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Heiji YASUI, Takekazu SAWA
Article type: Article
Pages
295-296
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In the previous report, the possibility of ultra-smooth grinding of fine ceramics with # 140 mesh metal bond diamond wheel was ascertained. In this paper, the effect of step feed parallel to grinding direction on surface roughness of ground silicon carbide ceramic (HPSC) is examined. It is found that the parallel step feed has large effect on the surface roughness. In addition, the surface roughness of silicon carbide ceramic formed by using suitable grinding conditions can attain to below within 22nm (Rz).
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Hitoshi OHMORI, Weimin LIN, Kazutoshi KATAHIRA, Yutaka WATANABE, Teruk ...
Article type: Article
Pages
297-298
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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We have developed a "Nano-Precision Machining System" which machines have produced metal die for ultra precision micro lens and liquid crystal optical wave guides etc. The developed machine is mainly composed of the high stiffness machine frame, NC controller, air hydrostatic spindles and supporting devices such as oil tanks and temperature control units. The machine has 6 axes. Three linear axes (X, Y and Z-axes) can be controlled at a feeding resolution of 1 nm under full closed feedback. The maximum workpiece size is 220 mm × 170 mm along the X and Y axes. In this paper, the concept of the "Nano-Precision Machining -System" are proposed and introduced. The system configuration, features, and specifications were described.
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Hitomi YAMAGUCHI, Takeo SHINMURA, Megumi SEKINE
Article type: Article
Pages
299-300
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper studies the application of an internal magnetic abrasive finishing process to internal finishing of SUS304 stainless steel bent tubes with relatively small diameters (10 mm OD, 8 mm ID, 41 mm radius of curvature). The miniaturization of the tube increases the difficulty in generating the magnetic field, which controls the finishing force and motion of the magnetic abrasive needed for finishing. This paper discusses the finishing conditions, which depend on the magnetic field at finishing area, required for the success of the process for small-sized bent tubes; and methods are recommended to satisfy the required conditions. The finishing experiments using the proposed methods show the process feasibility for the internal finishing of small-sized bent tubes and convey and understanding of the mechanism involved.
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Yoichi AKAGAMI, Yusuke Takahashi
Article type: Article
Pages
301-302
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The abrasive particles dispersion typed functional fluids have been found to reciprocate between electrodes under AC field at low frequencies. We have tested the positive use of this phenomenon for finishing process on chips of the micro cutting tools. In this study, in order to be a more long life time performance of the micro cutting tools. We developed the new way of finishing method using the functional fluid under AC. electric field. This finishing method is easy to improve more long life time of micro tool that be treated the new finishing.
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Kazuhito OHASHI, Shinya TSUKAMOTO, Toshikatsu NAKAJIMA
Article type: Article
Pages
303-304
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In this paper, the cavitation aided machining is proposed as a precision manufacturing method, based on the new concept using positively the cavitation that occurs in a suction flow for machining phenomenon. Then an efficiency of applying the cavitation aided machining as a precision surface finishing is proved by carrying out surface finishing on glass surface based on the machining phenomenon. Main conclusions obtained in this paper are as follows; (1) Fine finished glass surface with 60mm in length is generated by applying a fundamental machining phenomenon of cavitation aided machining along flowing direction fo machining fluid continuously. (2) WA abrasive grains generate finer machined surface than GC abrasives that is harder or AZ abrasives that have higher specific gravity.
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Weimin LIN, Hitoshi OHMORI, Kazutoshi KATAHIRA, Yutaka WATANABE
Article type: Article
Pages
305-306
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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For grinding the ultra thin wafer, an ELID-grinder for substrates had developed. In this study, the authors thus attempted the mirror surface grinding of thin silicon wafer by the electrolytic in-process dressing (ELID) grinding method, which has been successfully used to obtain efficient and high quality ground surfaces of brittle materials. In the experiments, #2000 and #4000 cast bonded diamond wheels were used to investigate the ELID grinding characteristics of silicon. The results of the experiments showed that the ground surface roughness improves as the abrasive diameter becomes smaller, and a high quality-grinding surface of 7.0 nm Ra can be achieved with the #4000 wheel, and good surface flatness can be obtain.
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Etsuji OHMURA, Kazufumi NOMURA, Isamu MIYAMOTO
Article type: Article
Pages
307-308
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In this study, conversion efficiency and pulse shape of second harmonic generated by KTiOPO_4(KTP) were investigated theoretically supposing a Gaussian pulse shape for the incident fundamental, and the results were compared with a rectangular pulse. In the present analysis model, laser absorption was considered and a coupling problem composed of propagation of electric field and heat conduction was analyzed. Time variation of conversion efficiency shows the same fluctuation for these two pulse shape. However the fluctuation for Gaussian pulse is slower than that for rectangular shape. Pulse shape of output second harmonic also varies with time. Especially, power density of pulse center fluctuates significantly, yielding pre-pulse. These fluctuations of conversion efficiency and pulse shape are caused more significantly under the pulse irradiation with higher peak power.
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[in Japanese], [in Japanese], [in Japanese], [in Japanese], [in Japane ...
Article type: Article
Pages
309-310
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Laser beam machining has mainly been applied to the rough processing like the cutting of the metal sheet. At present, the application is also examined to minute parts such as electronic equipment and communication equipment, and the development of the minute and high-precise processing technology by the laser processing has been challenged. However, the technology of the laser processing which can process the wide area at high speed has not yet been established. In this study, such high-speed, wide and high-precise laser beam processing system was developed by using the large fθ lens system assembled by the shrink fitter and the galvano motors which can be scanned in the biaxial directions.
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Hiroki OKUNO, Shigeki MATSUO, Saulius JUODKAZIS, Hiroaki MISAWA
Article type: Article
Pages
311-312
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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It has been established that femtosecond pulse laser is a useful tool for direct microfablication of solid materials. We investigate micro-drilling of the small and deep holes into stainless steel plates with femtosecond laser pulses. We have adjusted beam diameter and focus length of lens, which determines the diameter of laser beam at the focus, and obtained holes with 180μm diameter by using an objective lens of 31mm focus length and 4mm beam diameter. But it isn't deep enough to utilize in many industrial applications. For making much deeper holes, we have demonstrated laser-scanning ablation by using galvanometer scanner, and also the ablation in low vacuum atmosphere.
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Ryohei HANAYAMA, Yasuki YANAGI, Shinichi WARISAWA, Mamoru MITSUISHI
Article type: Article
Pages
313-314
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper describes a trial for the micro-structure machining of brittle materials by means of UV laser, whose wave length is 355nm. Grooving by the UV laser was executed for alumina ceramics and LiNbO_3 to search cutting conditions for crack free cutting. As a result, the region of such cutting conditions was presented on a map with energy/pulse and pulse/length in the horizontal and the vertical axis, respectively. Using the cutting condition in the region, a slit for waterjet mask machining was made on alumina ceramics plate successfully. The width of the slit was 50μm. Furthermore, a linear protuberance for optical devices was made on LiNbO_3. However the shape of the structure was not enough smooth for an optical device.
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Hidehiko KARASAKI, Katsuichi UKITA
Article type: Article
Pages
315-316
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Recently, the laser micro-via drilling technology was induced to reduce the size and weight of personal cell phone. In 1996,Matsushita electric was developed ALIVH PWB^(TM) (A__-ny L__-ayer I__-nterstitial V__-ia H__-ole P__-rinted W__-iring B__-oard) using laser via-drilling process. Then the smallest cell phone (NTT Docomo P201), had only 98g weight, was realized. Within few years, laser micro-via formation technology was adapted for new field, for example LCD driver Flex-PWB, SAW filter, CCD, MPU and Sip (System in Package) Packages. In this paper, trend of the laser micro-via drilling technology was represented within few years.
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Junichi IKENO, Keita USHIZAKA, Masaru YUASA, Yusuke NAKAGAWA
Article type: Article
Pages
317-318
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Laser trapping is a very effective method for various minute objects manipulation. If various forms of minute objects can manipulate, assembling of the micro-device is possible. Moreover, if minute reflective objects of metals can manipulate, the production of function material is possible in a limited part. In this paper, the manipulation methods of these minute objects is explained and examined. Three-dimensional manipulation of minute reflective objects is possible in the water. In this method, the laser beam is reformed in a ring-shaped and this ring-shaped laser beam is allowed for irradiation intermittently from the bottom of the minute reflective object. It is observed that the minute reflective object is hold in the fixed position by the laser beam. During this process, convection occurred in the water. The minute reflective object became unstable by the effect of convection. When a surfactant is added, the occurrence of the convection is disappeared and consequently it is possible a stable three dimensional manipulation of minute reflective objects in water. In air, the manipulation of minute objects of various forms is examined. It is observed that a minute rod is changed its posture from the horizontal to vertical position due to the effect of laser irradiation. Moreover, it is also possible to manipulate a minute rod without changing its posture. On the other hand, the manipulation of an object, which is consists of a minute particle and a rod, is also possible. A thin quartz plate in air is successfully manipulated to change its posture from the horizontal to the vertical position.
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Hiromasa KOMATSUBARA, Heisaburo NAKAGAWA, Toshiki HIROGAKI, Yoshitaka ...
Article type: Article
Pages
319-320
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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We have developed a in-situ heat treatment system using YAG laser on the machine tools table. In the Present report, we applied this system to a solution treatment of the work hardened area of the stainless steel. We carried out the experiments of laser irradiating the work hardened stainless steels under various conditions. As a result, it is confirmed that the solution treatment can be done by proper laser irradiation conditions on the machine tools table.
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Hironori MATSUOKA, Hajime ONO, Yoshihiro TSUDA
Article type: Article
Pages
321-322
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In this paper, the performance of various emulsions in water-soluble cutting fluids for hobbing was investigated with TiN and (Al, Ti)N coated tools, in term of tool life (flank wear). Experiments were carried out using a fly tool. With the TiN coated tool, though an emulsion containing sulfuric EP additive or synthetic lubricating additive is effective for improving the tool life between the cutting speeds of 86m/min and 117m/min, the tool lives become short and there is no difference in them at high cutting speed of 159m/min. With the (Al, Ti)N coated tool, the emulsion containing synthetic lubricating additive is available for the tool life at the cutting speed of 86m/min, and an emulsion containing synthetic lubricating additive and mineral oil is effective at 117m/min and 159m/min.
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Hua QIU, Akio KUBO, Chang Jun LIN
Article type: Article
Pages
323-324
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In NC machining of non-circular contours, where cutter is fed along a straight line intersecting perpendicularly the rotation axis of work piece, the cutter path usually consists of Archimedes's spiral segments, i.e. the polar straight line segments. From machining precision and efficiency point of view, an optimal interpolation principle and a practical algorithm for planar curves are presented. The segment number of the cutter path resulted from the algorithm is not only the fewest but also the interpolation accuracy agrees with the specified value. The validity of the algorithm is well demonstrated through interpolation results to machining of two disc cam profiles.
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Hua QIU, Akio KUBO, Hironobu NISITANI
Article type: Article
Pages
325-326
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In this paper, an autonomous measuring principle, in which two sensors with different purpose are combined with a servo motor, is proposed. A prototype device able to apply to machining center has been conducted. Attaching the device with the spindle and feeding the work piece set on the table of a machining center, the device can automatically follow the contour and measure its form along the scanning lines. Several measurement results sufficiently demonstrated the effectiveness of the proposed principle and developed device.
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Katsuyuki YOSHIKAWA, Naoki YOSHIZUMI
Article type: Article
Pages
327-328
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The solid-phase lap joining of layered thin metal materials is done by using the friction stir action. The proposed method can join the interface between the layered dissimilar metal materials with the minute joining width 1 mm or less. As the dissimilar materials, aluminum material and stainless steel are used. The rotating tool for friction-stir action is pressed down onto the upper thin aluminum plate, which is layered on the thin stainless steel. The generated friction heat and plasticity flow makes it possible to join the interface of layered dissimilar metals with the minute joining width. The temperature rises are measured at the bottom surface of the layered stainless steel under the conditions of the different keeping times and various indentation depths of the tool. It is shown that joining and non-joining conditions are deeply affected by the temperature distribution and the proposed solid-phase joining method enables the high coefficient joining.
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Katsuyuki YOSHIKAWA
Article type: Article
Pages
329-330
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The new compound processing is proposed, which can join the interface between the layered metal materials giving the plastic deformation to the joined region. Plastic deformation and the solid-phase joining are simultaneously done by the frictional stir action, which generates the pressure, frictional heat and plastic flow. As the similar materials, aluminum thin metal material is used and ass the dissimilar materials, aluminum material and stainless steel are used the rotating tool for friction-stir action is pressed down onto the upper thin plate, which is layered on the lower thin plate. The generated friction heat and plasticity flow make it possible to join each other the interface of the upper material and the lower material, which are deformed around the joined region. The temperature rises are measured at the bottom surface of the layered lower material under the conditions of the different keeping times and various indentation depths of the tool. It is shown that joining and non-joining conditions with the plastic deformation are deeply affected by the temperature distribution. The proposed processing can join the interface in the solid-state with the performance giving plastic deformation.
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Makoto YODA, Masayuki NAKAO
Article type: Article
Pages
331-332
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The paper introduces precise injection molding for miniature products by locally controlling heat flux in the cavity of two small injection molds in each injection cycle. The first 98 × 98 × 117 mm size mold has small sensors and actuators for controlling temperature / heat flux / pressure / deformation around the cavity of a box shaped product in 30 × 15 × 6 mm size with 1 mm thick walls, and the second Φ30 × 38.5 mm size mold made of copper-alloy, having small thermal capacity and large thermal conductivity, has very small thermal inertia. For example, we could improve the straightness of the box shaped miniature product from 20μm to 3μm.
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Hideki Aoyama, [in Japanese]
Article type: Article
Pages
333-334
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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CAM systems which can determine cutter locations and generate NC programs for machining are indispensable for operating machine tools. As the feed rate of cutting tools, the spindle speed, and the depth of cut, etc. are usually determined by CAM operators, or determined using available databases, it is often not the optimum value, and therefore may be corrected by machining experts according to their experience and intuition. In addition, since the clamping force of workpieces is also determined according to the experience and intuition of operators, workpieces may not always be secured by the optimum clamping force. The objectives of this study were thus to propose a method to determine the optimum feed rate of cutting tools and optimum clamping force of workpieces by the estimation of cutting force and to verify the usefulness of this method through cutting tests.
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Akitoshi MORISHIMA, Hiroyuki SUGANUMA, Masataka TODA
Article type: Article
Pages
335-336
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The appearance inspection of the product often relies on the sensory inspection, such as visual and/or touch checks. Therefore, the accuracy of inspection may greatly vary depending on feeling and distinguishable capability of the inspection personnel. In addition, the sensory inspection requires the high skill of the inspection personnel. The demand for the number of skilled personnel may also become a problem, as the overseas production sites are increased. A quantitative technology for detection of micro-distortion has been newly developed for door frames. Since the micro-distortion detection by development of the stripe density visual image method and the accept/reject judgement by person have been checked quantitatively. This paper describes the newly developed technology.
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Tamotsu MURAKAMI, Ryo NOZAKI, Seiji HAYANO, Katsunori TAKAGISHI
Article type: Article
Pages
337-338
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Making a rough form of a mold by metal power sintering and finishing it by high-speed milling is a new approach to manufacture a metal mold in short time. For such a new combination of material and process, we need to obtain knowledge and know-how through a lot of experiments and actual examples of milling molds. This study proposes a computerized method of preparing a database of milling examples and retrieving them based on similarity between a mold shape to be manufactured and the past example shapes from not the shape but the milling viewpoint. The method enables us to obtain appropriate manufacturing conditions from past relevant cases. The method is implemented as a computer program and applied to a simple mold shape example.
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Toshiaki KIMURA, Yasuyuki NISHIOKA, Yuichi KANDA
Article type: Article
Pages
339-340
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper describes an overview of a manufacturing support system for smaller enterprises and also describes a remote monitoring and management system as one component of the support system. A development and test operation of a load balancing system with remote control functions that is a sub-system of the remote monitoring and management system is also discussed in this paper. The load balancing system has MES, which integrated with a commercial manufacturing scheduling system by using PSLX. The system creates the workload balancing uniformity with the remote control by operating the production schedule file of the manufacturing system. This method allows the load balancing system to take the operator's decisions into consideration. The developed load balancing system performed quite well in the test operation and offers a practical solution for better management of manufacturing systems in smaller enterprises.
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Hendry MULJADI, Koichi ANDO, Makoto OGAWA
Article type: Article
Pages
341-342
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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In the production stage, dynamic changes such as increased production, machine breakdowns etc are ordinary occurrences. To deal with these dynamic changes, we presupposed the need to integrate design, manufacturing and scheduling activities. In order to develop a process planning system that can manage the dynamic changes in production stage and also integrate the design, manufacturing and scheduling activities, we proposed a manufacturing feature recognition method for the generation of multiple process plans to provide alternative plans for the process planning system. The manufacturing feature recognition method is constructed in 2 phases. First, using Extended Super Relation Graph Method, interacting and overlapping features can be extracted in several different ways, corresponding with different kind of machining operations. In the second phase, manufacturing features are organized into multiple manufacturing feature sets, where each manufacturing feature set corresponds with different kind of process plans. In this paper, the development of the Extended SRG Method to recognize not only primitive manufacturing features such as holes, slots and pockets, but also compound manufacturing features such as stepped-hole is discussed, and a case study to confirm the validity of the proposed development is presented.
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Shuu KUZE, Koichi ANDO, Hendry MULJADI, Makoto OGAWA
Article type: Article
Pages
343-344
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper describes the development of manufacturing feature recognition method for metal shearing operations of sheet metal part with various forms of components. The methodology initially processes geometric data for identifying different entity groups. The entity groups are classified into a raw material feature set, a boundary feature set and an inside feature set. Inside feature set belonging to boundary feature set are identified uniquely. Components (i.e. elements of the boundary feature set along with its elements of the inside feature set) are arranged lexicographically. Manufacturing features are identified based on the proposed classification system for shearing operations and using different feature sets. The above methodology, along with its principles, is illustrated with example.
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Masanori Nagato, Sang J. Song
Article type: Article
Pages
345-346
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper deals with the real-time information on the conditions of the shop floor to increase the ability of reaction to shop floor contingencies. The intelligent shop floor will be analyzed to support continuous improvements for sustaining the optimal cellular manufacturing in dynamic changing environment. This paper focuses on real-time shop floor is the activity of monitoring the progress of production and the actual shop floor situation in terms of current status and assignments of jobs, machines, tools, materials, operators as well as coordination of specific plans when deviations occur. To be useful in supporting of contingency-driven reactive shop floor control, a prototype system will be developed by using objective-oriented programmable language C++ through the user interface.
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Susumu FUJII, Toshiya KAIHARA, Takuma UTUNOMIYA, Toshiya SEKI
Article type: Article
Pages
347-348
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Previous work showed an autonomous specialization algorithm of MCs by deleting tool sets with low utilization. In this paper, we propose a multistep auction-based algorithm to form a line in the system specialized to a product type and an operation process. The algorithm firstly aims at the specialization to product type and then to the operation by changing the bid type for auction. The effectiveness of the algorithm is demonstrated by simulation.
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Yoshitaka TANIMIZU, Takayuki YONEDA, Syouhei KODAMA, Nobuhiro SUGIMURA
Article type: Article
Pages
349-350
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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Design processes of production lines are very complicated, and individual manufacturing engineers carry out production line design based on their own experiences. It is now eagerly required to establish systematic methods and supporting tools, in order to support all the design processes of the production lines. The objective of the research is to establish systematic methods and computerized support systems for the design processes of production lines by using numerical analysis.
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Eiji Katoh, Sang J. Song
Article type: Article
Pages
351-352
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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This paper focuses on the integrated supply-chain associated with managing the logistics and production activities in global manufacturing whose activities stretch across national boundaries. An optimal analysis of globally integrated supply-chain was developed by applying simulation optimization technique as a decision support tool. The globally integrated logistics supply-chain was formulated as an analytical problem, which contains two types of production decision problems : 1) determining production and logistic plans for each component and end-product, and 2) appropriate production conditions for the globally integrated supply-chain which will maximize the system's performances.
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Keiichi WATANUKI
Article type: Article
Pages
353-354
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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The environment where Japanese industry has been paid with respect is changing tremendously due to the globalization of economics, where Asia countries are undergoing economical and technical development as well as advancing in information technology. With acceleration of manufacturing bases relocating abroad, industrial hollowing out is happening; hence effort to transfer the technology and the design knowledge of machine design in a company is becoming an important subject. For example, in the design of custom casting product, a designer who is lack of casting knowledge may not be able to produce a good design. In order to obtain a good design and manufacturing, it is necessary to equip the designer and manufacturer with a support system related to casting process or so called, knowledge transfer and creation system. This paper proposes a new knowledge transfer and creation system for manufacturing technology; where machine design, which requires added values such as advanced technology, high quality, short delivery time, is taken as an example and both its explicit and tacit knowledge are cooperated by using synchronized multimedia and immersive virtual environment.
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Article type: Appendix
Pages
App2-
Published: August 05, 2003
Released on J-STAGE: August 01, 2017
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