Surface plasmon resonance (SPR) is the coupling between charge-density wave of free electrons and electromagnetic wave, such as visible light, at a metal surface. The property of SPR is characterized by the peculiar dispersion relation and the enhancement of electromagnetic near field. Purpose of this work is achievement of high diffraction efficiency and functional reconstruction of evanescent holography. We theoretically and experimentally investigate the characteristic of color selective reconstruction from white light excitation in plasmon holography.

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[in Japanese]

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A high-resolution new fringe analysis method for ESPI with only one camera is proposed by using the features of speckle interferometry. In this process, Hilbert transformation is employed. Hilbert transformation that is used widely in communication systems as the filter technology is the complex signal processing. The phase distribution of the deformation process of each pixel of the measured object can be detected by using the transformation. Furthermore, a virtual speckle pattern is produced based on these process and information in order to perform spatial fringe analysis method. The high-resolution new fringe analysis is realized by using the virtual speckle pattern. The validity of the principle of the method and the usefulness of the method are shown in experiments.

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[in Japanese]

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A lateral-shearing interferogram shows a contour map of a difference between a wave front under test and a sheared wave front, that is, a contour map of a derivative of the wave front under test. Therefore one can reconstruct the shape of the wave front under test by analyzing that difference. The Saunders method reconstructs a wavefront. However the wavefront data are reconstructed only at intervals of an amount of shear along a direction of the shear. Therefore the method has low spatial resolution. A method for reconstructing a wave front that is based on the Saunders method and has high spatial resolution is proposed. The proposed method analyzes the differences that are produced by shearing of the wave front under test in several amounts. In this paper, the method is described, and its validity is confirmed by simulation.

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Phase-Shifting Point Diffraction Interferometer (PS/PDI) with two optical fibers have been developed, which will be appropriate for the surface figure measurement of large aperture optics at sub-nanometer scale. To reduce the measurement error factors, fiber optic window (FOW) is used as a projection plane. A measurement accuracy of the PS/PDI is estimated with the interference pattern produced by the two optical fiber sources. The reduction of accuracy is mainly caused by an inhomogeneity of the FOW and an imperfection of optical alignment. If the errors are eliminated, the measurement accuracy of this system is less than 4nm P-V and 0.7nm rms.

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Recently, the spherical photodiode with incidence angle and uniform sensitivity can have been obtained. In this study, this device is utilized as a detector of position measurement system using the laser beam plane scanners. In this paper, multi points simultaneous measurement detector (MHD: Multi Heads Detector) and multi points simultaneous precision angle measurement unit (PAMU: Precision Angle Measurement Unit) were developed. As a result of the experiment, the rotation angle of the laser plane measuring accuracy is ± 10".

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This paper describes on high accuracy contour grinding. Variation in normal grinding force affects on the machining accuracy in contour grinding using a machining center because of grinding wheel with low stiffness. It is necessary in order to achieve higher efficiency and accuracy contour grinding to minimize the variation of the normal grinding force. Some methods has been tried to improve machining accuracy. However, influences of the normal force due to dynamic pressure caused by coolant flowing into grinding point has not been considered. Therefore, the normal force variation was estimated in consideration of contact arc length in order to improve machining accuracy. As a result, the variation of normal grinding force could be reduced in contour grinding.

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According to the previous study, damaged layers can be removed in a spark-out process by low static stiffness condition. This study proposes a principle of designing method of optimum grinding cycles without damaged layers. In this proposal, grinding cycle consists of two infeed processes and one spark-out process. As the experimental results, it is confirmed that damaged layers generated infeed process can be eliminated in the proposed grinding cycle.

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In this paper, the quantitative measurement method of the cutting edge density based on the working surface profile, which can be measured on the machine, is proposed.In addition, the validity is clarified based on the experimental and analytical examination.As a result, the following were clarified:The cutting edge density can be estimated from the distribution of the maximum height of the grain and the peripheral thickness of the grain layer, which is in contact with the workpiece surface.The grain height distribution can be estimated from the peak height distribution of the profile and the grain diameter.The peripheral thickness of the grain layer can be determined from the change in the peak height distribution on the working surface with grinding.The estimation validity is experimentally clarified from the relationship between the change in the cutting edge density and in the working surface.

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The helical scan grinding method in which a wheel or a workpiece is fed at an angle with the direction of wheel rotation can greatly improve the surface roughness on the workpiece without decreasing the processing efficiency compared with the case of a plunge surface grinding. In this research work, the helical scan grinding was carried out on the edge of the carbon steel workpiece by feeding table with an inclination for investigating dressing lead. The result showed that the surface roughness kept constant in the range though it became worse in the case of normal grinding when the dressing lead was varied between 126 and 500 mm/min.

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Surface of single crystal silicon can be machined and smoothened like mirror in ductile mode with a single crystal diamond tool when uncut chip thickness is smaller than critical thickness. Purpose of this study is to find out monitoring parameters of cutting process to make ductile mode machining stable by using adaptive control. As a result, it is demonstrated that RMS value of dynamic component of thrust force in ductile mode machining is clearly smaller than RMS value in brittle mode machining and RMS value of AE envelope signal also has the same characteristics as the RMS value of dynamic component of thrust force.

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[in Japanese]

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In recent years, machining center has been used widely in metal mold manufacturing process. Since metal molds used for injection molding are complex and fine in form, long end-mills with a small diameter have to be used in metal mold machining process. Long end-mills with a small diameter deflect on a large scale at a cutting point due to cutting forces. The purpose of this study is to establish a method of in real time estimating machining errors caused by deflection of end-mill. For this purpose, the growth mechanism of machining errors caused by deflection in straight end-mill was investigated by comparing estimated value of deflection of tool using cutting force with each measured value of deflection of tool and machining error.

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The RP is an experimental method of generating a solid model by using the shape data input on three-dimensional CAD.Today, for all manufacturing, it becomes a big proposition that "How rapidly can the product be sent to the consumers with good quality which mean how can we shorten the time of development through shipping by reducing the cost." staked one's survival. There are several different systems in the RP. Especially, the cutting RP is small in shape and cheap. It can be also be used at offices since it does not take so much energy. It is thought that certain estimation of the processing time and the examination of tool route using the CAM data/NC program from the real process can be done when using endmil in the RP. Recently relating NC machines expansion, small NC machine is made with high accuracy. This machine is used in small lot product of nonferrous metals and manufacture resin and gypsum shaping which does not need high strength. The purpose in this research is to develop a system by acquire the process information when the real process is operated.

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The interrupted conventional cutting of the material composed of metal and nonmetal was carried out and the surface integrity was examined experimentally. Here, the material composed of 60-40 brass and acrylic resin was used. As a result, it was difficult to extract the conditions for getting the ideal finished surface of both brass and acrylic resin, but was clear to get somewhat ideal finished surface if brass does not generate the leaned burrs.

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This report deals with a fabrication method of a wire saw by electrical discharge machining (EDM). A deposition method by EDM with powder suspended in working oil has been proposed. Hard bumps were patterned on the surface of a thin stainless steel wire. Titanium powder was adhered after changing into titanium carbide by the reaction with the cracked carbon from the working oil. A soda lime glass rod could be cut with the wire saw.

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[in Japanese]

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It is known that the vibratory OD-blade slicing which applies a low-frequency vibration to an OD-blade or a workpiece has self-corrective effect of the OD-blade caused by repeating intermitted phenomena with contact and separation between the OD-blade and the workpiece. Moreover, the previous paper demonstrated the mechanism of the self corrective effect using dynamic numerical simulation, and this effect can reduce the blade elastic deformation and the waviness of sliced surface. This paper discusses this effect using FEM simulation, and shows the dynamical results of blade elastic deformation during the vibration slicing. Furthermore, this paper describes the vibratory slicing which applies the vibration to the OD-blade can improve the tool life experimentally.

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[in Japanese]

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The industry of die and mold is bases of Japanese manufacturing such as cur industry, electronics industry and machine industry, etc. The rationalization of design and manufacturing process by using software tools of CAD/CAM/CAE etc. and the network is indispensable so that Japanese industry of die and mold can maintain the international competitive edge in the future. In this report, our cases of research and development are explained, which relate to the production technologies of die and mole such as the manufacturing software and the automation system.

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In the structure part design of a mold part, a long time period is consumed to verify that all features specified on the structure can be completely machined without cutter and holder collisions. In this paper, the authors propose an algorithm for automating this task. Our algorithm realizes the verification by sequentially applying the inverse offset computation, cutter path generation on the offset shape, and milling simulation. Features which are not machinable can be detected by comparing the geometric model of the structural part and the milling simulation result. Proposed algorithm is implemented and an experimental system for assisting the structural part design is demonstrated.

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The purpose of this research is to develop hi-speed and hi-accuracy machining system which is corresponded to 1 micron of accuracy. The servo data is the set of position command at every servo cycle time, which is minimum unit of position command in NC machining processes. The servo data is directly generated by geometric model interpolation without NC program. And motion errors are simulated and compensated automatically. This report refers to the result of machining experiment by adapting the geometric model interpolation and compensation of motion error by using contour cutting path.

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A NC geometric cutting simulator is widely used software that is able to verify a tool path without real machining process by executing the machined shape check and the interference check between a tool and a workpiece during machining. However, current NC machining simulator is only considered for the geometric information of an objective shape and a tool. For this reason, it is difficult to represent the tool deflection and wear caused by a physical phenomenon. In this study, to realize further high-precision machining, a high-precision NC machining simulation algorithm is developed for the tool wear. This paper describes about calculation algorithm of tool wear from removal volume and the result of comparison between calculated tool wear with machining experiment.

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Cycle time is an important factor in plastic injection molding process. It has a direct relationship with the cost of plastic product. By decreasing the cycle time, the cost of plastic injection molding products will be decreased. This paper describes a new method of decreasing cycle time of plastic injection molding by controlling of mold temperature precisely using sheet metal laminated mold. The mold was insulated to decrease the heat transfer rate during the process of injection molding. The difference between maximum and minimum temperature was kept near to a stable value. The sheet metal laminated mold allows controlling the maximum and minimum temperature near to the stable value during the injection molding process. Precisely controlling the temperature, decreasing cycle time and product cost of injection molding process, is enabled by using the sheet metal laminated mold.

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More than three-fourths of the cycle time in the injection mold process is spent in cooling period, however, non-uniform cooling in the plastic injection mold is always a problem. This paper proposes a new method based on block laminated to make molds with complex cooling system. In addition, we have completed an optimization design for the cooling structure using generation algorithm. Our numerical experiment results show that by using this method, the cooling effect of mold with complex cooling structure is enhanced. In this study, electronic beam welding was used to bond the block; a procedure of optimizing the shape of cooling structure is demonstrated

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[in Japanese]

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In these years, injection moldings are demanded to be thin. But resin flow in moldings with thin wall is significantly reduced, so it is important to improve resin flow. In this study, I assume moldings with uneven thickness with a lead flow part and analyze it, examine resin flow of it.

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We investigated the amount of wear to cemented carbide tools by cutting a difficult-to-cut titanium alloy material (Ti-6Al-4V) using minimum quantity lubrication (MQL), and obtained results comparable to those using the conventional wet cutting processes. We also experimentally investigated tool coatings suitable for the MQL cutting of titanium alloys and found that the newly developed TiBON coating increases tool life. In addition, dry cutting tests of titanium alloy using CBN tools were conducted.

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Applying large quantity of cutting fluids during cutting is characterized by problems in the immediate working environment and in waste disposal. These problems result in a large number of ecological problems and in a climate of increasingly strict work safety and environmental legislation. To reduce the quantities of cutting fluids, dry cutting and near-dry cutting should be replaced conventional oil supplying method. Near-dry cutting is put in practical use partly. It was proved Kaneeda et al that lubrication of cutting fluids was almost due to lubricant applying effect. This research investigated a lubrication mechanism of near-dry cutting using lubricant applying effect when SUS304 was cut.

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Micro little lubrication (μLL) cutting (MQL cutting in the case that oil supply was less than 1ml/h) was applied to finish-turning of a nickel-base superalloy, Inconel 718. From the experimental result and the flow analysis using a general purpose code of computational fluid dynamics, it is shown that blowing the oil mist to the cutting point from the minor flank side is the effective method to prevent the progress of tool wear at decreased rate of oil mist supply.

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A water recovery method from a difficult-to-process water-soluble coolant was developed. The methods with an oil-decomposed microorganism and a freeze-thawing showed a little potential to recover the water. The demulsifying by an activator was very effective to recover the clear water. The recycle water obtained by activator method had 7.5 of pH and 0.1% of Brix%. The water-soluble coolant can stable emulsion in the recycle water. The recycle coolant diluted with recycle water showed the same pH and Brix% as those of virgin coolant. There was no difference in lapping force change, removal rate and finishing surface roughness between the lapping of SUS304 with recycle and virgin coolants. These facts indicate that the recycle water recovered from a difficult-to-process coolant can be re-utilized as a diluter of renewal coolant.

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On the high-speed end milling, it is thought that the dispersion of the cutting fluid from surface of tool body by centrifugal force and the dispersion by collision with rake face have a large influence on the small particle generation process when the cutting fluid is supplied. Then, the tool rotational speed and the tool shape were paid to attention to clarify those influences. And the behavior of the small particles and its dispersion state were observed with high-speed camera. As a result, it was found that the generated particle becomes small as the tool rotational speed becomes high, and the small particle disperses horizontally when the number of teeth increases.

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Recently, many ecological machining methods are reported. One of the most popular technique is cutting with lubricant mist. But the mist can hardly reaches cutting point and most of them fly away into atmosphere. The flown mist makes machine tool dirty and may give bad effects on workers. So we thought out as a new method of supplying lubricant using lubricant form. Lubricant form may hard to fly away. In addition, lubricant may stay at the cutting point longer than other method. Especially, In drill process, lubricant form may stay at the cutting point. Though, intermittent supply of form may cause the excess temperature raise at the cutting edge. In this study, lubricant form was generated by N2 gas. N2 gas is typical inert gas, so the heat generation at cutting point is expected to be decreased.

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[in Japanese]

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The authors have proposed a new coolant named "micro babble coolant" in which many micro babbles (20-50 micrometer) are incorporate. In this paper a micro babble coolant was applied to the grinding with CBN grinding wheel and normal (PA) grinding wheel respectively. The results indicate that the micro babble coolant was effective in suppressing wheel wear and improving surface roughness by 20% in the case of CBN grinding. In addition the coolant could suppress burning at ground surface of SKD11 with CBN wheel. On the other hand, grinding property was deteriorated by 20% in the case of normal (PA) grinding wheel.

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[in Japanese]

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[in Japanese]

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[in Japanese]

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To improve characteristics of optical parts such as liquid crystal displays, patterning vast numbers of micro lenses on a surface increases technical importance. A cutting method using a diamond tool is examined to machine a die of micro lenses. Realizing the cutting procedure, the developed machining system adopts a cutting unit actuated by PZT and a synchronous control system between the cutting unit and a NC controller. Through experiments using this developed system, it is confirmed that machining a lot of micro lenses on a molding die with high precision is possible. And we confirmed that a high-speed cutting of micro lens array for roll die which is used for manufacturing plastic films is possible.

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Elliptical vibration cutting is applied to ultra-precision machining of tungsten alloy molds for optical glass parts in the present research. The tungsten alloy is expected as a new mold material instead of conventional ones such as sintered tungsten carbide and CVD-silicon carbide. Ultra-precision molds of the tungsten alloy for a prism, a small spherical lens and an array of micro V-grooves were machined by the elliptical vibration cutting. It is confirmed that surface roughness of less than 100 nmRz and desired shape can be attained. They were applied to glass molding of borosilicate glass BK7 without any coatings, and it is found that accurate transcript with no adhesion can be achieved successfully.

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In recent years, attention is paid to diffractive optics which implies surface shape like diffraction grating or Fresnel lens. A variety of machining methods are requested to effectively produce metal mold of diffractive optics, especially consisting of a variety of microgrooves with various shapes. One of them is flat-end microgrooves. Flat-end microgrooves mean microgrooves having no slope at the end. As the existence of the slope causes unnecessary diffraction lights and losses, the slope is requested to remove. In this study, curved microgroove with two flat-ends is created on a curved surface. Then, the experiment of the cutting edge detection is done to do the setting more simplify and high accurately.

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This paper describes the mechanism of the tool wear in diamond turning of electroless Ni-P plating material. The erosion tests were carried out which simulate the tool wear. Namely, Ni-P wire into contact with the diamond was heated to temperature range from 473 to 773K in vacuum. After the tests, the diamond surface was observed with a scanning probe microscopy. As a result, the erosion pit was observed on the diamond surface. On the other hand, the wire was analyzed with an energy dispersive X-ray spectrometer .As a result, carbon atoms were observed in the cross section of the wire. Accordingly, it was found that the main cause of tool wear is the diffusion of carbon atoms into Ni-P.

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[in Japanese]

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The paper describes an correct setting method for 5-axis control ultraprecision machining. The problem of the setting error is the main factor to deteriorate the machining accuracy in the ultraprecision machining technology. To make good use of a highly advanced ultraprecision machining center, it is necessary to reduce the causes of errors in the initial setting and to develop a simplified setting method. Though the fundamental compensation method based on the measurement of trial cutting has been reported, this study deals with the generalization of the method. From the result of 5-axis controlled machining experiments, it is found that the proposed method is extremely effective.

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This paper describes compensation techniques for quadrant glitches that have often been observed in circular trajectories of the XY table. Since the trajectories of a cutting tool relative to a workpiece determines the surface machined, highly accurate motion is always required. Hence many researchers have executed research works on the quadrant glitches because the quadrant glitch is the main cause of inaccuracy. In this paper, firstly, some research works carried out up to now is surveyed. After that, a newly proposed friction compensator and some experimental results are introduced. The proposed compensator can eliminate the quadrant glitches at all radius and feed rate in the circular motion.

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This study aims at realizing a simple positioning mechanism with nanometer level resolution over a one-millimeter stroke using a differential ball screw. In this report, the macroscopic feed characteristics and microscopic behavior are measured in detail to discuss the positioning performance of the differential ball screw on the positioning mechanism, which was designed and constructed in previous report. The experimental results on the actual stage displacement are compared to the theoretical value, and discussed fundamentally. Though the feed error of the mechanism becomes simple by the effects of differential operation, cyclic fluctuations caused by ball circulation become dominant.

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[in Japanese]

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[in Japanese]

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For the balancing effect of the aerostatic lead screw, the drunkenness of the female screw is not directly transferred from the male screw; it can be reduced responding on the balance conditions of the load at each flank surface. In this research, an attempt is made to calculate the drunkenness of the aerostatic lead screw, based on the balance conditions of the load, where the shape of the flank surface is considered. Then, the drunkenness of the air-floating female screw is measured experimentally. The balancing effect was clarified from the comparison of the theoretically value and the experimental value.

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