The realization of a stable operation of the accelerator structure at the acceleration field of 75MV/m is one of the most critical issues of the linac design for linear collider. Therefore, the analysis of surface conditions of oxygen-free copper enable to stand such electric high field is required. In this paper, the effect of the surface roughness of copper electrodes and cutting fluid on the electrical breakdown characteristics has been discussed. The experiments showed that the breakdown field decreases with increasing the surface roughness of the electrode and due to the cutting fluid remaining the electrode surface.

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SiC thin films are suitable for MEMS structure in severe condition. However, the interfacial strain of SiC/Si layer, due to the difference of lattice constant, causes unnecessary deformation in the subsequent process. This study aims to propose multilayer structure of SiC/Si or Si/SiC/Si using molecular beam epitaxy on Si substrate. We found the conditions that can generate monocrystal Si/SiC multilayer structure. Hardness and Young′s modulus of the layer indicate intermediate value between those of Si and SiC monolayer. Adhesion with Si substrate was as good as the Si homoepitaxial film though lattice mismatch was introduced. It was found that this type of structure can be applicable for MEMS and other fields.

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Thin films containing boron have been prepared on silicon substrates by DC magnetron sputtering using a sintered B₄C target. The influences of CH₄ addition as a plasma gas on the chemical bonding states, the critical loads in scratch tests and the friction coefficient of the films are investigated. Fourier-transform infrared spectroscopy measurements show that CH₄ addition in the film formation process enhanced the formation of the B-C bond. Furthermore, frictional properties of the film against a steel ball are improved by CH₄ addition in this study. Contrary to the frictional properties, the critical loads did not appreciably vary with the CH₄ introduction.

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This research analyzes quantitatively the surface having stratified functional properties to increase the lubrication property and the wear characteristic of a sliding surface under severe conditions. Although ISO proposes assessment and analysis methods for the roughness profile of the surface having stratified functional properties, actual results are hardly reported. Therefore, this research actually measures the surface having stratified functional properties, assesses and analyses quantitatively it by a material ratio curve and a material ratio curve on a probability paper.

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Measured 3-D surface topography data often contain outliers. The outliers not only prevent proper visual recognition of the 3-D topography features by human eyes, but also prevent accurate geo-statistical parameter evaluation. In this paper a statistical method to detect such outliers that utilizes windows of detection with different size was proposed. In addition, a method to estimate an adequate value for detected outlier was presented.

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In this study, we developed a diamond micro milling tool for micro-to-nano scale machining. This tool is manufactured by attaching a diamond cutting edge to tip of rotational axis. The diamond cutting edge with various shapes named “diamond array tool” are fabricated by depositing polycrystalline diamond using CVD on silicon molds which are made by anisotropic wet etching of the single crystal silicon. By using this micro milling tool to machining for single crystal silicon, the chip of silicon was observed largely by SEM image. It was found that the micro milling tool was possible to machining with high efficiency and accuracy.

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In this study, we developed a diamond AFM cantilever for micro-to-nano scale machining. The diamond AFM cantilever is composed of single crystal silicon cantilever and a cutting edge with controlled tip shape. The former is fabricated by anisotropic etching of the single crystal silicon, the latter is taken out from diamond array tool. The diamond array tools are fabricated by depositing polycrystalline diamond using CVD on silicon molds which are made by anisotropic wet etching of the single crystal silicon. As a result, the diamond cantilever with pyramidal shape of probe fabricated from (100) single crystal silicon was fabricated.

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Nanomachining of silicon using the specially designed cantilever, which has a single diamond array tool as a cutting edge, is demonstrated in this study. To verify the machining characteristics of the cantilever, machining experiments is conducted under the various parameters. As a consequence, silicon surface can be removed several tens nanometers deep with ductile mode, and the cantilever shows a prior wear resistance. Demonstration of these nanomachining experiments indicates high performance of developed cantilever for nanomachining.

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The laminated structure of K4Nb6O17 consists of 2nm thickness layers. Our research have allowed the mechanical removal processing of the unit layer with an accuracy of 2nm in depth by using Atomic Force Microscope(AFM), and the result of the research seemed to expand the range of the possibility that K4Nb6O17 is applied to micro electro mechanical systems. The result, however, couldn′t make the mechanism of the mechanical micro removal processing clear. In this paper, we measured and estimated the mechanical property of K4Nb6O17 to reveal the micro removal processing. Both the hardness and Young′s modulus of the material are found out after a micro hardness test carried out. Our estimation indicated that K4Nb6O17 is a ductile material based on the obtained hardness and Young′s modulus values and B.R.Lawn′s report. Also the estimation showed the anisotropy of K4Nb6O17 is determined by calculating the binding forces between the composed atoms. From those results, we got useful data in discussing the mechanism of the mechanical micro removal processing.

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When cutting in microscopic area, it is important for both a tool life and good processing to estimate the load concerning a tool. Therefore, we did cutting with a frictional force microscope and the cutting force was calculated from the twist of the cantilever in processing in this research. We considered about the experiment on two cases. As for one, research for effect by a change in load, as for another, research for effect by a change in some samples. As the result, we found relation between cutting force and cutting result brought by load and samples.

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In order to obtain the basic data to analyze the material removal mechanism in the nano-grinding, the fundamental experiments to generate the nanoscale grinding grooves have been conducted using an atomic force microscope combined with a two-axis capacitive force/displacement transducer. The influences of the normal load, the loading rate and the machining speed on the formation mechanism of nanoscale grooves have been clarified.

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Cementite receives much attention, because of its high hardness, good recycling efficiency and ferromagneticity. However, we have little knowledge in mechanical properties of cementite. Therefore, it is important to clarify these of cementite for materials design and processing. This study aims to analyze the deformation behavior and mechanical properties of cementite. Micro scratching test is one of the methods to analyze these phenomena. This paper reports on the results of micro scratching test on the hypereutectoid steel cementite.

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The deformation behavior was examined by a scratching on fluorocarbon resin such as a poly-tetra-fluoro-ethylene (PTFE). A diamond indenter was used as a scratching tool. The shape of its tip is triangular pyramid with apical face angle of 105 degrees. Scratching test was performed in the following two ways; (1) one edge facing toward the scratching direction (edge scratch) and (2) one face toward the scratching direction (face scratch). The angle of inclination of the indenter was also changed. Consequently, it is found that face scratch makes deeper grooves than edge scratch and the shape of cross section of a scratching trace depends on the inclination of a scratching tool.

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In order to observe micro cutting phenomena, the groove cuttings are carried out on phosphor bronze, bakelite and glass surface with cutting depth from sub-micrometer to 5 micrometer by combining the micro X-Y table of 60 micrometer stroke and the vertical fine feed unit attached the trigonal pyramid diamond indenter as cutting edge. The three-dimensional shape of cut groove is measured by the scanning of a diamond stylus over the groove area. The pile up due to plastic deformation is observed on both groove sides and it is varied by the work material and the geometrical state of cutting edge.

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As for the picking up lens for the optical disk, making to high accuracy according to making to a large capacity is requested. And making to high performance and the optical system compact is requested because of reduction in costs. Therefore, severe shape accuracy and complex shape in addition to roughing the surface are needed for the metal mold for mass production. Because we made two or more lens metal molds as a basic research by various shape, the condition, and the processing method with a superprecision processing machine, it reports on this part.

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A new grinding wheel included nano diamonds was developed for high efficiency mirror grinding of hard materials. Silicon was ground with the grinding wheel on M/C. It was found out that the grinding wheel had good ability to remove a silicon. We also developed a new type grinding wheel, inclued nano diamonds and silica particles, to obtain a smooth surface of silicon wafer. As the result, a surface roughness of 3” silicon wafer was 9.49nmPV. Grinding ratio was 1.2.

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This paper describes a feasibility study of the fabrication of micro-scale machine parts measuring less than 100μm in diameter and having an extremely large aspect ratio by an ultrasonic-shoe centerless grinding technique. First, an experimental apparatus capable of micro-scale fabrication was designed and constructed based on the ultrasonic-shoe centerless grinding method proposed by the present authors in previous works. Then, grinding test was carried out on the built apparatus involving a carbide steel workpiece having dimensions of 0.6mm in diameter and 15mm in length. As a result, a micro-scale cylindrical component of around 60μm in diameter and 15mm in length, the aspect ratio of which was over 250, was obtained, validating the new micro-scale fabrication technique.

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In micro-EDM, introduction of vibration assisted machining can dramatically reduce the machining time. This can be thought as the results of improvement of machining stability due to the reduction of electrical short. In this reports, at first the relations between vibrational frequency and amplitude and the short are described. Then, the effect of vibration on the wear of tool electrode is also shown.

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In general, the clearance of the die and punch has a profound effect on the properties of shearing work. So the optimum clearance for general shearing work has been proposed. However, the optimum clearance for metal thin sheets has not been made clear. So in this study, we have carried out experiments on stamp out machining, which is a kind of shearing work, for metal thin sheets with various clearance and measured the profiles of cross sections of the holes. Thus, we have made clear the relationship between the clearance and shearing work properties.

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In order to analyze the processing phenomenon in incremental bulge forming of a sheet metal, pyramidal shells are fabricated under various tool diameters using the desktop-controlled CNC milling machine. As a result, it could be known that tool diameters have an influence on surface quality after processing. The experimental results show that the surface roughness related to the overlap ratio of each tool passes. The surface roughness of processed area depends significantly on the tool diameter. Finally, we can fabricate an array of pyramidal shells with a small diameter tool.

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In the production of electronic parts, the miniaturization of the cutting machine is requested. As the reason, the energy saving and lowering the cost is expected. Then, we are developing a smaller micro-sized machine using micromachining and silicon fabrication. This machine is composed an electrostatic microactuator and remarkable tool “micropyramid” in the micro size. The tool is created using anisotropic etching, and has the performance that can cut the glass. We carried out the test that cut Si with which Al was deposited on the surface, and confirmed its motion property.

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The development of a micro-machining center is strongly demanded in the field of small sized machine tools. In order to make a micro-MC practicable, automatic tool changer appears to be an essential device. Therefore, the development of an automatic tool holding device for micro-ATC is required. From this point of view, we have made three kinds of automatic tool holding devices on an experimental basis. These devices enable to hold a tool with one-action and without a slip by cutting forces. Actual cutting tests were conducted and basic characteristics.

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In micro-turning of thin shafts, the height of a cutting tool must be measured and adjusted against the work-piece center. The height difference may affect error in diameter and surface roughness. But, it is difficult to adjust the tool tip with visual inspection. In conventional turning, vernier calipers or micrometers are commonly used for diameter measurements, but it is extremely difficult to measure workpieces with diameters, for example, in the range of 0.1 mm with these instruments. In this research we have tried to apply image processing techniques for these measurements need.

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Micro Turning System 4 (MTS4) is a super small precision lathe for exclusively machining micro-parts. In order to make a source code of CNC (computer numerical control) software for the MTS open, the software was developed based on a personal computer (PC) and the Microsoft Visual C++ was chosen as the development environment. For easy addressing micro order dimensions of the parts, the software was designed to mainly use a mouse. Especially, a simple computer-aided design (CAD) and computer-aided manufacturing (CAM) system that can automatically generate a tool path for a machining form, drown by mouse-click over the displayed figure of the work on the PC monitor was implemented. The CAD/CAM system can also generate commonly used G-code program from the drown form.

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This report deals with the examination of size effect of accuracies of the assembly, the motion, the deformation by cutting and the thermal displacement for the machine tools design. The calculation method for the machine accuracy is proposed and applied to the lathe models. The enlarged and the reduced models based on the machine size of micro lathe which developed by the authors were used for the calculation. The size effect is assumed by other reports and simple FEM calculations. From the result, the relation between model size and the evaluation function is obtained and the optinum machine size suitable for the work size is determined.

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The micro lathe having a machine base size of 150×100 mm (postcard size) was developed by the authors. The use of downsized machines for small parts is effective to decrease energy consumption and a space occupation. A traction drive reducer is applied to the work spindle, because the micro motor suitable for the machine size has small toque to cut a work. Some cutting tests of brass and vibration measurements were carried out using the traction drive and gear types work spindles, respectively. The circularity and the vibration level in case oh the traction drive are smaller than that of the gear.

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A machining model is proposed to predict 3 dimensional structure in the FIB process. The removal model is made by the intensity of the beam. The machined structures can be predicted with the beam path and the removal model. Some examples are shown to verify the model.

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We study on the fine laser ablation technology that surpasses the theoretical spatial resolution. We focused attention on the ionized-processing using high photon energy. This ionized laser ablation technology dissociates a nucleus directly from interatomic bond. So we used the ArF excimer laser (Wavelength: 193nm) This laser has enough photon energy to cleave an interatomic bond. We sort out a sufficient energy density of laser selectively to do ionized-processing because there is a characteristic of Gaussian distribution in the pencil of laser. In this way, we′ve verified the melting-less laser ablation. We can conduct the process surpassing theoretical spatial resolution by using near-field light with optic fiber.

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A new laser breaking method to obtain high quality and to realize 3D-laser breaking was proposed in this report. A feature of the method is used two laser beams to irradiate on side of glass. It was tried to clear effect on the method by FEM and some experiments. As the result, It was found out that a feature of laser breaking by two beams was better than one of method by one beam.

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In this work, we have fabricated 3D PDMS structure using electron beam resist. We obtained the following conclusions: 3D PDMS structure with 5-depth tones was fabricated using electron beam exposure by changing accelerating voltages. PDMS structure was fabricated using electron beam exposure without development.

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The keynote paper presents a linguistic approach on following three words; manufacture, cutting and machine. The word “manufacture” is known as “monozukuri” in Japan and the meaning of this word is discussed. The Japanese translation of the word “cutting” is “sessaku” and the origin of this Japanese word is surveyed through an examination of old journals. Finally, the definition of the “machine” is surveyed historically.

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Becoming the 21st century, we hold various new unrests and expectations. There are many difficult problems also in the science and the technical fields which have accomplished remarkable progress. In this report, the problem of ethics for engineers will be discussed based on some news. Moreover the four layer structure with laws, ethics, and specialized or common knowledge.

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The most important art is abridged experiment by canonical decomposition of response, applied even to the logarithmic scattering of response. The success or failure should be checked, case to case, in each profession of the theme. Mahalanobis-Taguchi (MTS) and Taguchi-Schmidt (TS) procedures are used for a randomly assembled multitude of treatments-responses. Very broad interpretations rumored of the arts should be checked, too, case to case, in each field of the theme in accuracy and precision of the prediction as compared with the realized facts. Standardization, international or domestic, is proposed often for the promotion of the art but that is quite useless and harmful for serious application of the art.

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In human-centered design with its diverse values, conventional engineering methods by themselves are no longer sufficient in this age of sensibility. At the same time, Leonardo′s Codices reveal a sufficient design methodology even for today that promotes aesthetic creative activity. This is seen in his multi-objective design method that made an experiment on his Codices with ISM (Interpretive Structural Modeling). This “new Creative design methodology that introduces Leonardo′s Codices” is an aesthetic design method for developmental designing of yet unknown aesthetic products for the future.

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A curriculum of Fundamental Engineering Drawing, which serves to support engineering design education, is beginning a series of lecture on spring term of the freshman. In this course, students experiences the “learning of basic skill for drawing” , “drawing of idea for personal article” and “communication through drawing”. As a result they are able to acquire “drawing skill for engineering design” using their own abilities. In this paper describes the relationship between the mechanical drawing and engineering drawing.

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Kochi University of Technology started Study Skills′ education for freshmen in 2003. This year it was improved by mutual discussion of instructors. This report showed the experiences and evolution of effects. The themes are productive work, field research work, experimental and handy craft work etc. The results of students′ ability are evaluated quantitatively and connected to the students′ carte. We started Study Skills 2 to the disqualifications of Study Skills 1. This was planned for the students life style support and completion of works.

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I describe to effect and estimate of “Advanced Workshop” subject to grind with “MONODUKURI” to participate in a meeting. I will teach this subject to students while letting I let them understand for “MONODUKURI” and, actually, do design and implementation. It is the results about design and implementation of students lasting for three years of a “Fuel-Cell-Car team” and estimate in this time.

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Recently, there has been much interest in using the MindStorms kit for robotics and mechatronics education. The DC motor is controlled by the programmable control unit, called an RCX. The RCX supports four kinds of sensors. In addition, it is easy to build and rebuild the mechanical systems by using blocks. This paper focuses on the evaluation of the MindStorms kit. As an illustration, the master-slave manipulator is considered and developed. The slave arm can hold and move an object based on the operating command from the master arm. Experimental results show that the MindStorms kit can be helpful in teaching robotics and mechatronics.

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This paper aims to provide modeling method of prediction for product function and develop its support system. The method in this paper is composed of three steps. The first step is to apply each part′s geometry to type of TTRS. The above method enables each part′s geometry to find its Degree of freedom. Second is to apply combinations between two parts to TTRS. The second step also enables combinations between two parts to find their degree of freedom. Based on the results of the second steps, the third step enables product to identify motion behavior. Finally, the required function and unrequired function for product will be predicted.

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To pursue the profit of the business, the maximization of the profit to the development cost is demanded. The designer must be demanded an improvement of the function and performance which are superior to ones of other companies. This research, a certain product is compared with the other product in the various points of view. And the efficiency value of the product is calculated by using Data Envelopment Analysis. The purpose is to support deriving the target of the product development with good performance. In conclusion, this research succeeded in deriving the target of the product development with good efficiency value. The designer can understand a part of policy of a new product development from efficient product data.

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In a design, when defining parameters, generally the value that a designer can satisfy is found out using the calculating methods, such as the optimum designing method and the satisfactory designing method. However, since the influence to the performance and conditions which each parameter does etc. is grasped, the value of a variable is changed and work of repeating inquiring and performing it may be performed. This is called “Parameter Study”. In this paper, in order to enable it to perform a Parameter Study Tool visually, I made the parameter study tool using 3D-Graphics build, and decided that it applies to some exercises and inquires.

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Swarm algorithms such as Particle Swarm Optimization (PSO) are non-gradient probabilistic optimization algorithms that have been successfully applied to obtain global optimal solutions for complex problems such as multi-peak problems. However these algorithms have not been applied to complicated structural and mechanical optimization problems since local optimization capability is still inferior to general numerical optimization methods. This paper discusses new swarm metaphors that incorporate design sensitivities concerning objective and constraint functions and are applicable to structural and mechanical design optimization problems. Single- and multiobjective optimization techniques using swarm algorithms are combined with a sequential linear programming (SLP) method. In the proposed techniques, swarm optimization algorithms and SLP are conducted simultaneously. Finally, truss structure design optimization problems are solved by the proposed hybrid method to verify the optimization efficiency.

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We have proposed the persona based scenario model as a receiver′s behavior model in the service modeling and discussed the specifications of scenario builder to be implemented in the service modeling tools. In this paper, we describe a process of scenario modeling from the setting of a persona to the extraction of RSP (Receiver State Parameter) with an example by using the scenario builder implemented based on the specifications, and verify the effectiveness of the scenario model.

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The authors have been developing a computer aided design system for service design, called Service CAD. In addition, the service design process has been formalized in order to expand the contents of service design aid with the Service CAD in the previous report. In this report, the authors restructure the design process model of a service for the sake of the implementation, and clarify the required specification of the design guidance function of the Service CAD based on this model. By developing a prototype of this guidance system, its effectiveness is verified.

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We add a dynamic simulation feature in applying Colored Petri Nets technique to the proposed Service Modeling technique, and it proposes the evaluation of Service of Receiver based on the relations between parameters on the Service Model. Moreover, it expresses the evaluation of agent which Service composes with the method. It builds the way to evaluate and to verify the result and tested effectiveness of the proposal technique.

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There are very few methodologies applicable to environmentally conscious service design. This research aims at proposing a design methodology of environmentally conscious service and service CAD tool for that using the idea of service engineering we have proposed. This paper proposes a Model for Balancing Values and Costs called MVC and framework to solve conflicts in design. Values and Costs in MVC are agents′ state changes in a service preferred and not preferred, respectively. Some examples for service modification using MVC are demonstrated.

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We propose surface modeling with homogenized polyhedral subdivision techniques. The homogenized subdivision technique uses, in the homogeneous vector space, the algorithm that Catmull and Clark proposed in 1978. In our method we can control the degree of roundness of limit surfaces by changing associated weight values. But it is difficult for designers to know the shape of limit surfaces with homogenized Catmull-Clark subdivision. And it is cumbersome procedure to change weight values. So we propose the algorithm that enables us to generate homogenized Catmull-Clark subdivision surfaces with uniform rational cubic B-spline curves.

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In our research, we have been developed a triangular mesh generation method based on multiresolution technique of high-density meshes for robust and quality controllable finite element mesh generation. In this paper, we propose a data structure based on Partial Entity Structure for representing the non-manifold models, and a mesh simplification method of the non-manifold model, which well preserves boundary and non-manifold edge shapes. These extensions allow us to apply our multiresolution method for finite element analysis to several kinds of models such as assembly models and medial surface models.

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In reverse engineering, one generates a mathematical model in the computer from measured data of a physical model by 3D scanner, but the measured data are composed of a great number of points including errors. Hence, they have to be smoothed and preserved their feature shapes such as edges between faces. We propose a smoothing method which obtains a smoothed surface preserving feature shapes by dividing the given surface into a number of segments and taking special treatments for vertices on the boundary.

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Mesh curvature is required in many applications, such as mesh simplification and mesh segmentation. Therefore much research on mesh curvature estimation methods are reported. In this paper, we compared and evaluated previous mesh curvature estimation methods and found the method which is the most useful edge extraction method we have proposed for reverse engineering. This method is the modified version of Razdan′s method. This enabled more accurate feature edge extraction.

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