proportional to the force applied on the material and depends on the direction of the force. A sensor with four coils around the film of the ferromagnetic material was proposed and developed for detecting the cutting force based on x, y, and z component forces and the torque. Static and dynamic experiments confirmed that the developed sensor has the ability to detect x, y, and z components and torque applied on the cutting edge.

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This paper describes a rapid prototyping method using multiple materials. Because of a capability of utilizing wide range of materials, a rapid prototyping system based on fused deposition modeling using extrusion by screws and cylinders was designed and made. The system has multiple sets of screw and cylinder, each of which contains different materials. The system selects the screw-cylinder during fabrication process so that it can fabricate a solid object consisting of multiple materials. When fabricating an object consisting of multiple materials, bonding between two materials at the boundary is not strong enough in some material combination. To strengthen the bonding, path overlapping method for neighboring two materials in the same layer and path interlace method for two layers of different materials were proposed. By fabricating objects consisting of multiple materials such as polypropylene, elastomer and conductive resin, efficacy, possibility and current limitation of this study are examined.

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Planning, design and evaluation processes of manufacturing systems are very complicated, and individual manufacturing engineers carry out manufacturing system design based on their own experiences. It is now eagerly required to establish systematic methods and supporting tools, in order to support all the engineering processes for the planning, design and evaluation of the manufacturing systems. The objective of the research is to establish systematic methods and computerized support systems for the manufacturing system engineering (MSE) processes.

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A project management is indispensable for a design of manufacturing system when many people are cooperated with. Description of design processes is required for cooperative designers to recognize what and how they decide and where they are standing. This paper proposes a method to record and manage the design processes which are generated in the design of manufacturing system. The core concept of the management method is a performance management of the manufacturing system. The system using proposed management method is developed, and a case study reveals the effectiveness of the system.

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We have developed basic software modules as the first step to support the manufacturing design using information technology. One of these modules is "module to store design cases and navigatedesigners". This module has been developed by considering that multiple designers do design activities concurrently under the distributed environment. It has the functionality to store design cases and to generate a simple sequence of design processes. This paper shows the basic idea to develop this modules and explain its capabilities.

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Recently, production volume and period are uncertain because of the diversification of consumer's demand and the shortening of product's lifecycle. For the uncertainty, the ability of the rapid configuration of a production system is extremely needed. This paper deals with decentralized autonomous automated production system, which were designed for adaptive production system (APS) as a rapidly configurable system. The concept of APS is based on human-based assembly line, which has the flexibility for production type, volume and period because of cooperative function of human. To install cooperative function of human into the APS, autonomous mobile robots were developed. But to achieve high productivity in a certain production condition, it is important to fit cooperative algorithm for the condition. The proposed fitting system using simulation technology for cooperative algorithm makes it possible, that the operators in the APS rapidly adjust cooperative algorithm according to the change of production condition.

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This paper describes a manufacturing system simulation using the scaling technology to integrate consistently a design process for manufacturing systems. The design process for the manufacturing system are analyzed. In order to cope with the analyzed results, we propose simulation models using the scaling technology and functions of data management between models of different abstraction degree. For implementing the proposed models and functions, object-oriented technology is examined. Then the scaler and manager object that corresponds to the functions are proposed. The outline of the java based manufacturing system simulator XOS in which the proposed scaling technology is implemented is shown.

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This paper deals with a real-time scheduling system for holonic manufacturing systems. An object-oriented simulation model is adopted to develop a simulation model of a holonic machining system. A mechanism is implemented to the simulation system in order to carry holonic out real-time scheduling for the holonic machining system.

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On designing the manufacturing system, it is important to estimate working time by workers. Manufacturing simulator can estimate working time for automated machine and robots, but cannot estimate one by a human work. Especially, in a small lot production, it is difficult to measure time for working. Out research is to make the worker model for working time estimation in a simulator. The model is an Object Oriented Model based on "Time estimate system by operator function". The model can be animated on a simulator. In this paper, the modeling method is proposed, the worker model is implemented, and the model is applied to the U-shape Line.

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Distributed virtual factory (DVF) based on the concept of distributed simulation has been proposed as a new simulation environment to evaluate the performance of large scale manufacturing systems. To develop a DVF, it is necessary to add three functions on existing area level simulators. These functions, i.e, communication, synchronization and adaptation of data description are developed as a unified communication interface which can be implemented on the simulators with minimum changes and enables to reuse them in an open environment. An area level simulator of a prototype DVF developed on a local area network with engineering work stations, of which OSs are the same but simulation packages are different, is replaced by one on a PC with another simulation package in this study. The effectiveness of developed interface is discussed from the view point of work load for program modification.

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We have proposed the high volume flexible manufacturing system (HV-FMS) that has a parallel-serial arrangement of machining cells to realize a high volume production. We propose a specialization-and-generalization algorithm for the tool assignment problem in cylinder head manufacturing by using an auction method as an autonomous decision making method. From results of simulation, we have an efficient system configuration of HV-FMS by using proposed algorithm.

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In bag-packing problem one must decide which hoppers to open to achieve desired weight with a computerized scale. To find the right combination one should convert the problem into a constraint satisfaction problem. By solving its problem using enumerative method, one can simulate the bag-packing process with a computerized scale. Then, one can conclude that its solution reduces to the one which is far from desired weight in a special case, and also that the special case is determined by average and variance of all hoppers' weight.

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The study deals with an integrated main processor for six-axis control machining. The six-axis control machining, where non-rotational cutting tools are used, has a lot of advantages, compared with the conventional one using rotational cutting tools. The main processors, which have developed till now, can generate cutter location data corresponding to the kind of six-axis control machining. However, it is not convenient to prepare the main processor for each machining method. To solve the problem, the integration of the main processors is intended, where cutter location data corresponding to specific machining method is automatically generated on the basis of judgment of the shape pattern standing for the kind of six-axis control machining. In this report, two kinds of software module were developed to generate six-axis machining cutter location data for corner and character line shape. As a result, it was experimentally confirmed that the developed module allows us to carry out six-axis machining without tool collision occurring.

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In manufacturing, exchange of manufacture information through computer network is an important requirement for speeding up production. Recently, there is an increase in demand of machining free surfaces. In conventional method, manufacturing free surfaces is done by using CAD/CAM data, but it is difficult to manufacture an existing object, which does not have any CAD/CAM data. In this paper, we measured an existing object by 3D measuring instrument and the converted data to CAD/CAM data. We built a computer network system for the measurement and manufacturing process and illustrated the system with the example of the free surface of a computer mouse.

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This paper describes a monitoring system for NC machine tool at remote place through computer network. Most conventional methods use parameters like spindle speed, feed speed, etc. and the operator needs to watch them continuously. In this paper, we propose a semi-automatic trouble detection method without using the above-mentioned parameters. Sound and video of the operation are continuously collected and only the video is sent to the operator. The system detects the trouble automatically by performing frequency analysis of the sound using Fast Fourier Transform (FFT). The essence of semi-automatic trouble detection system here is that even if the system detects and trouble in the NC machine, it does not stop the operation, but sends an emergency signal to the operators. It is the operator who decides on stopping or continuing the operation by observing the video data.

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Manufacturing systems that can be adapted to the fluctuations of the number of orders and the kind of the products for smaller enterprises are required. These systems are based on the premise that manufacturing products in small quantities by manual operations is done in the daytime and large quantities are manufactured at night using automated systems. But, recent sharp fluctuations in the number of orders make the continuation of the present way of manufacturing difficult. On the other hand, open oriented information technologies such as the Internet and open controllers are available for offices and large-scale manufacturing systems today. Therefore, this research discusses a manufacturing support system, which takes into consideration manual-operated processes coexisting with automated processes for smaller enterprises. This becomes possible by using the open oriented information technologies. This paper describes a concept of the planned manufacturing support system and development of a load balancing system with a remote control function as one of the components of the system.

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There is no systematic approach for reviving products that are still functionally sound but cannot follow changing requirement or environment. We are developing a new design method to change functions and/or performance of existing products to adapt to changing requirements or environment. This approach aims to promote reuse of product components rather than material recycles, as it is more desirable from the point of reducing environment burden. Targeted products are large machines including machine tools, plants and production systems

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This paper describes an easy modeling system based on a sketch and a modeling operation system based on Kansei Language. The systems aid the design processes of the body form of a car. A 3-D math-model can be semi-automatically built in a computer from a 2-D sketch drawn by a designer. Furthermore, the form of the 3-D math-model is developed with designer's words : Kansei Language into the forms which are liked more by the designer.

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In a part recycling system, reusable parts in the collected waste products are employed to produce new products with new parts. Two assembly methods are considered in the part recycling system. The primary method is random assembly, in which new parts are selected randomly from the entire population and assembled. The remaining method is selective assembly based on the combinatorial optimization method, in which a combination of reusable parts and new parts is optimized so that high quality assembled units are obtained in a lot unit at the maximum assembly rate while dimensions of each part are referred to appropriately. The assembly methods are applied to the part recycling system where hole parts are combined with shaft parts. In this paper the effectiveness of parts-mix, reusable parts and new parts, is clarified in various situations.

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Sheet metal parts have been widely used in industry and much information for parts has been accumulated in the database. In planning the manufacturing process of a sheet metal part, if the similar process plan of the part to be manufactured can be retrieved, the process plan would be faster and more consistent. In this paper, the effective method of searching the sheet metal parts with the similar process plan is proposed. This method consists of two stages. The first flat pattern drawings of the parts with the same set-up numbers are classified into several topological construction patterns. The second, the parts which possess the same process plan with the part to be manufactured are selected based on the process plan obtained by the process planning expert system, including the geometric element of the flat pattern. The expert system is operated by taking the geometric element of flat patterns into consideration. The effectiveness of the method is described and illustrative examples are shown.

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In recent years, as is the same in other technological fields, many technologies have been developed efficiently by aggressively using computer simulations in the field of plasticity technology. We also widely utilize simulations for advanced evaluations of the deformability and for troubleshooting during prototype production. In this paper, we will introduce an example of sheet metal forming part for an automobile air-conditioner compressor. We have improved the axial-symmetric FEM (finite element method) solver to treat the Lankford value of sheet metals. Specifically, we used the Hill's yield function which is concerned with metallic unisotropy. By applying the FEM solver to the sheet metal forming processes, we designed a series of sheet metal forming processes for the compressor part.

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Conventional data formats for rapid prototyping (RP) such as STL (STereo-Lithography) are not originally designed to represent property distribution. This Paper describes a new software method for rapid prototyping data with 3-D property distribution such as materials and colors by extending the interpretation of existing STL and VRML (Virtual Reality modeling Language) format so that the compatibility between current data formats is maintained. The proposed method uses Multi-STL or VRML as input data format instead of single STL data. We report the algorithm of how to make layer scan data with different mat4erials or colors from input 3-D data and give the experiment results on multi-material and color-distribution rapid prototyping using these scan data.

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