THE INTERNATIONAL ACADEMY FOR PRODUCTION ENGINEERING
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CIRP ANNALS 2010 |
GO TO STC: A C Dn E F G M O P S Cross-STC |
STC A |
| Development of Micro Assembly Processes for Further Miniaturization in Electronics Production |
| K. Feldmann (1), J. Franke, J.F. Schüssler |
| STC A, 59/1/2010, P.1 |
| Keywords: Miniaturization, Assembly, Soldering |
|
Abstract : Steady increase of functionality and concurrent reduction of the package size are one of the key driving forces in
electronics production. In this paper we will present solutions developed at the institute for the automated assembly
of highly miniaturized flip-chips with pitches down to 100 μm. In particular the present and future influences of
miniaturization on the main process steps wafer bumping, component placement, reflow soldering and inspection
are examined as well as the influences on complementary materials used. Results regarding the achievable yield
after assembly and the reliability of the structures will be presented in addition to an analysis of the failure
mechanisms. |
| Assessment of operator stress induced by robot collaboration in assembly |
| T. Arai (1), R. Kato, M. Fujita |
| STC A, 59/1/2010, P.5 |
| Keywords: Assembly; Robot; Human-robot collaboration |
|
Abstract : To improve productivity of assembly in cell production, a robot is introduced to help operators physically. A moving robot around a
human operator however induces much stress on human operators because they need to work coexistently and compellingly with the
robot. This paper deals with strain measurement caused by industrial robots, and discuss design criterions of robot collaboration with a
human operator. Several basic strains are experimentally measured: distance from a swinging robot to an operator, speed at robots
movement towards an operator and so on. The results are applied in a novel cell production assembly system. |
| A new cell production assembly system with human-robot cooperation |
| M. Morioka, S. Sakakibara (3) / T. Arai (1) |
| STC A, 59/1/2010, P.9 |
| Keywords: Assembly, Safety, Human-robot cooperation |
|
Abstract : In manufacturing, where the wages of operators are high and the availability of expert operators remains limited, it is proving impossible to improve the efficiency of cell production assembly systems. Even novice operators are asked to achieve high levels of productivity and reliability with a diverse range of products. To satisfy this demand, the authors have developed a new cell
production assembly system with human-robot cooperation. This system consists of three key technologies; parts feeding by double manipulators on a mobile base, production process information support for the operator, and safety management for cooperation between the operator and the robot. |
| Integrated visual nanometric three dimensional positioning and inspection in the automated assembly of AFM probe arrays |
| M. Lanzetta (2), M.L Culpepper |
| STC A, 59/1/2010, P.13 |
| Keywords: Assembly, Visual Inspection, Localization |
|
Abstract : This paper presents the design of a monocular three dimensional artificial vision system attached to a 20ï‚´
microscope lens for precision and microsystems applications. Possible uses in assembly include: positioner
calibration, sensor-based part handling, positioning, and inspection in the nanometric range. The developed
image acquisition method – along one direction (in steps of 100 nm), the depth-from-focus algorithm and
subpixel interpolation (of 5 acquisitions for concurrent localization and inspection), allow to overcome the
physical optics limitation achieving a resolution under 200 nm. The vision strategy and algorithms, described in
the paper, have been validated by handling an AFM probe array by a micropositioner. |
| Development and testing of a brush feeder |
| G. Fantoni, M. Santochi (1) |
| STC A, 59/1/2010, P.17 |
| Keywords: Assembly, positioning; feeding |
|
Abstract : Some manufacturing processes and many packaging operations require oriented and aligned parts. When a high feed
rate cannot be obtained by human operators or when sophisticated vision systems, able to guide the picking operations, are too expensive or too complex for a specific application, a different approach to solve the problem is necessary. In this paper a brush feeding system based on tilted brushes is presented. It allows the controlled motion and the correct alignment of products different in shape, weight and surface roughness. The brush feeder is analyzed both from a theoretical and experimental point of view. |
| Automated Energy Monitoring of Machine Tools |
| A. Vijayaraghavan, D. Dornfeld (1) |
| STC A, 59/1/2010, P.21 |
| Keywords: Energy, monitoring, event stream processing |
|
Abstract : Reducing the energy consumption of machine tools can significantly improve the environmental performance of manufacturing systems. To achieve this, monitoring of energy consumption patterns in the systems is required. It is vital in these studies to correlate energy usage with the operations being performed in the manufacturing system. However, this can be challenging due to complexity of manufacturing systems and the vast number of data sources. Event stream processing techniques are applied to automate the monitoring and analysis of energy consumption in manufacturing systems. Methods to reduce usage based on the specific patterns discerned are discussed. |
| Minimising Embodied Product Energy to Support Energy Efficient Manufacturing |
| S. Rahimifard, Y. Seow / T. Childs (1) |
| STC A, 59/1/2010, P.25 |
| Keywords: Sustainable Development, CO2 Emission, Energy Efficient Manufacturing |
|
Abstract : Green sources of power generation and efficient management of energy demand are among the greatest challenges facing manufacturing businesses. A significant proportion of energy used in manufacturing is currently generated through fossil fuels. Therefore in the foreseeable future, the rationalisation of energy consumption still provides the greatest opportunity for reduction of greenhouse gases. A novel approach to energy efficient manufacturing is proposed through modelling the detailed breakdown of energy required to produce a single product. This approach provides greater transparency on energy inefficiencies throughout a manufacturing system and enables a 20-50% reduction of energy consumption through combined improvements in production and product design. |
| Global Manufacturing and the Embodied Energy of Products |
| S. Kara (1), S. Manmek, C. Herrmann |
| STC A, 59/1/2010, P.29 |
| Keywords: Manufacturing, Energy, Environment |
|
Abstract : Manufacturing energy efficiency has become a key concern due to increasing energy costs and their associated environmental impact. It is important however, that investigations into the embodied energy of a product be in the context of global manufacturing rather than
energy efficiency related to a particular product life cycle. This paper presents a model to assess the impact of global manufacturing on the embodied energy of products. Six different products manufactured from various raw materials in a global manufacturing network were used to carry out the assessment. The results show that product, material and key supply chain parameters play a crucial role. |
| Sustainable Design of Injection Moulded Parts by Material Intensity Reduction |
| G. Lucchetta, P.F Bariani (1) |
| STC A, 59/1/2010, P.33 |
| Keywords: Sustainable development, Recycling, Injection moulding |
|
Abstract : Life cycle engineering of injection moulded components is often aimed at minimizing the material intensity
mainly by decreasing the part volume and increasing the use of recycled materials, while fulfilling structural and
manufacturability requirements. However both these solutions produce an additional environmental impact, due to
the higher energy consumption in manufacturing, that is often overlooked. The paper addresses the multiobjective
problem of minimizing the overall environmental impact by incorporating the numerical simulation of the process and the structural analysis of the part in a CAD-based shape optimization environment. The proposed approach has been demonstrated through an industrial case study. |
| Carbon footprint as environmental performance indicator for the manufacturing industry |
| A. Laurent, S.I Olsen, M.Z. Hauschild (2) |
| STC A, 59/1/2010, P.37 |
| Keywords: Manufacturing, Lifecycle, Carbon footprint |
|
Abstract : With the current focus on our climate change impacts, the embodied CO2 emission or ―Carbon footprint‖ is often used
as an environmental performance indicator for our products or production activities. The ability of carbon footprint to
represent other types of impact like human toxicity, and hence the overall environmental impact is investigated based
on life cycle assessments of several materials of major relevance to manufacturing industries. The dependence of the
carbon footprint on the assumed scenarios for generation of thermal and electrical energy in the life cycle of the
materials is analyzed, and the appropriateness of carbon footprint as an overall indicator of the environmental
performance is discussed. |
| Strategic decision making method for Eco-business planning |
| S. Kondoh, N. Mishima / H. Yoshikawa (1) |
| STC A, 59/1/2010, P.41 |
| Keywords: Lifecycle; environmental; eco-business |
|
Abstract : Due to growing concerns about environmental problems, product life cycle design that aims to maximize total value while minimizing environmental load and costs should be implemented. To do so, the processes of idea generation and decision-making for eco-business strategies, as well as the design of a target product, should be systematically supported. This paper proposes a strategic decision-making
method for eco-business planning that allows a designer to easily find a set of eco-business ideas that effectively improves environmental and economic performance simultaneously. A decision-making procedure based on this method is illustrated with a simplified example of a laptop computer business. |
| Life Cycle Management of Production Facilities Using Semantic Web Technologies |
| R. Harms, T. Fleschutz, G. Seliger (1) |
| STC A, 59/1/2010, P.45 |
| Keywords: Knowledge Based System, Life Cycle, Semantic Web |
|
Abstract : High added value along the life cycle stages design, installation, operation, adaptation and disposal of production
facilities is achieved by services. Activities like commissioning, maintenance, reuse or training are knowledge
intensive and require efficient ways of managing relevant knowledge. Distributed semantic web knowledge
bases enable companies or networks to make knowledge explicitly available to all involved agents at the right
place and on the right time. This paper presents a semantic web based approach for the life cycle management of
production facilities, and verifies it on a reuse planning case study of an automotive body-in-white facility. |
| Development of a Cost Model and its Application in Determining Optimal Size of a Diesel Engine Remanufacturing Facility |
| J.W. Sutherland (2), T.L Jenkins, K.R. Haapala |
| STC A, 59/1/2010, P.49 |
| Keywords: Sustainable Development, Optimization, Remanufacturing |
|
Abstract : Remanufacturing represents a business opportunity and a means to promote environmental sustainability. In
planning remanufacturing operations for a specific product in a particular market, determining the facility size is
a critical decision. A large centralized facility offers economies of scale advantages, but has greater
transportation costs relative to a set of smaller distributed facilities. A remanufacturing facility cost model is
developed and applied for diesel engine remanufacturing that includes product, operation, inventory, and
transportation-related costs. The effects of product yield, remanufacturing efficiency, transportation cost rate,
and product mass on remanufactured product unit cost and remanufacturing facility size are examined. |
| Manufacturing Complexity in Assembly Systems with Hybrid Configurations and Its Impact on Throughput |
| H. Wang, S.J. Hu (2) |
| STC A, 59/1/2010, P.53 |
| Keywords: Assembly, Productivity, Complexity |
|
Abstract : A measure of product variety induced manufacturing complexity has been proposed based on the choices of assembly activities that operators make in serial, manual mixed-model assembly lines. In this paper we extend the complexity measure to assembly systems with parallel and hybrid configurations. The complexity measure takes into consideration operator choices at each station and the
assembly system configuration. In addition, we develop throughout analysis models for assembly systems by incorporating complexity based on the operator reaction time and fatigue effects. The complexity and throughput models are applied to comparing performance of
assembly systems with different configurations. |
| Adaptive planning and optimization of joining and assembling sequences using parallel acting working units |
| M.W. Putz (3), A. Richter, M. Pfeifer / R. Wertheim (1) |
| STC A, 59/1/2010, P.57 |
| Keywords: Assembly, Productivity, Production planning |
|
Abstract : The use of multiple, parallel-acting working units is becoming more common today especially when large parts and high working volumes within limited production and station times are required. In order to effectively maximize the higher working capacity of two or more units with machining, joining or assembling functions, a number of restrictions, including maintenance, breakdowns, available working space, etc., must be considered. This paper deals with new adaptive planning and optimization strategies, enabling the compensation of those effects. Results of a case study in aircraft component manufacturing are presented. |
STC C |
| Creation of V-Shaped Microgrooves with Flat-Ends by 6-axis Control Ultraprecision Machining |
| T. Moriya, K. Nakamoto, T. Ishida, Y. Takeuchi (1) |
| STC C, 59/1/2010, P.61 |
| Keywords: Micromachining, Grooving, Flat-end |
|
Abstract : The use of diffractive optics having surface appearance like diffraction grating or Fresnel lens, which
consist of a number of microgrooves with various shapes is analyzed. One of them is flat-end
microgrooves having no slope at the end. The existence of a slope limits the design of microgrooves and
causes unnecessary diffraction of light and losses. Thus, the slope must be eliminated. The study deals
with the creation of curved V-shaped microgrooves with two flat-ends on a curved surface by using 6-
axis control non-rotational cutting tools. The proposed method shows the effectiveness in creating flatended
curved microgrooves on curved surfaces. |
| Advanced Microstructures and its Production through Cutting and Grinding |
| B. Denkena (1), J. Kästner, B. Wang |
| STC C, 59/1/2010, P.67 |
| Keywords: Cutting, Grinding, Friction |
|
Abstract : Microstructures can be used to improve the tribological performance of surfaces, to reduce flow losses or
even to store information. In order to assure the functionality of these surfaces, the relationships between
the microstructure designs and the manufacturing processes have to be understood. In this paper, the
relevant design criteria for three advanced microstructure applications and the proposed manufacturing
solutions as well as the resulting surface properties are discussed. In addition, the mechanisms during
chip formation are identified and the output parameters of several machining experiments on the
different workpieces are evaluated. |
| The effect of substrate pretreatments and HPPMS deposited adhesive interlayers' materials on the cutting performance of coated cemented carbide inserts |
| K.D. Bouzakis (1), G. Skordaris, S. Gerardis, G. Katirtzoglou, S. Makrimallakis, M. Pappa, S. Bolz |
| STC C, 59/1/2010, P.73 |
| Keywords: Coating, Wear, HPPMS |
|
Abstract : High power pulsed magnetron sputtering (HPPMS), substrate pretreatments and adhesive interlayers can
enhance tool life significantly. In the conducted research, TiAlN PVD-films and W-, Ti- or Cr-adhesive
nanointerlayers were deposited by HPPMS on different superficially treated hardmetal inserts. The
mechanical properties of the coatings were determined via nanoindentations and mathematical analysis.
Additionally, inclined impact tests and milling investigations were performed to examine the substrate
pretreatment and interlayer effects on film adhesion and wear behaviour. The results reveal that HPPMS
jointly with an appropriate substrate pretreatment and a Cr-nanointerlayer lead to significant adhesion
and cutting performance improvement. |
| Investigations on The Effects of Multi-Layered Coated Inserts in Machining Ti-6Al-4V Alloy with Experiments and Finite Element Simulations |
| T. Özel, M. Sima, A.K. Srivastava (3), B. Kaftanoglu (1) |
| STC C, 59/1/2010, P.77 |
| Keywords: Machining, Finite element method, Titanium Tool |
|
Abstract : This paper presents investigations on turning Ti–6Al–4V alloy withmulti-layer coated inserts. Turning of
Ti–6Al–4V using inserts with uncoated, TiAlN coated, and TiAlN + cBN coated single and multi-layer
coated tungsten carbide inserts is conducted, forces and tool wear are measured. 3D finite element
modelling is utilized to predict chip formation, forces, temperatures and tool wear on these inserts.
Modified material models with strain softening effect are developed to simulate chip formation with
finite element analysis and investigate temperature fields for coated inserts. Predicted forces and tool
wear contours are compared with experiments. The temperature distributions and tool wear contours
demonstrate some advantages of coated insert designs. |
| Laser Assisted High Speed Finish Turning of Superalloy Inconel 718 under Dry Conditions |
| H. Attia (2), S. Tavakoli, R. Vargas, V. Thomson |
| STC C, 59/1/2010, P.83 |
| Keywords: Cutting, Laser, Machinability |
|
Abstract : Inconel 718 (IN718) is used in aerospace applications due to its superior mechanical properties. This
study investigates the high-speed machinability of this material under laser-assisted machining (LAM)
and dry conditions. Finish turning tests were performed for cutting speeds up 500 m/min and feeds up to
0.5 mm/rev, using focused Nd:YAG laser beam and ceramic tool (SiAlON). At optimum machining
conditions, nearly eight-fold increase in material removal rate and significant improvement in the tool
life and surface finish were achieved, compared to conventional machining. The mechanisms of tool
failure were identified. SEM analysis and microstructure examination of machined surfaces revealed the
improvement in the surface integrity under LAM conditions. |
| Turning of Difficult-to-Machine Materials with Actively Driven Rotary Tool |
| A. Hosokawa, T. Ueda (1), R. Onishi, R. Tanaka, T. Furumoto |
| STC C, 59/1/2010, P.89 |
| Keywords: Turning, Temperature, Cutting tool |
|
Abstract : Turning with a spinning insert called actively driven rotary tool (ADRT), where the cutting tool revolves
by a powered and programmable spindle, is investigated from the thermal aspects. Dry and MQL external
turning tests of austenitic stainless steel (AISI 304) and heat-resistant Ni-based alloy (Inconel 718) are
carried out. The tool temperature at the flank face is measured using a newly assembled fiber-coupled
two-color pyrometer. In dry turning of AISI 304 steel, the tool temperature decreases from approximately
730 8C to 640 8C as the tool rotation speed increases from 10 m/min to 200 m/min. |
| Influence of cutting edge radius on cutting forces in machining titanium |
| C.-F. Wyen, K. Wegener (3) / R. Züst (1) |
| STC C, 59/1/2010, P.93 |
| Keywords: Machining, Cutting edge, Ploughing |
|
Abstract : The performance of machining titanium can be enhanced by using cutting tools with rounded cutting
edges. In order to better understand the influence of rounded cutting edges and to improve the modelling
of the machining process, their impact on active force components including ploughing forces and tool
face friction is analysed. This paper presents experimental results of orthogonal turning tests conducted
on Ti–6Al–4V with different cutting edge radii and changing cutting speeds and feeds. As an accurate
characterisation method for the determination of the cutting edge radius is prerequisite for this analysis,
a new algorithm is described which reduces uncertainties of existing methods |
| High Bandwidth Temperature Measurement in Interrupted Cutting of Difficult to Machine Materials |
| M. Armendia, A. Garay, M.A. Davies (1), P.J. Arrazola (2) |
| STC C, 59/1/2010, P.97 |
| Keywords: Milling, Temperature, Titanium |
|
Abstract : High-speed milling is used across industries from aerospace to electronics. Tool wear can be affected by
cutting interruptions in milling that lower tool–chip interface temperatures but also cause thermal and
stress cycling. Micro-thermal imaging was used to determine the temperature during interrupted cutting
of titanium alloy Ti6Al4V and AISI 4140 steel for percentage of time-in-cut from 100% to 10%. TiAlN/TiN
coated carbide milling inserts were used with cutting speeds up to 180 and 640 m min1. This technique
is the first to allow spatial mapping of thermal fluctuations on the tool which may be critical to
determining causes for tool failure. |
| Titanium Machining with New Plasma Boronized Cutting Tools |
| S. Basturk, F. Senbabaoglu, C. Islam, M. Erten, I. Lazoglu (2), T. Gulmez |
| STC C, 59/1/2010, P.101 |
| Keywords: Titanium, Machining, Wear |
|
Abstract : Titanium is a commonly used material in various critical applications such as aerospace and biomedical
applications. In this article, for the first time in the literature, development and implementation of a novel
plasma boronizing process on Tungsten Carbide (WC) cutting tools is introduced. Plasma boronizing on
WC tools is performed with gas combination of 10% BF3, 40% Argon and 50% H2 at different temperatures
and durations. Performance enhancements of plasma boronized WC tools on Titanium (Ti–6Al–4V)
machining are investigated under various cutting conditions. It is found that new plasma boronizing of
WC is a very cost effective solution for significantly increasing tool life in Titanium machining |
| Suppression Mechanism of Tool Wear by Phosphorous Addition in Diamond Turning of Electroless Nickel Deposits |
| N. Furushiro, H. Tanaka, M. Higuchi, T. Yamaguchi, S. Shimada (1) |
| STC C, 59/1/2010, P.105 |
| Keywords: Turning, Diamond, Wear |
|
Abstract : An appropriate phosphorous addition to electroless nickel deposits remarkably reduces tool wear in
diamond turning. To understand the wear suppression mechanism of phosphorous addition, erosion tests
simulating tool wear process and ab initio molecular dynamics calculations of interactions between
diamond and Ni–P and Ni are carried out. The erosion tests show that carbon diffusion into the workpiece
is reduced, and the ab initio calculations suggest that dissociation of carbon atoms on diamond surface
due to the interaction with the workpiece is reduced. The results suggest that another possible additive to
suppress tool wear can be found by the method proposed. |
| Tool wear control in diamond turning of high-strength mold materials by means of tool swinging |
| J. Yan, Z. Zhang, T. Kuriyagawa / H. Sato (1) |
| STC C, 59/1/2010, P.109 |
| Keywords: Ultraprecision, Cutting, Ceramic mold |
|
Abstract : A tool-swinging method was proposed to reduce tool wear in diamond turning of high-strength mold
materials. A round-nosed diamond tool was swung by rotating the B-axis rotary table of themachine, the
center of which was aligned with the tool center. The tool-decentering error was detected and
compensated for by an on-machine measurement system. The effects of tool-swinging direction,
swinging speed, lubricant type, and tool rake angle were investigated. The tool wear was greatly reduced
compared to the conventional method. A surface finish of 4 nm Ra was obtained on reaction-bonded
silicon carbide by generating continuous chips. |
| A numerical model incorporating the microstructure alteration for predicting residual stresses in hard machining of AISI 52100 steel |
| D. Umbrello, J.C. Outeiro (2), R. M'Saoubi (2), A.D. Jayal, I.S Jawahir (1) |
| STC C, 59/1/2010, P.113 |
| Keywords: Cutting, Finite element method, Surface integrity |
|
Abstract : Residual stresses induced by machining processes are a consequence of thermo-mechanical and
microstructural phenomena generated during the machining operation. Hard machining of AISI 52100
bearing steel is a typical case where the microstructural phenomena associated with white and dark
layers formation influences the residual stress distribution. Unfortunately, very limited physical models
are available for residual stress prediction including the microstructural effects. This paper presents an
experimental and numerical approach to predict residual stresses by incorporating the microstructural
phase transformations induced during machining of AISI 52100 steel. |
| Investigation of surface near residual stress states after micro-cutting by finite element simulation |
| V. Schulze, H. Autenrieth, M. Deuchert, H. Weule (1) |
| STC C, 59/1/2010, P.117 |
| Keywords: Micromachining, Finite element method (FEM), Residual stresses |
|
Abstract : Surface layer properties, namely residual stresses, surface work hardening and surface roughness, have a
great influence on the service life of components. Especially the residual stress state of the surface layer
after cutting is of great importance and shows a strong material specific behavior. Therefore the
dependence of the residual stresses on the cutting edge radius, which plays a crucial role for microcutting,
is investigated in chip forming simulations using ABAQUS/Standard. The residual stress states are
evaluated for the reference material normalized AISI 1045 and are compared with a model material
representing a hardened material state. The process knowledge will be increased by the systematic
separation of physical effects leading to material specific residual stress states after cutting. The
simulation results are validated by the comparison with experimentally determined residual stress depth
profiles, using X-ray diffraction method, showing a good correlation. |
| Modelling of the heat input for the face-milling processes |
| R. Pabst , J. Fleischer (2), J. Michna |
| STC C, 59/1/2010, P.121 |
| Keywords: Cutting, Milling, Heat input |
|
Abstract : Due to the lack of coolant in dry machining processes, there is an increase of heat input into workpieces
during the cutting process. As a result, an inhomogeneous temperature distribution occurs, which can
lead to problems concerning compliance with critical tolerances, because of distortions of the workpiece.
Using the FEM simulation it is possible to calculate and handle these distortions. This paper contains a
mathematical model developed to calculate the surface heat flux as input data for FEM simulation. In
comparison to former publications, this paper deals not only with single results, but rather with an
overview of the results of the past two years. |
| A General Approach to Simulating Workpiece Vibrations during Five-Axis Milling of Turbine Blades |
| D. Biermann (2), P. Kersting, T. Surmann |
| STC C, 59/1/2010, P.125 |
| Keywords: Milling, Simulation, Chatter |
|
Abstract : Workpiece vibrations have a significant influence on the machining process and on the quality of the
resulting workpiece surface, particularly when milling thin-walled components. In this paper a
simulation system, consisting of an FE model of the workpiece coupled with a geometric milling
simulation for computing regenerative workpiece vibrations during the five-axis milling process, is
presented. Additionally, a modeling method for visualizing the resulting surface is described. In order to
validate the simulation model, turbine blades were machined and the experimental results were
compared to the simulation results. |
| Extrusion-like Chip Formation Mechanism and Its Role in Suppressing Void Nucleation |
| K.S. Woon, M. Rahman (1) |
| STC C, 59/1/2010, P.129 |
| Keywords: Micromachining, Mechanism, Tool edge radius |
|
Abstract : The mechanism of chip formation transforms from concentrated shearing to an extrusion-like behavior at
a critical combination of undeformed chip thickness and tool edge radius. Finite element analysis shows
that material is removed by severe deviatoric stress within the boundary of elastic–plastic deformation
during extrusion-like chip formation while this boundary is constantly redistributed to accommodate
chip growth. Simultaneously, the deformation region is contained within active compressive
components and hydrostatic pressure as chips are extruded. Under such operating conditions, void
nucleation is prevented according to the Le-Chateliers principle. Exceptional surface finish was produced
experimentally through the extrusion-like chip formation mechanism. |
| Microstructural and mechanical characteristics of recycled hard metals for cutting tools |
| M.G. Faga, R. Mattioda, L. Settineri (2) |
| STC C, 59/1/2010, P.133 |
| Keywords: Cutting tool, Carbide, Recycling |
|
Abstract : WC–Co-based materials are widely used for cutting tools, however, powders for the materials
preparation are rare and research is addressed to recycle worn materials. This paper presents a
comparison between recycled and traditionally prepared WC–Co-based materials for cutting tools.
Evaluation of efficiency in turning with application to 100Cr6, AISI 304 and Inconel 718 was considered,
using uncoated and PACVD coated tools. Results show that carbides produced via recycling presented
some residual porosity and larger grain size distribution, with different performance in cutting. Coating
minimises the differences in performance between recycled and traditional hard metal tools. |
| Surface Characteristics Generated in CNC Chip Breaking Tool Paths |
| S. Smith (1), J. McFarland, T. Assaid, D. Tursky, B. Barkman, E. Babelay |
| STC C, 59/1/2010, P.137 |
| Keywords: Turning, Surface, Modelling |
|
Abstract : One method for creating broken chips in turning processes involves oscillating the cutting tool in the feed
direction utilizing the CNC machine axes. Using computer simulations it is possible to combine the
motion of the axes with the geometry of the cutting tool to predict the surface characteristics, mapping
surface parameters for a wide range of chip breaking situations. These data allow the selection of chip
breaking cutting parameters to simultaneously ensure broken chips, and acceptable surface
characteristics. This paper describes the computational method, and presents results of comparison
for cutting tests using single axis, linear taper and outer contouring motions. |
| An Experimental Evaluation of Graphite Nanoplatelet Based Lubricant in Micro Milling |
| A. Marcon, S.N. Melkote, K. Kalaitzidou, D. DeBra (1) |
| STC C, 59/1/2010, P.141 |
| Keywords: Micromachining, Lubrication, Graphite nanoplatelet |
|
Abstract : Micro-milling is characterized by significant frictional interaction between the tool and workpiece,
leading to relatively short tool life. This paper evaluates a graphite nanoplatelet based cutting fluid
specifically developed to reduce friction and associated heat generation at the tool-workpiece interfaces
in micro-milling. The results of micro-slot milling experiments on H13 tool steel (50 HRc) with and
without graphite lubrication are presented. In particular, cutting forces, slot depth, and surface finish
obtained under different lubrication conditions are compared and discussed. Possible explanations for
the experimental observations are given. |
| Simulation-based twist drill design and geometry optimization |
| E. Abele (2), M. Fujara |
| STC C, 59/1/2010, P.145 |
| Keywords: Drilling, Tool geometry, Optimization |
|
Abstract : Designing a high-performance twist drill is difficult due to the complex relationship between drill geometry
and numerous and conflicting design goals. Earlier approaches of computer-aided twist drill design are
limited to only few design aspects. This article presents anewholistic method of using computing power for
twist drill design and optimization. A complete drill geometry model is used to obtain drill performance
characteristics and to ensure functional capability. Numerical simulation models calculate structural
stiffness and strength, torque and thrust force, coolant flow resistance, chip evacuation capability and chip
flute grindability. A multi-objective geometry optimization is realized by implementing metaheuristic
optimization algorithms. As a result, a numerical overall optimization of twist drill performance is possible. |
| Process Mechanics and Surface Integrity by High-Speed Dry Milling of Biodegradable Magnesium-Calcium Implant Alloys |
| Y.B. Guo, M. Salahshoor / W.A. Knight (1) |
| STC C, 59/1/2010, P.151 |
| Keywords: Cutting, Surface integrity, Biomedical |
|
Abstract : Compared to conventional metallic implant materials, biodegradable Mg–Ca alloys are attractive
orthopedic biomaterials that avoid negative stress shielding and revision surgeries. However, the process
mechanics and surface integrity by high-speed dry milling Mg–Ca0.8 are poorly understood. Key findings
of the synergistic experimental and numerical study are: (a) Mg–Ca0.8 alloy is sensitive to strain rate and
adiabatic softening; (b) high-speed dry milling can be safely performed using PCD tools with process
characteristics of lamella structured chips and slight flank build-up; and (c) machined surface integrity is
characterized by low roughness, highly compressive residual stress, increased microhardness, and
microstructure without phase changes. |
STC Dn |
| RFBS: A model for knowledge representation of Conceptual Design |
| F. Christophe, A. Bernard (1), E. Coatanea |
| STC Dn, 59/1/2010, P.155 |
| Keywords: Design method, Modelling, Knowledge based system |
|
Abstract : Conceptual design has been broken down into sub-processes and elementary tasks in methodologies.
These methodologies proposed suggest their systematic application. This paper assumes the possible
execution of these tasks automatically. Nevertheless, it is necessary for computers to integrate the
knowledge required during the conceptual design process. Knowledge models have been proposed, for
instance Geros Function–Behaviour–Structure (FBS) model for design. This paper presents the
integration of methodologies with a model of knowledge for conceptual design in accordance with
model-driven engineering. Our proposition extends the FBS model and presents its practical
implementation through ontology and language such as SysML. |
| Design of a 4-DOF hybrid PKM module for large structural component assembly |
| T. Huang (2), P.F. Wang, X.M. Zhao, D.G. Chetwynd |
| STC Dn, 59/1/2010, P.159 |
| Keywords: Parallel kinematic machines, Virtual prototype design, Assembly |
|
Abstract : This paper presents a novel 4-DOF hybrid parallel kinematic machine (PKM), named Bicept, comprising a
2-DOF parallel mechanism plus a 2-DOF rotating head. The PKM is designed as a rigid yet compact
module that can act as a robot cellmoving along a long track for aircraft structural component assembly, a
wing box for example. Dimensional synthesis of the 2-DOF parallel mechanism is carried out to achieve a
relatively good kinematic performance within a prescribed task workspace that has a large width/height
ratio. Then, using commercial CAE software, rigid body dynamics and stiffness analyses are carried out for
motor sizing and performance evaluation of a full-size virtual prototype. |
| Two Design Problems Identified in Consumer Product Recalls: Degradation over Extended Use and Scarce FR-Coupling |
| M. Nakao (2), T. Miyamura, K. Tsuchiya, K. Iino |
| STC Dn, 59/1/2010, P.163 |
| Keywords: Design, Failure, Axiomatic |
|
Abstract : One hundred recalls of consumer products, e.g., home electronics, in the Japanese market identified two
design problems; aging degradation causing failure to meet functional requirements (FR) over extended
use and scarce FR-coupling failure that affect meeting other FRs. The former was found in 22% of the
recalls with products used over 10 years. The designer could not foresee the long-term degradation in
plastic or insulator. The latter contributed to 66% with an extremely low failure rate of less than 0.01% of
all production. Rare design error affected by secondary FRs like cooling or friction is another hard-tonotice
factor for designers. |
| A Pipe Route Design methodology by Imitating Human Imaginal Thinking |
| Y.H. Yin, C. Zhou, J.Y. Zhu (1) |
| STC Dn, 59/1/2010, P.167 |
| Keywords: Design methodology, Artificial intelligence, Human imaginal thinking |
|
Abstract : Pipe system design like aero-engine, not only a typical NP-hard problem in limited 3D space, must also
extraordinarily depend on human experience. This paper presents a methodology for designing compact
pipe systems by fully imitating humans imaginal thinking based on image. The feasible workspace is
represented as images of the holistic layout of pipes on the basis of human experience. The improved
visible graph imitating human pipe-routing behaviour is conducted to form possible edge sequence tree.
Moreover, the global optimal pipe path is generated from the tree. The simulation demonstrated the
effectiveness of the pipe route design methodology. |
| A Systems Architecting Tool for Mechatronic Systems Design |
| H. Komoto, T. Tomiyama (1) |
| STC Dn, 59/1/2010, P.171 |
| Keywords: Computer aided design, Product development, System architecting |
|
Abstract : System architecting in mechatronic systems design is a crucial task to define physical and logical
configurations of subsystems and components that realize desired functions and behaviors. Particularly,
it is crucial to consider sensor–actuator configurations that control the quality of desired functions. The
paper proposes a computer-based tool based on extended Function-Behavior-State (FBS) modeling
method that incorporates visualization of geometric information and introduction of an intervaltemporal
logic. These extensions allow system architects to communicate with experts in different
domains and domain experts to conduct domain specific design tasks without having quantitative design
information about physical configuration. |
| Design for Mass Personalization |
| M.M. Tseng (1), R.J. Jiao, C. Wang |
| STC Dn, 59/1/2010, P.175 |
| Keywords: Design, Product development, Personalization |
|
Abstract : With pervasive connectivity of the Internet, personalization has become increasingly accepted for digital
products. As opposed to customization, which emphasizes on meetings explicit requirements of defined
market segments, personalization aims at effectively and efficiently satisfying individual needs. By
considering customers as individuals, implicit characteristics such as personal taste, traits, innate needs
and experience become important integral parts of product design. This new dimension for design opens
up many new research issues. Design for mass personalization (DFMP) aims at effectively and efficiently
satisfying customers as individuals by offering personally unique products with positive user experience.
To this end, design is approached through the formulation of a product ecosystem based on a design
platform and active customer participation. |
| Towards Hybrid Modelling Environments - Merging Desktop-CAD and Virtual Reality-Technologies |
| R. Stark, J.H. Israel, T. Wöhler / F.L. Krause (1) |
| STC Dn, 59/1/2010, P.179 |
| Keywords: Modelling, Virtual reality, Human–computer interaction |
|
Abstract : Immersive virtual environments are a important technology within the overall toolset of virtual product
creation [1]. Immersive modelling systems which allow for creating productmodels receive interest from
both academic research and industry [2–4]. This paper describes three empirical studies on immersive
modelling techniques conducted with 52 industrial designers, engineers and design students. Based on
the results of these studies, a methodology for hybrid modelling environments is introduced and
exemplified. This methodology enables designers and engineers to solve spatial, interactive and creative
design tasks in immersive, collaborative environments while maintaining CAD modelling as a familiar
design method. |
| An Energy Factor Based Systematic Approach to Energy-Saving Product Design |
| H.C. Zhang (2), H. Li |
| STC Dn, 59/1/2010, P.183 |
| Keywords: Lifecycle, Design, Energy-saving |
|
Abstract : In order to reach to an energy-saving product design, this paper presents a mathematic energy model to
calculate the total energy consumption within entire product lifecycle. Energy factor is the essential
coefficient of this model to represent the energy consumption throughout the entire product lifecycle,
including raw material extraction, manufacturing, assembly, use, disassembly, and recycling. With an
aim to create a systematic approach to energy-saving product design, the authors integrate the axiomatic
design and modularity design theories with energy factor, and the energy factor is eventually optimized
together with other major design factors in a multiple objective decision making model. |
| Design and modelling of a passive wireless pressure sensor |
| J. Zhai, T.V. How, B. Hon (1) |
| STC Dn, 59/1/2010, P.187 |
| Keywords: Sensor, Design, Miniaturization |
|
Abstract : This investigation is concerned with the design and modelling of a passive wireless pressure sensor to
detect blood pressure inside an abdominal aortic aneurysm sac after endovascular repair of the
aneurysm. The sensor consists of a coil and a capacitor to form an inductor–capacitor (LC) resonant circuit
which oscillates electrically at its resonant frequency. This miniature sensor has a size of 6
mm 6mm 1 mm and can be fabricated by microelectromechanical system (MEMS) technology.
By activating the sensor with an electromagnetic field, aneurysm sac pressure information can be
acquired. The properties and behaviour of this sensor based on computer simulation are also presented in
this paper. |
| Method for Supporting Conflict Resolution for Efficient PSS Development |
| Y. Shimomura (2), T. Hara |
| STC Dn, 59/1/2010, P.191 |
| Keywords: Design, CAD, Service |
|
Abstract : A method is proposed to enable service designers to identify existing conflicts in design solutions and to
develop basic strategies to solve them. For this purpose, two different approaches for detecting conflicts
are introduced: one entails the use of lexical expressions of functions, and the other involves the ranges of
design parameters. In the remainder of this paper, the authors describe a detailed process to identify
conflicts in design solutions and to develop strategies for resolving them by applying the proposed
methods in an actual service case. The proposed method is expected to lead to an improvement in the
efficiency of PSS development. |
| A Robust Design Approach to Determination of Tolerances of Mechanical Products |
| J. Zhang, S.P. Li, N.S. Bao, G.J. Zhang, D.Y. Xue, P.H. Gu (1) |
| STC Dn, 59/1/2010, P.195 |
| Keywords: Product design, Robust design, Tolerance design |
|
Abstract : Tolerance specifications of design parameters influence both functional performance and manufacturing
cost of products. Product functional performance is usually affected by uncertainties of design
parameters, robust design can make product functional performance insensitive to those uncertainties.
Based on the robust design method and the cost-tolerance models, a mathematical model has been
developed for describing the relationships among functional performance, manufacturing costs, design
parameters and tolerances. A new robust optimization method has also been developed to determine
tolerances and design parameters simultaneously. This new approach has been used for determining
design parameters and tolerances of a coating head of printing machinery. |
STC E |
| Sequential laser and mechanical micro-drilling of Ni super-alloy for aerospace application |
| M.M. Okasha, P.T. Mativenga, N. Driver, L. Li (1) |
| STC E, 59/1/2010, P.199 |
| Keywords: Laser, Drilling, Hybrid machining |
|
Abstract : Laser percussion drilling is inherently associated with poor geometry and thermal defects. While
mechanical micro-drilling produces good quality holes, premature drill breakage often occurs and it is
difficult to drill holes at acute angles. This paper presents the feasibility and basic characteristics of a new
approach for micro-drilling In718 alloy sheets at an acute angle, using sequential laser and mechanical
drilling. The results demonstrate that sequential laser-mechanical micro-drilling alleviates the defects
associated with laser-drilled holes, reduces burr size and machining time and increases the tool life
compared with mechanical drilling. |
| Laser-Based Repair of Carbon Fiber Reinforced Plastics |
| F. Fischer, L. Romoli, R. Kling (3) / G. Dini (1) |
| STC E, 59/1/2010, P.203 |
| Keywords: Laser, Composite, Repair |
|
Abstract : The recent progress in laser system technology enables innovative techniques for machining of carbon
fiber reinforced plastics (CFRPs). A representative application is the layer-by-layer removal of damaged
composite material to provide a cavity for refilling with repair plies. Results show that it is possible to
achieve a reliable and automatable removal rate to perform arbitrary repair cavity geometries, obtaining
a relevant time-reduction with respect to the conventional manual grinding process. The combination of
modern UV-laser sources with a scanning technology enabling deflection speeds up to 2 m/s, suppresses
heat affected zones (HAZs) and detachment of fibers from the polymer matrix. Amethod for the selective
removal of surface matrix without damaging the fibers beneath is also presented. |
| Laser surface hardening of martensitic stainless steel hollow parts |
| G. Tani (3), A. Fortunato, A. Ascari, G. Campana / M. Santochi (1) |
| STC E, 59/1/2010, P.207 |
| Keywords: Surface hardening, Laser heat treatment, Stainless steel |
|
Abstract : This paper deals with numerical simulation and experimental validation of laser heat treatment of an
industrial axisymmetric hollow mechanical part by means of a strategy based on helical tracks. This
component,made of AISI 420B martensitic stainless steel, features a low wall thickness and, according to
this, it is not easily treatable by means of laser surface hardening. The work carried out was aimed at
demonstrating that numerical simulation allows a drastic reduction of the experimental activity and that
it makes possible to prove a very high sensitivity of the results to process parameters variation. |
| Direct Laser Deposition of Cu Alloy on forming tool surfaces - process window and mechanical properties |
| M. Schmidt (3), R. Kolleck (3), A. Grimm, R. Veit, K. Bartkowiak / M. Geiger (1) |
| STC E, 59/1/2010, P.211 |
| Keywords: Coating, Laser beam machining, Direct laser deposition |
|
Abstract : Direct laser deposition offers a widespread spectrum of applications. Creating functional surfaces for
forming tools is one of them where inexpensive material for the main tool body is complemented layer by
layer with a secondmaterial to tune the desired properties and shape. Investigations on coating mild tool
steel with copper alloy have been carried out to outline the chances and challenges in this cost effective
way of producing forming tools for processing stainless steels, e.g. 1.4301. This paper reports on
experimental investigations showing the influence of the absolute angle of the tool surface and the
relative angle between surface and laser beam/powder nozzle on the process window and the mechanical
properties that can be obtained. |
| Electro-erosion edge honing of cutting tools |
| N.Z. Yussefian, P. Koshy (2), S. Buchholz, F. Klocke (1) |
| STC E, 59/1/2010, P.215 |
| Keywords: Cutting edge, Sinking EDM, Edge preparation |
|
Abstract : Sink EDM of fine features necessitates the application of several tool electrodes to sequentially generate
the required geometry, due to the inevitable localized wear of the tool that rapidly rounds-off sharp
edges. Be that as it may, this phenomenon can be exploited to hone sharp edges of electrically conducting
cutting tools by sinking the cutting edge into an appropriate counterface material. This paper presents the
proof-of-concept and operating characteristics of this innovative process. Robust edge geometry
generation, and a significant improvement in the life of high speed steel tools consequent to such
preparation of the cutting edge are demonstrated. |
| Achieving High Accuracy and High Removal Rate in Micro EDM by Electrostatic Induction Feeding Method |
| T. Koyano, M. Kunieda (1) |
| STC E, 59/1/2010, P.219 |
| Keywords: Electrical discharge machining, Micromachining, Pulse generator |
|
Abstract : With conventional relaxation pulse generators used in micro-electrical discharge machining, due to the
difficulty in keeping the minimum necessary discharge interval between pulse discharges, localized
discharge and abnormal arc occur frequently. In contrast, with the newly developed electrostatic
induction feeding method, only a single discharge occurs for each cycle of the periodic pulse voltage. As
this realizes sufficient cooling of the discharge gap between pulses, thermal stress on the machined
surface is less and duty factors can be increased, resulting in higher accuracy and machining speed
compared to the relaxation pulse generator. |
| Development of an operations evaluation system for sinking EDM |
| B. Lauwers (1), H. Oosterling (3), W. Vanderauwera |
| STC E, 59/1/2010, P.223 |
| Keywords: Sinking EDM, Evaluation, Time estimation |
|
Abstract : This paper describes the development and validation of an operations evaluation system for sinking EDM
operations. Based on a given workpiece geometry (e.g. mould), regions to be EDMed are automatically
indentified. For a given electrode configuration, consisting of one or more regions, EDMmachining times
are calculated, making a proper process planning possible. The EDM time calculation is based on
reference values formachining timeswhich are then corrected for changes in the electrode geometry and
generator settings. The developed system has been validated, proving a better and more accurate
machining time estimation. |
| Special wire guide for on-machine wire electrical discharge dressing of metal bonded grinding wheels |
| E. Weingärtner, S. Jaumann, F. Kuster (3), M. Boccadoro (3) / D. Dauw (1) |
| STC E, 59/1/2010, P.227 |
| Keywords: Wire EDM, Dressing, Grinding |
|
Abstract : To improve accuracy in wire electrical discharge dressing (WEDD), special attention should be given to
wire vibration. In this work, the use of a specially designed wire guide is proposed, which is responsible
for both ensuring the stability of the wire and improving the efficiency of dielectric delivery to the
dressing zone. For carrying out experiments with metal bonded diamond grinding wheels, a WEDDdevice
was designed, manufactured and integrated into a grinding machine. High erosion material
removal rates and dressing accuracy were achieved, thus demonstrating the feasibility and efficient
performance of this in situ dressing process. |
| Evaluations of Spark Distribution and Wire Vibration in Wire EDM by High-speed Observation |
| A. Okada (2), Y. Uno, M. Nakazawa, Y. Yamauchi |
| STC E, 59/1/2010, P.231 |
| Keywords: Wire EDM, Analysis, Spark location |
|
Abstract : In fine wire EDM using thin wire electrode, uniform distribution of spark location is necessary to achieve
stable machining performance. However, it is difficult to precisely evaluate the distribution of spark
location by the conventional branched electric current method when the workpiece is thin. A new
evaluation method by using a high-speed video camera is proposed. The locations of spark are measured
by analyzing the recorded images. Then the effects ofmachining parameters, such as servo voltage, pulse
interval time, wire running speed and others on the distribution of spark location are investigated. The
possibility of evaluating the wire vibration is also discussed. |
| Wire Electro Discharge Trueing and Dressing of Fine Grinding Wheels |
| A. Klink / F. KLocke (1) |
| STC E, 59/1/2010, P.235 |
| Keywords: Electrical discharge machining (EDM), Dressing, Trueing |
|
Abstract : In this paper fundamental investigations are presented regarding the capabilities of Wire-EDM for
trueing and dressing of fine grained metal bonded diamond grinding wheels. These wheels are often used
for precision grinding operations of hard and brittle mould materials like ceramics or cemented carbides.
They are characterised by high profile constancies and wear resistances. Due to the electrical conductivity
of the bond material, Wire-EDM offers an efficient and powerful alternative to conventional trueing and
dressing. Achievable grit protrusion and possible thermal damage to smallest diamond grits are
theoretically and experimentally examined. Additionally, machining strategies for high profile accuracy
are presented. |
| Electrochemical drilling of multiple holes with electrolyte-extraction |
| D. Zhu (1), W. Wang, X.L. Fang, N.S. Qu, Z.Y. Xu |
| STC E, 59/1/2010, P.239 |
| Keywords: Electro chemical machining (ECM), Flow, Hole |
|
Abstract : This paper proposes an electrochemical drillingmethod of multiple holes in which the reverse electrolyte
flow is achieved in the way of electrolyte-extraction, instead of traditional forward electrolyte flow which
often causes poor electrolyte flow condition and so unstable machining process. The combining manifold
is optimized to equalize electrolyte flow rate in each electrode tube. Furthermore, wedge-shaped
electrode tubes are adopted in order to distribute the electrolyte flow more uniformly while holes with
inclination angles are processed. By the proposed technique, multiple holes with diameter of 1–2 mm
and aspect ratios of 2 have been produced with good quality and efficiency. |
| Modelling of the electrochemical machining process by the boundary element method |
| J. Pattavanitch, S. Hinduja (1), J. Atkinson |
| STC E, 59/1/2010, P.243 |
| Keywords: ECM, Milling, Boundary element method |
|
Abstract : This paper describes the development and application of the boundary element method to model the
machining of simple milling and turning features. The 3D model uses linear triangular elements to
discretise the workpiece and tool surfaces. Highlights of the program include the use of analytical
integration to calculate the element matrices rather than numerical, and the automatic refinement of the
mesh as the workpiece is progressively machined. The program has been tested for milling slots using a
rectangular tool and for turning a thin-walled tube. It is shown that there is good agreement between the
predicted and experimental results. |
| Quantitative Analysis of a Chemical Treatment to Reduce Roughness of Parts Fabricated Using Fused Deposition Modeling |
| L.M. Galantucci (1), F. Lavecchia, G. Percoco |
| STC E, 59/1/2010, P.247 |
| Keywords: Fused deposition modeling, Finishing, Mechanical behavior |
|
Abstract : The surface finish of Fused Deposition Modeled (FDM) parts can be improved by performing chemical
dipping based on immersion in a dimethylketone–water solution.
The authors aim to gain a more in-depth knowledge of this process, by analyzing and comparing the
mechanical properties and the surface quality of treated and untreated FDM parts. Tensile and bending
mechanical properties have been investigated by designing and performing four Central Composite
Designs (CCDs) of experiments, totalizing about two-hundred tests. The results have been verified by
testing an FDM marine turbine blade employed to generate energy. |
| Mechanisms and processing limits in laser thermochemical machining |
| A. Stephen, F. Vollertsen (1) |
| STC E, 59/1/2010, P.251 |
| Keywords: Laser, Etching, Mechanism |
|
Abstract : Metallic microparts can be produced with high quality by laser thermochemical machining when the
etching liquid is injected coaxially to the laser beam directly into the irradiated area. The basic
mechanisms and limits of the process are described. It is shown that the reaction is temperature driven
independent of the laser wavelength. A limiting factor is the diffusion of the anions identified by
comparing experimentally determined and calculated diffusion coefficients for the reaction products.
The machining quality with respect to aspect ratio, edge radius and roughness can be enhanced by
increasing the velocity of the etching liquid. |
| An Experimental Evaluation of an Etching Simulation Model for Photochemical Machining |
| A. Bruzzone (2), A.P. Reverberi |
| STC E, 59/1/2010, P.255 |
| Keywords: Etching, Surface, Simulation |
|
Abstract : Photochemical machining can satisfy the large demand coming from the microproducts market. The
metal etching technologies lack however a precise control over the micro-geometry of surfaces. Metal
etching results from diffusive and kinetic phenomena whose relative importance depends on process
parameters. The effects of the chemical kinetics on the etching regime and, consequently, on the surface
generated by wet-chemical etching need a thorough investigation. This paper reports an experimental
assessment of a 2D simulation model of etching, where also the role of reaction products dynamics is
considered. Furthermore an experimental analysis of the process parameters on micro-geometry is
reported. |
| Prevention of hillock formation during micro-machining of silicon by using OTS-SAM and SiO2 coatings |
| T.S. Oh, H.J. Kim, D.E. Kim / D.Y. Yang (1) |
| STC E, 59/1/2010, P.259 |
| Keywords: Micro-machining, Silicon, OTS-SAM |
|
Abstract : The feasibility of using a dual coating system consisting of SiO2 and OTS-SAM thin films on the micromachining
characteristics of silicon wafer were investigated with the aim to eliminate the formation of
undesirable hillocks. The outermost OTS-SAM coating was used as a sacrificial layer to pattern the SiO2
film, which in turn served to pattern the silicon substrate. After selectively removing the OTS-SAM
coating by micro-machining, HF and KOH chemical etching processes followed to remove the SiO2 layer
and create patterns on the silicon substrate. By this process, groove patterns of about 1 mm width could
be successfully fabricated on a silicon wafer without the formation of undesirable hillocks. |
| Submicron imprint of trench structures by external and intrinsic electromagnetic force |
| H. Hocheng, T.T. Wen / G. Sohlenius (1) |
| STC E, 59/1/2010, P.263 |
| Keywords: Nano manufacturing, Miniaturization, Submicron imprint |
|
Abstract : This paper describes a novel method for replication of submicron trench features by intrinsic
electromagnetic imprinting force derived from the material made by mixing nanosize ferrite
powders into ultraviolet-curable polymer, leading to the advantages of good uniformity and reduced
structural deformation compared to mechanical nanoimprint methods. The features are fabricated to
0.5 mm wide and 0.2 mm high under the ultraviolet curing of 480 mJ/cm2, imprinting cycle time of
30 s and pressure as low as 0.92 kgf/cm2. The imprinting technique possesses the potential for
fabrication of submicron magnetic features at room temperature across large area with high
production rate and good pattern fidelity. |
STC F |
| Increased Total Flexibility by 3D Servo Presses |
| P. Groche (2), M. Scheitza, M. Kraft, S. Schmitt |
| STC F, 59/1/2010, P.267 |
| Keywords: Press, Flexibility, Manufacturing |
|
Abstract : It is widely accepted that uncertainties influencing product costs and quality can be overcome by an
increased manufacturing flexibility. Several approaches for flexible manufacturing machines and
processes are known from literature. So far forming machines which enable high process flexibility have
not been discussed thoroughly. In this paper, recent developments in the field of servo press technology
are described and discussed under this aspect. Special attention is paid to the recent development of a 3D
Servo Press concept which opens new horizons for flexible forming machines. |
| A new fixture for FSW processes of Titanium alloys |
| L. Fratini (2), F. Micari (1), G. Buffa, V.F. Ruisi |
| STC F, 59/1/2010, P.271 |
| Keywords: Friction Stir Welding, Titanium, Microstructure |
|
Abstract : FSW of titanium alloys is nowadays one of the most challenging welding operations, even with a solid
state process, due to the thermo-mechanical and thermo-chemical characteristics of suchmaterials. Due
to the relevant application of titanium alloys in the aeronautic and aerospace industries, in the recent
years few attempts were carried out to develop FSW processes aimed to maximize the mechanical
performances of the welded parts. In the paper a new fixture is presented allowing obtaining effective
FSW joints of titanium blanks, which were investigated through mechanical and metallurgical tests
highlighting the peculiarities of FSW of titanium alloys. |
| Reduction of vibrations in blanking by MR dampers |
| A. Ghiotti, P. Regazzo, S. Bruschi (2), P.F. Bariani (1) |
| STC F, 59/1/2010, P.275 |
| Keywords: Sheet metal forming, Blanking, Vibration |
|
Abstract : The break through shock during sheet metal blanking operations generates uncontrolled high reverse
loads, mechanical vibrations and loud noise that may cause problems such as fatigue cracks in the press
components, premature wear in tooling and great discomfort for press operators.
In this paper, the application of magneto-rheological (MR) dampers to reduce the shock response of
press systems is considered with the aim of evaluating, through full-scale experiments, feasibility and
practicability of their implementation and understanding the potential benefits in comparison with
conventional dampers. |
| Finite element analysis of the effect of blanked edge quality upon stretch flanging of AHSS |
| P. Sartkulvanich, B. Kroenauer, R. Golle, A. Konieczny, T. Altan (1) |
| STC F, 59/1/2010, P.279 |
| Keywords: Piecing, Hole expansion, High-strength steel |
|
Abstract : Elimination of edge cracking is one of the major challenges in flanging of advanced high-strength steels
(AHSS). Several studies show that edge cracking occurs at lower strains than those predicted by the
forming limit curves (FLC) and it is influenced significantly by the sheared or blanked edge quality. This
study focuses on FEM modeling and experiments on blanking and hole expansion of AHSS DP590. The
FEM model of blanking was developed to characterize the edge quality for different punch/die clearances.
Hole expansion was simulated to demonstrate the effect of sheared edge upon stretchability. Thus, it was
possible to demonstrate how metal flow, strains and stresses in blanking affect the part quality and
potential edge cracking in stretch flanging. |
| Experimental investigation of the cutting force reduction during the blanking operation of AHSS sheet materials |
| A. Mackensen , M. Golle, R. Golle, H. Hoffmann (2) |
| STC F, 59/1/2010, P.283 |
| Keywords: Sheet metal, Cutting, Force measurement |
|
Abstract : Within the manufacturing process of sheet metals, blanking represents an essential process
operation. As the industrial application of high-strength multi-phase steels grows, the blanking
process must consider high blanking and shear forces which are characteristic of these materials. This
paper presents possibilities for reducing these forces. Experiments were performed utilizing a novel
tool concept which can correlate necessary blanking forces to the punch stroke in three dimensions
and in direct force path. Results from three different AHSS materials are presented showing the
variation of decisive blanking parameters such as clearance, shearing angle and sheet positioning
angle. |
| Enhancement of Bending Formability of Brittle Sheet Metal in Multilayer Metallic Sheets |
| J. Yanagimoto (2), T. Oya, S. Kawanishi, N. Tiesler, T. Koseki |
| STC F, 59/1/2010, P.287 |
| Keywords: Sheet metal forming, Multilayer metallic sheet, Enhanced formability |
|
Abstract : The formability of multilayer metallic sheets is evaluated by tensile, V-bending, hat bending and
hemming tests. A monolithic type-420J2 stainless-steel sheet cannot be formed because of poor
elongation as small as 1.7%. Marked enhancement of the bending formability was observed in the
bending of type-420J2 stainless-steel sheets when they are layered by type-304 stainless-steel sheets and
composed into a multilayer metallic sheet. The mechanism of the enhancement of the formability of
type-420J2 stainless steel in a multilayer metallic sheet is investigated analytically by focusing on the
delay of the initiation of necking, and by performing stress analysis by finite element method (FEM). |
| Tailor die quenching in hot stamping for producing ultra high strength steel formed parts having strength distribution |
| K.I. Mori (2), Y. Okuda |
| STC F, 59/1/2010, P.291 |
| Keywords: Hot stamping, Sheet metal, Quenchable steel |
|
Abstract : Tailor die quenching in the hot stamping of quenchable steel sheets was developed to produce ultra-high
strength steel formed parts having strength distribution. Local portions of the heated sheet were
quenched by holding grooved tools at the bottom dead centre during the stamping. Non-contact portions
were generated in the sheet by grooving the tools, and thus the strength in the contact portions is high
owing to the quenching and that in the non-contact portions is low owing to the lack of the quenching.
Hat-shaped products having a tensile strength of approximately 1.5 GPa only at four corners were
formed. |
| Time dependent determination of forming limit diagrams |
| M. Merklein (2), A. Kuppert, M. Geiger (1) |
| STC F, 59/1/2010, P.295 |
| Keywords: Forming, Sheet metal, Failure criterion |
|
Abstract : The forming limit diagram (FLD) is a convenient tool for classification of sheet metals formability in the
finite element analysis as well as in the press shop. The FLD indicates the maximum strain values which
can be applied on a material without failure as a function of the strain condition. In contrast to the
standardized evaluation method described in the standard ISO 12004-2 a new time dependent analysis
method is presented. Using a regression analysis the onset of necking can be detected automatically
independent of the strain state. Results will be presented and discussed in contrast to the existing
standard procedure. |
| Effect of current density and zinc content during electrical-assisted forming of copper alloys |
| C.M. Dzialo, M.S. Siopis, B.L. Kinsey, K.J. Weinmann (1) |
| STC F, 59/1/2010, P.299 |
| Keywords: Forming, Deformation, Material properties |
|
Abstract : Electrical-assisted forming (EAF), where current is directly applied to the workpiece during deformation,
has been shown to dramatically reduce the flow stress of the material. In this paper, the effect of altering
the Zn content in Cu specimens during EAF is investigated. Varying results were observed depending on if
the threshold density, which produces significant reductions in flow stress, was surpassed. Thus,
temperature increases due to resistive heating alone are not the cause of the observed effects. Once the
threshold current is exceeded, the flow stress reductions increased with increasing Zn content. These
results support theories regarding the physical mechanism of EAF as dislocations are able to move past
alloying elements more effectively. |
| Experimental and numerical investigation of grid sheet bending behaviour in four-roll bending |
| X. Gu, M. Franzke, M. Bambach, G. Hirt (2) |
| STC F, 59/1/2010, P.303 |
| Keywords: Bending, Simulation, Sandwich material |
|
Abstract : Grid sheet is a sandwichmaterial consisting of two metal face sheets and a core of woven wire mesh that
are joined by welding. It has been designed to act as an actively cooled heat shield, e.g. for steam turbine
casings. For this purpose, cylindrical parts have to be produced from initially flat grid sheet. This paper
focuses on four-roll bending of grid sheet. It is shown that springback and the number of failed spot welds
after forming can be reduced by stress relief annealing and appropriate forming conditions. A finite
element model of roll bending of grid sheet is presented, which has been set up to predict springback and
spot weld failure. |
| Twist Revisited: Twist Phenomena in Single Point Incremental Forming |
| J.R. Duflou (2), H. Vanhove, J. Verbert, J. Gu, I. Vasilakos, P. Eyckens |
| STC F, 59/1/2010, P.307 |
| Keywords: Incremental sheet forming, Deformation, Twist |
|
Abstract : Twist phenomena in incrementally formed parts have been observed both in the domain of single and
two point incremental forming. In the reported experiments the resulting twist direction typically
corresponds to the toolpath direction and can be explained by the monotonous tangential force
component exerted on the workpiece when using unidirectional toolpaths. When processing parts with
high drawing angles, however, twist deformations corresponding to in-plane shear in opposite toolpath
direction have been observed by the authors. In this paper this phenomenon is documented and
explained by means of strain measurements and FEA results. The role of asymmetric, cumulative,
extended strain effects, resulting in severe thinning, and reinforced when stiff, semi-vertical rib features
are present in the part geometry, is demonstrated by means of a detailed deformation analysis. |
| Single Point Incremental Forming at High Feed Rates and Rotational Speeds: Surface and Structural Consequences |
| K. Hamilton, J. Jeswiet (1) |
| STC F, 59/1/2010, P.311 |
| Keywords: Incremental sheet forming, Roughness, Speed |
|
Abstract : Effects of forming at high feed rates and tool rotational speeds were studied and analyzed in single point
incremental forming (SPIF). Parts formed were examined on the following criteria: external non-contact
surface roughness (orange peel effect), thickness distribution and sectional microstructure. Ra and Rz
roughness and forming parameterswere used to create models for an equivalent combinatory roughness
which characterizes orange peel roughening. Equivalent roughness shows strong sensitivity to a defined
shape factor and the forming step size. Effective roughness ranges are established with conditions for
which they valid. Thickness distribution and grain structure remains similar to lower speed forming. |
| The New TSS Bending Process: 3D Bending of Profiles with Arbitrary Cross-Sections |
| S. Chatti , M. Hermes, E.A. Tekkaya (1), M. Kleiner (1) |
| STC F, 59/1/2010, P.315 |
| Keywords: Bending, Machine, Torque Superposed Spatial (TSS) |
|
Abstract : A new roll-based process and machine for three-dimensional bending of profiles with symmetrical and
asymmetrical cross-sections have been developed. Compared to conventional processes like stretch
bending, the advantage of the Torque Superposed Spatial (TSS) bending is the kinematic adjustment of
the bending contour, leading to higher flexibility and cost efficiency, especially in small batch production.
To define the spatial geometry of the workpiece, a torque is superposed to the bending moment. Results
of the analytical and numerical investigations concerning the mechanics of deformation and the machine
parameters of the new process are presented. |
| Optimal design of manufacturing chain based on forging for copper alloys, with product properties being the objective function |
| M. Pietrzyk (2), L. Madej, R. Kuziak |
| STC F, 59/1/2010, P.319 |
| Keywords: Die forging, Optimisation, Microstructure |
|
Abstract : The design of manufacturing copper alloys is the objective of the paper. The whole manufacturing chain
based on forging is considered. Plastometric tests with various preheating schedules were performed,
and rheological models dependent on the material structure were developed. Various manufacturing
sequences were considered next. Numerical simulations were performed using CAFE model, and a
production schedule, which allows achievement of the required properties and minimum tool wear, was
selected. Industrial experiments were performed and the designed technology was validated.
Experimental results confirmed correctness of the developed technology. |
STC G |
| Chemo-Mechanical Magneto-Rheological Finishing (CMMRF) of Silicon for Microelectronics Applications |
| V.K. Jain, P. Ranjan, V.K. Suri, R. Komanduri (1) |
| STC G, 59/1/2010, P.323 |
| Keywords: Non-traditional machining, Chemical mechanical planarization (CMP), Magneto-rheological finishing (MRF) |
|
Abstract : A new finishing process, namely, chemo-mechanical magneto-rheological finishing (CMMRF) was
developed for polishing silicon blanks that combines the beneficial features of chemical mechanical
polishing (CMP) and magneto-rheological finishing (MRF) without the detrimental effects of either
process involved. Chemical reactions associated with CMP are used to enhance the finish quality while
the magneto-rheological polishing fluid is used to control the magnitude of the forces acting on the
workpiece that controls the material removal rates (MRR) andminimizes the surface integrity problems.
An apparatus for CMMRF was designed and built for nanometric finishing of silicon substrates. This
process is able to finish silicon blanks with nanometric finish, minimal surface defects, and higher
removal rates. |
| Scratching by Pad Asperities in Chemical-Mechanical Polishing |
| N. Saka, T. Eusner, J.H. Chun (1) |
| STC G, 59/1/2010, P.329 |
| Keywords: Defect, Polishing, Semiconductor |
|
Abstract : In the fabrication of micro- and nano-scale semiconductor devices and electromechanical systems, the
chemical–mechanical polishing (CMP) process is extensively employed. During the CMP process,
undesirable scratches are produced on metal-interconnect and low-k-dielectric surfaces by the softer pad
asperities. This paper presents contact mechanics models for the initiation of scratching in terms of the
pad asperity geometry, the interfacial friction, and the mechanical properties of materials. Results of dry,
wet and lubricated experiments on Cu coatings qualitatively validate the theoreticalmodels. Tomitigate
scratching by pad asperities during CMP, the developed models suggest that the friction coefficient be
kept below 0.2. |
| Hybrid polishing mechanism of single crystal SiC using mixed abrasive slurry (MAS) |
| H.S. Lee, D.I. Kim, J.H. An, H.J. Lee, K.H. Kim, H. Jeong (2) |
| STC G, 59/1/2010, P.333 |
| Keywords: Silicon carbide (SiC), Polishing, Mechanism |
|
Abstract : Single crystal SiC is a mechanically hard and chemically inert material used in optical and power devices.
This work proposes the development of a hybrid polishing technique using a mixed abrasive slurry (MAS)
with colloidal silica and nano-diamond. Hybrid removal mechanism of the MAS on the SiC is investigated
by polishing results, chemical analyses and AFM studies. Each role of two abrasives is distinguished by
scratching tests with AFM contact mode on the chemically reacted SiC surface. Finally, this paper
provides an optimum MAS condition to realize highly efficient material removal rate (MRR) keeping
defect-free surface. |
| Chemical Machining of the Zerodur Material with Atmospheric Pressure Plasma Jet |
| Y.X. Yao (2), B. Wang, H.L. Jin, Y.F. Zhang, S. Dong |
| STC G, 59/1/2010, P.337 |
| Keywords: Machining, Surface roughness, Atmospheric pressure plasma jet |
|
Abstract : The material of Zerodur is widely used in high performance optics because of its excellent thermal
stability characteristics. This paper deals with the development of an APPJ (Atmospheric Pressure Plasma
Jet) chemical machining process for defect free and high efficiency machining of Zerodur. The APPJ
chemical machining mechanism for multi-phase multi-composite materials is presented. The chemical
property of the plasma jet is investigated via the atom emission spectrum analysis method and the
experimental results of Zerodur material removal function and surface roughness variation with different
processing parameters are discussed. Scientific explanations for the experimental observations are given. |
| Geometrical modelling of abrasive waterjet footprints: a study for 90° jet impact angle |
| D. Axinte (2), D.S. Srinivasu, J. Billingham, M. Cooper |
| STC G, 59/1/2010, P.341 |
| Keywords: Waterjet machining, Modelling, Jet footprint |
|
Abstract : Modelling of abrasive waterjet footprints is of critical importance when aiming to generate
controlled freeform surfaces. The paper reports on a geometrical model of the jet footprint (kerf) in
maskless controlled-depth milling applications. The model firstly needs to find the material specific
erosion (etching) rate that is obtained from the jet footprint by taking the limiting conditions (high
jet feed rates) of the model. Once this is found, the jet footprint can be predicted accurately for any
jet feed speed. An example of model validation is presented for 908 jet impingement angle against a
SiC ceramic as target material. |
| Ultraprecison Finishing of Micro Aspheric Surface by Ultrasonic Two-Axis Vibration Assisted Polishing |
| H. Suzuki (2), S. Hamada, T. Okino, M. Kondo, Y. Yamagata, T. Higuchi |
| STC G, 59/1/2010, P.347 |
| Keywords: Polishing, Ultrasonic, Mold |
|
Abstract : Micro-glass lenses for digital cameras and blue laser DVD pick-up devices are generally molded by using
micro-aspheric ceramic molds made of tungsten carbides. These molds are finished by micro-polishing
using loose abrasives after grinding. Improvement to the accuracy of the molds is necessary, and high
numerical aperture (NA) optics with steep angles are required. In order to finish themolds of high NA, an
ultrasonic two-axis vibration assisted polishing machine with piezo-electric actuators was proposed and
developed. Some micro-aspheric molds made of binderless tungsten carbide were polished, and surface
roughness of 8 nm Rz was obtained. |
| Magnetic field assisted finishing for micropore X-ray focusing mirrors fabricated by deep reactive ion etching |
| H. Yamaguchi, R.E. Riveros, I. Mitsuishi, U. Takagi, Y. Ezoe, N. Yamasaki, K. Mitsuda, F. Hashimoto |
| STC G, 59/1/2010, P.351 |
| Keywords: Finishing, Polishing, Micromachining |
|
Abstract : A magnetic field-assisted finishing process has been studied for high-aspect-ratio ion-etched silicon
curvilinear micropore structures, which have potential application as mirrors for satellite-borne X-ray
telescopes. The micropore sidewalls act as X-ray focusingmirrors, and lead to reductions in the mass-toeffective-
area ratio of 10–1000 times, compared to traditional X-ray telescopes. This paper describes the
processing principle for the surface finishing of the sidewalls of micropore structures (10, 20 mm and
depth: 300 mm), and the feasibility of achieving roughness 4 nm rms and
improving the X-ray reflectivity of micropore sidewall surface are demonstrated. |
| An Experimental Study on a Novel Diamond Whisker Wheel |
| G.F. Zhang, B. Zhang (2), Z.H. Deng, Y.Q. Tan |
| STC G, 59/1/2010, P.355 |
| Keywords: Grinding, Aluminum, Whisker wheel |
|
Abstract : This study proposes a novel diamond whisker wheel for grinding of advanced materials. The wheel is
designed to have preferable spatial distributions and orientations of diamond whiskers which are
prepared using a laser cutting technique. To obtain desirable cutting edge geometries, the whisker edges
are formed on a lapping machine with diamond powders. The whisker wheel is used in a machining test
on a silicon carbide particulate reinforced aluminum alloy and compared with a tungsten carbidemilling
cutter. The whisker wheel grinding provides better surface finish and significantly reduced machining
force than for milling at the same material removal rate. |
| A Novel Dressing Technique for texturing of Ground Surfaces |
| J.F.G. Oliveira (1), A.C. Bottene, T.V. Franca |
| STC G, 59/1/2010, P.361 |
| Keywords: Dressing, Grinding Wheel, Texturing |
|
Abstract : This work presents a novel dressing technique that allows the inscription of pre-configurable patterns, or
textures, on the grinding wheel surface. An electro-mechanical exciter connected to the dressing tool
receives synchronized signal from a control software engraving patterns on the grinding wheel. The
dressing and grinding operations were evaluated using the AE mapping technique. The presented
applications show the use of textured grinding wheels for better grinding process performance in
conventional applications and also for the production of patterned surfaces in order to change its
functional performance. The results and analysis allow a better understanding of the grindingmechanism
with patterned wheels. With the application of the proposed method it was possible to inscribe different
patterns on workpieces and also to increase the grinding performance in conventional applications. |
STC M |
| Thermo-mechanical model of spindles |
| T. Holkup, H. Cao, P. Kolar, Y. Altintas (1), J. Zeleny (1) |
| STC M, 59/1/2010, P.365 |
| Keywords: Spindle, Temperature, Finite-Element method (FEM) |
|
Abstract : This paper presents a Finite-Element-method-based thermo-mechanical model of spindles with rolling
bearings. The heat generated in the bearings and the motor is transferred to the ambient air, the motor
coolant and the spindle structure, and causes thermal expansion of spindle parts. The experimentally
validated thermo-mechanical spindlemodel predictstemperature distribution and thermal growth, as well
as bearing stiffness and contact loads, under specified operating conditions. Transient changes in
temperatures, deformations, viscosity of the lubricant, and bearing stiffness are considered in the solution.
The predicted bearing properties are used to estimate the changes in the dynamic behavior of spindles. |
| A Comparative Study on the Spindle System Equipped with Synchronous and Induction Servo Motors for Heavy Duty Milling with Highly Stable Torque Control |
| Z. Wang, M. Soshi, K. Yamazaki (1) |
| STC M, 59/1/2010, P.369 |
| Keywords: Spindle, Dynamics, Heavy duty milling |
|
Abstract : In order to create a higher torque spindle system for productive milling operations, rotational speed
stability against the torque disturbance has been studied with respect to the spindle mechanical design
parameters, actuator types and spindle control algorithms. The study showed a remarkable difference in
the spindle rotational speed stability against torque disturbance between a spindle system equipped
with an induction servo motor and a permanent magnet synchronous servo motor. The results of this
study have been obtained by theoretical analysis, numerical simulation and physical experiments, and
the experimental study showed that the hybrid actuation spindle achieves longer tool life. |
| Control Design and Experimental Validation of an Adaptive Spindle Support for Enhanced Cutting Processes |
| R. Neugebauer (1), W.G. Drossel (3), A. Bucht, B. Kranz, K. Pagel |
| STC M, 59/1/2010, P.373 |
| Keywords: Piezo-electric, Control, Adaptive spindle |
|
Abstract : In this paper we present an adaptive spindle support that can be used for additional fine positioning
movements during machining operations. This is achieved by an overlaid piezo-based hexapodkinematic
structure that is mounted between the machine structure and the motor spindle. Here we
present the analysis of the spindle support regarding control aspects. The basis is a finite-elementmodel
that was used to determine a state space model of the component. The model was validated by
an experimental modal analysis of the structure. Knowing the modal characteristics allows an
analysis of the mechanical couplings between the different axes of the spindle support which
accordingly enables the design of a controller considering mechanical couplings. For experimental
validation the controller was implemented into a rapid prototyping system. The presented results
show that during cutting operations the spindle can be moved with high precision within a wide
range of frequencies. |
| Modelling of Angular Contact Ball Bearings and Axial Displacement for High Speed Spindles |
| J. Jedrzejewski (1), W. Kwasny |
| STC M, 59/1/2010, P.377 |
| Keywords: Bearing, Model, Spindle |
|
Abstract : This paper presentsmodelling ofmoving sleeve and spindle tip displacements in spindle bearing systems
equipped with angular contact ball bearings. The balance of axial forces produced in high-speed bearings
is examined, with a particular consideration of centrifugal forces, gyroscopic moments, contact
deformations, and contact angles. It has been shown that centrifugal forces acting on bearing balls do not
cause sleeve axial shifts. Those sleeve shifts can only result from gyroscopic moments, and changes in
spindle dimensions due to centrifugal forces. The proposed model has been verified experimentally, and
can be used for compensation of spindle tip displacements. |
| Process Monitoring with Sensory Machine Tool Components |
| H.C. Möhring, K.M. Litwinski, O. Gümmer / L. Cronjäger (1) |
| STC M, 59/1/2010, P.383 |
| Keywords: Machine, Monitoring, Sensor integration |
|
Abstract : Increasing automation paired with demands from high speed and high performance cutting leads to the
need for process monitoring methods which avoid faulty or destructive conditions. This paper describes
new monitoring methods using a sensory machine tool. By integrating a sensing fixture and an adaptive
sensory milling spindle the process and workpiece behavior can be observed from both sides of the
process. Interaction of these components allows new monitoring capability. A new concept for sensor
fusion results in methods for automated self-calibration and a detailed insight into the process. Effects
from spindle, workpiece and process dynamics can be separated. |
| Suppression of regenerative chatter vibration in simultaneous double-sided milling of flexible plates by speed difference |
| E. Shamoto (2), T. Mori, K. Nishimura, T. Hiramatsu, Y. Kurata |
| STC M, 59/1/2010, P.387 |
| Keywords: Milling, Chatter, Simultaneous double-sided milling |
|
Abstract : This paper presents a new method to machine flexible plates with high accuracy and high productivity.
Precision steel plates are finished conventionally by face milling with electro-magnetic chucks. It is
difficult to correct flatness of the flexible plates, because they deform to fit the chuck surfaces when
chucked. To solve this problem, the authors have tried simultaneous double-sidedmilling, but this causes
the regenerative chatter vibration. Thus, the newmethod is proposed and verified to suppress this chatter
vibration, in which the regenerative effects on both sides are cancelled out by rotating the two milling
cutters at different speeds. |
| Robust Chatter Stability in Micro Milling Operations |
| S. Park, R. Rahnama / E. Rivin (1) |
| STC M, 59/1/2010, P.391 |
| Keywords: Chatter, Dynamics, Micro-machining Milling |
|
Abstract : Micro-milling utilizes miniature end mills to fabricate complex shapes at high rotational speeds. One of
the challenges inmicro-machining is regenerative chatter, which results in severe tool wear and reduced
part quality. The high rotational speeds of micro-milling cause changes in dynamics; and, the elastoplastic
nature of micro-machining operations results in changes to the cutting coefficients. Variations in
dynamics and cutting coefficients affect the stability lobes. The tool tip dynamics can be indirectly
obtained through mathematical coupling of substructures using the receptance coupling method. The
effect of process damping is also considered. The robust chatter stability theorem, which is based on the
edge theorem, is employed to provide the robust stability within the minimum and maximum
boundaries of changing parameters. |
| Development of an active clamping system for noise and vibration reduction |
| J. Hesselbach (2), H.-W. Hoffmeister, B.-C. Schuller, K. Loeis |
| STC M, 59/1/2010, P.395 |
| Keywords: Machine tool, Vibration, Adaptronic |
|
Abstract : Noise emissions of up to 110 dB(A) occur during the machining of composite boards. Vacuum clamping
systems are predominantly used for machining particle boards on woodworking machining centers.
These clamping systems enable a good accessibility to the workpiece edges during milling. As a result to
this clamping method the boards have non-clamped areas. Consequently they vibrate over a wide
frequency domain during machining. The quality of the particle board edges is reduced and a high noise
level is induced by these vibrations. An active clamping system based on piezo-stack actuators has been
designed and implemented to reduce these vibration amplitudes. All required steps of its development,
the localization of the vibrations and the noise emission, the mechanical and control design and the
system integration into the machine table, are presented in this paper. The achieved results of this
research demonstrate the significance of active systems in machine tools. |
| On-line Measurement of Contact Pressure Distribution at Tool-Workpiece Interfaces in Manufacturing Operations |
| R.X. Gao, S. Sah, N. Mahayotsanum / S. Malkin (1) |
| STC M, 59/1/2010, P.399 |
| Keywords: Forming, Measurement, Contact pressure |
|
Abstract : A new method is proposed for determining the contact pressure distribution (CPD) between the tool and
the workpiece in sheet metal forming processes. Contact pressure is measured at discrete points at the
tool–workpiece interface by sensors that are structurally embedded beneath the tooling surface. An
analytical framework is developed for determining the pressure values between the sensing points
through the construction of continuous CPD maps. This is achieved using the Thin Plate Spline (TPS)
surface generation method, which creates temporal snapshots of the CPD during a forming process. The
effectiveness of this technique is illustrated for a panel stamping operation. |
| Identification and Modeling of Process Damping in Turning and Milling Using a New Approach |
| E. Budak (2), L.T. Tunc |
| STC M, 59/1/2010, P.403 |
| Keywords: Chatter, Stability, Damping |
|
Abstract : Process damping can be a significant source of increased stability inmachining particularly at low cutting
speeds. However, it is usually ignored in chatter analysis as there is no model available to estimate
process damping coefficients. In this study, a practical identification and modeling method is presented
where process damping coefficients are obtained from chatter tests. The method is generalized by
determining the indentation force coefficient responsible for the process damping through energy
analysis. This coefficient is then used for process damping and the stability limit prediction in different
cases, and predictions are verified by time domain simulations and experimental results. |
| Stiffness of 5-Axis Machines with Serial, Parallel, and Hybrid Kinematics: Evaluation and Comparison |
| Y. Shneor, V.T. Portman (1) |
| STC M, 59/1/2010, P.409 |
| Keywords: Stiffness, Machine tools, Parallel kinematics |
|
Abstract : Introduction of parallel kinematics mechanisms in structures of modern machine tools results in
resumed development and investigation of stiffness performance indexes. In this paper, a new stiffnessrelated
engineering index – minimum collinear stiffness value (CSV) – is applied for stiffness evaluation
of machine tools with different kinematics types. The evaluation embraces both local stiffness values in a
given configuration and global stiffness features over all workspace. A dimensionless form is entered as
the ratio of the CSV to the stiffness value of a single actuator. Stiffness features of 5-axis machines with
serial, parallel, and tripod-based hybrid kinematics are simulated using the developed approach. |
| A calibration method of redundantly actuated parallel mechanism machines based on projection technique |
| D. Jeon, K. Kim, J.I. Jeong, J. Kim (2) |
| STC M, 59/1/2010, P.413 |
| Keywords: Accuracy, Calibration, Parallel mechanism |
|
Abstract : This paper presents a new calibration method for redundantly actuated parallel mechanism machines
without measuring stiffness of actuating joints directly. The stiffness measurement of the actuating joints
was amandatory procedure to calibrate the redundantly actuated parallel mechanism in previous works.
A new error propagation formula by using projection technique is established, which projects the
constraint force terms onto the orthogonal complementary terms, in order to remove the need to know
joint stiffness. Two sets of experimental verification are presented: (1) a two d.o.f. Gosselinsmechanism
manipulator with three actuators and (2) a three d.o.f. parallel platform with four actuators. |
| High Speed Contouring Control Strategy for Five Axis Machine Tools |
| Y. Altintas (1), B. Sencer |
| STC M, 59/1/2010, P.417 |
| Keywords: Machine tool, Drive, Control |
|
Abstract : Accurate contouring of five-axis tool-paths with CNCmachine tools is important in high speed machining
of dies, molds and aerospace parts having sculptured surfaces. This paper presents a new control
approach where all five drives of the machine tool are controlled simultaneously with an objective of
minimizing contouring errors. Contouring errors are estimated analytically from differential path
geometry and the kinematics of the machine. A multi-inputmulti-output (MIMO) sliding mode controller
is designed to control three Cartesian and two rotary drives simultaneously with kinematic coupling.
Experimental results show that contouring errors o are reduced significantly by controlling all five drives
simultaneously. |
| C-Space based Approach for the Calculation of Toolpaths for Freeform Surfaces in B-Spline Description |
| K. Schützer, C. Stroh, H. Schulz (1) |
| STC M, 59/1/2010, P.421 |
| Keywords: Computer aided manufacturing (CAM), Spline, Toolpath interpolation |
|
Abstract : The usage of B-Spline toolpath for the machining of freeform surfaces offers advantages compared to
linear interpolated toolpaths, since the continuous and continuous derivable splines allow the machine
tool to move with higher speeds. Common CAM systems can calculate spline interpolated toolpath using
triangulations, that discretisise spline data models of the workpieces. This paper presents new methods
based on the C-space approach. Cutter location surfaces in B-Spline description are generated and
toolpaths are calculated by projecting guide curves onto these surfaces. All hereby used algorithms utilise
the B-Spline description without any discretisation. |
| Precision Machine Tool X-Y Stage Utilizing a Planar Air Bearing Arrangement |
| K. Erkorkmaz (2), J.M. Gorniak, D.J. Gordon |
| STC M, 59/1/2010, P.425 |
| Keywords: Conceptual design, Metrology, Control |
|
Abstract : This paper presents a new X–Y stage concept for precision machine tools. A large work area
(300 mm 300 mm) is achieved using a T-type gantry arrangement, which locates the work table
supported on a vacuum preloaded air bearing on top of a reference granite surface. Actuation is provided
with direct drives that fulfil the functions of motion controls, stiffness enhancement, and vibration
damping. Thermal deformations are mitigated by designing internally cooled motor couplings. The error
budget for the stage, as well as multivariable control law design and stability analysis, and metrology
results are discussed in the paper. |
| Correlation between feed velocity and preloading in ball screw drives |
| A.W. Verl (2), S. Frey |
| STC M, 59/1/2010, P.429 |
| Keywords: Machine tool, Wear, Ball screw |
|
Abstract : The efficiency and reliability of ball screw feed drives is a mayor issue concerning the productivity of
modern machine tools. The preloading of a ball screw thereby determines the dynamical operational
behavior as well as the attainable life span. The research results presented in this paper now clearly show
that the value of pretension changes depending on the velocity of the feed motion. This correlation has a
major impact on the actual equivalent load on a ball screw during operation and therefore has to be
considered when estimating the operating life of a feed drive. |
STC O |
| Embedding a process plan in function blocks for adaptive machining |
| L. Wang, M. Holm, G. Adamson / J.P. Van Griethuysen (1) |
| STC O, 59/1/2010, P.433 |
| Keywords: CAPP, Machining, Function block |
|
Abstract : This paper presents a function block enabled approach towards adaptive process planning and
machining. A two-layer structure of supervisory planning and operation planning is proposed to separate
generic data frommachine-specific ones. The supervisory planning is only performed once, in advance, at
the shop level to generate machine-neutral process plans, whereas the operation planning is carried out
at runtime at the machine level to determine machine-specific operations. Such adaptive decision
making is facilitated by event-driven algorithms embedded in the function blocks. It is expected that the
new approach can greatly enhance the dynamism of fluctuating job-shop machining operations. |
| Enhanced control of complex production structures by tight coupling of the digital and the physical worlds |
| B. Kadar, A. Lengyel (3), L. Monostori (1), Y. Suginishi (3), A. Pfeiffer, Y. Nonaka (3) |
| STC O, 59/1/2010, P.437 |
| Keywords: Simulation, Production planning, Manufacturing control |
|
Abstract : Unexpected disturbances and local decisions almost always deteriorate the execution of manufacturing
plans. Digital enterprise technologies are hard to use, due to the complexity of production and the
frequently changing circumstances. One of the main goals of the research described in the paper is the
automatic model building of the discrete-event simulation system, based on intelligent analysis of the
huge amount of information incorporated in the production database. The developed solution supports
shop-floor dispatching and shop-floor managers in making control decisions. |
| A STEP compliant knowledge based schema to support shop-floor adaptive automation in dynamic manufacturing environments |
| A. Valente, E. Carpanzano (2), A. Nassehi, S.T. Newman (2) |
| STC O, 59/1/2010, P.441 |
| Keywords: Factory automation, Adaptive control, STEP-NC standard |
|
Abstract : Onthe factoryshop-floor adaptive automation and scheduling plays a sensitive role for production systems
agility, representing the soft layer between the factory physical resources and business processes. A
fundamental requirement for adaptive shop-floor solutions is to incorporate a data structure that
comprehensively integrates product, processandphysical resource information. This paper presents a novel
data structure entitled SKEM – STEP compliant Knowledge Engine for Manufacturing, conceived as an
abstract, extensible, scalable, multi-granular, integrated and evolving platform. A software tool based on
SKEMis tested through a case study to illustrate the benefits of its application for a dynamic manufacturing
factory environment. |
| Co-evolution Hypotheses and Model for Manufacturing Planning |
| T. AlGeddawy, H. ElMaraghy (1) |
| STC O, 59/1/2010, P.445 |
| Keywords: Manufacturing, Systems, Co-evolution |
|
Abstract : It is desirable to prolong manufacturing systems life and use them for many product generations. The
matched evolution course of co-evolving biological species demonstrates their symbiotic interdependency.
Analogously, this hypothesis forms the foundation of a new co-evolution model in manufacturing
between products design and manufacturing capabilities which is mathematically formulated and
interpreted using parsimony analysis of cladograms. The model is validated using case studies involving
assembly of automotive engine accessories. The new co-evolution model supports a more efficient codevelopment
of products and manufacturing capabilities, links their past generations to the present and
identifies their promising future evolution directions. |
| Analysis of the Production Variability in Multi-Stage Manufacturing Systems |
| M. Colledani, A. Matta, T. Tolio (1) |
| STC O, 59/1/2010, P.449 |
| Keywords: Manufacturing systems, Production logistics, Production variability |
|
Abstract : The evaluation of the average performance ofmanufacturing systems has been widely investigated in the
manufacturing system engineering literature. However, there is industrial evidence that production
variability due to random disturbances cause the observed production rate to be different from its
average value. This paper presents a theory and a methodology to analyze the production rate variability
in unreliable manufacturing systems. The dependency of the variance on the system parameters is
investigated. The industrial benefits are shown through application of the method to real manufacturing
contexts. This analysis paves the way to improved system designs that meet desired service levels. |
| Proactive Maintenance Scheduling in a Re-entrant Flow Shop Using Lagrangian Decomposition Coordination Method |
| T. Kaihara, N. Fujii, A. Tsujibe, Y. Nonaka / K. Iwata (1) |
| STC O, 59/1/2010, P.453 |
| Keywords: Scheduling, Optimization, Equipment maintenance |
|
Abstract : Proactivemaintenance scheduling is necessary to prevent facility trouble and to ensure high productivity
in semiconductor production systems. For such systems, it is usually difficult to determine a proper plan
because of complex process flows, which necessitate that jobs often re-enter a facility. This paper
presents a method for re-entrant production floor optimization using Lagrangian decomposition
coordination. By regarding maintenance as jobs that are limited by a starting and finishing time, the
proposed approach produces a schedule that can facilitate proper maintenance. Feasibility is discussed
using computer simulation results: the proposed method produces feasible solutions for minimizing
overall tardiness problems. |
| Dynamic production control using a flow based formulation |
| L. Laperriere (2) |
| STC O, 59/1/2010, P.457 |
| Keywords: Production, Simulation, Control |
|
Abstract : The dynamic behaviour of production systems is explained to a great extent by the time varying flows of
parts entering, accumulating, and leaving workstation buffers. In this paper a continuous flow
formulation to model such dynamics is analysed, using the law of conservation of mass as the main
governing equation. The paper shows how integral and differential mass balances relate to important
production planning and control variables. The dynamic flow basedmodel is then used in a simulation to
investigate how different control strategies affect some key performance measures in the context of time
varying total production capacity with local disturbances. |
| Graph Coloring Dynamics: A Simple Model Scenario for Distributed Decisions in Production Logistics |
| K. Windt, M.T. Hütt / N. Duffie (1) |
| STC O, 59/1/2010, P.461 |
| Keywords: Decision making, Modelling, Design of networks |
|
Abstract : Graph coloring is the process of placing colors onto and modifying the color of nodes of a network until no
neighbors share the same color. It is a powerful tool for analyzing coloring strategies that could be
mapped to job shop scheduling strategies. We analyze how the performance of solving temporal conflict
graphs depends on strategy and problem complexity. We observe for example under strategic waiting of
nodes, some network features that can be exploited to better solve conflicts on graphs. We show how
these features can be used in the design of robust production networks. |
| Dynamic Flexible Flow Shop Problems - Scheduling Heuristics vs. Autonomous Control |
| B. Scholz-Reiter (2), H. Rekersbrink, M. Görges |
| STC O, 59/1/2010, P.465 |
| Keywords: Production, Simulation, Autonomous control |
|
Abstract : Flexible flow shop problems are well known and common tasks. Two practice-oriented extensions are
unrelated parallel machines on the one hand and dynamic aspects in terms of distributed release times on
the other hand. Triggered by the growing complexity of logistics systems, the paradigm of central
planning is being shifted to decentralized autonomous control. This work focuses on two different
autonomous control methods applied to flexible flow shop problems with both of the extensions
mentioned above. In order to evaluate these methods, various common scheduling heuristics and one
genetic algorithm are taken as references. Problem instances are defined and solved by autonomous
control and the reference algorithms. The results of this evaluation are shown and discussed. |
| Axiomatic approach for efficient healthcare system design and optimization |
| J. Peck, D. Nightingale, S.-G. Kim (1) |
| STC O, 59/1/2010, P.469 |
| Keywords: Axiomatic, Optimization, Health care |
|
Abstract : The one most serious issue in health care is that its costs are too high and rising too quickly while the
quality of service is lagging behind. We view this is a consequence of complexity associated with current
health care systems. We report the Axiomatic approach, which has been used to optimize many complex
engineering systems, can be applied towards unravelling the complexity associated with a healthcare
system and suggesting optimal design solutions. This paper presents cases of the Axiomatic approach in
health care including the improvement of patient flow in emergency rooms and organizational design for
a multi-campus mental health hospital. |
| Modeling of Decision Making in Membership Services as Public Goods Problems |
| N. Nishino, K. Ueda (1), Y. Sato |
| STC O, 59/1/2010, P.473 |
| Keywords: Service, Decision making, Public goods |
|
Abstract : A membership service is a service system framework. For example, an airlines frequent flyer program
conforms to a membership service framework. To design appropriate membership services, the
mechanism must be elucidated. This study examines membership services as public goods problems.
Public goods are defined as products or services with properties of non-rivalry and non-excludability.
Membership services particularly have the property of non-rivalry. A model of decision making is
constructed to analyze the membership services mechanism. Decision making of pricing by a service
provider and that of joining membership by service receivers are analyzed using theoretical analysis,
experiments with human subjects, and multi-agent simulation. |
| The Changing Concept of Sustainability and Economic Opportunities for Energy-Intensive Industries |
| P. Schönsleben (2), M. Vodicka, K. Bunse, F.O. Ernst |
| STC O, 59/1/2010, P.477 |
| Keywords: Sustainable development, Manufacturing, Energy-intensive industry |
|
Abstract : In the past decades there has been a shift in the concept of sustainability from a distant, environmentally
oriented ideology to an imperative factor for competitiveness. This paper first discusses this paradigm
change as seen from an industry perspective. Second, motivated by energy-related improvement
potentials in energy-intensivemanufacturing industries (steel, cement, pulp and paper, chemicals), novel
economic drivers for environmental commitment are identified. Third, based on the outcomes of a recent
EU-funded roadmapping project, measures and concepts in production organization are introduced and
assessed with respect to the above motivation. We conclude that the novel economic drivers call for reevaluation
of environmental strategies. |
| Implications of k-best Modular Design Solutions to Global Manufacturing |
| J.J. Yoo, S. Kumara (1) |
| STC O, 59/1/2010, P.481 |
| Keywords: Modular design, Product development, Optimisation |
|
Abstract : The recent trends in modularization facilitate the automation of product design leveraging digital design
repository in global manufacturing environment. This paper proposes a method to find k-best designs.
We formulate the problem using integer programming to obtain the optimal solution, and use cutting
planes to find the next best solution. k-best design solutions provide manufacturers or product designers
with more holistic view on the feasible solution space than the sole optimal solution. The k-best solutions
help suppliers assess the competitiveness of theirmodules. We show how k-best design solutions can be
utilized in product design practices through a case study. |
| A quantum multi-agent evolutionary algorithm for selection of partners in a virtual enterprise |
| F. Tao, L. Zhang, Z.H. Zhang, A.Y.C. Nee (1) |
| STC O, 59/1/2010, P.485 |
| Keywords: Optimization, Decision-making, Quantum multi-agent evolutionary algorithm |
|
Abstract : Combining agents and quantum-bit, a novel quantum multi-agent evolutionary algorithm (QMAEA) for
addressing partner selection problems (PSP) in a virtual enterprise is proposed. In QMAEA, each agent
represented by a quantum-bit is defined as a candidate solution, and agents can reproduce, perish,
compete for survival, observe and communicate with the environment. Operators such as energy
evaluation, competition, crossover, mutation, and trimming are designed to specify the evolvement of
QMAEA. Three evolutionary strategies are designed to balance the exploration and exploitation of
QMAEA. The effectiveness and scalability of the proposedQMAEA in addressing PSP is demonstrated with
experimental results and comparisons. |
| Multidimensional Evaluation of Value Added Networks |
| G. Lanza, J. Ude / H.P. Wiendahl (1) |
| STC O, 59/1/2010, P.489 |
| Keywords: Decision making, Uncertainty, Production network |
|
Abstract : The configuration of Value Added Networks consisting of globally distributed locations of a company and
its partners and suppliers is a long-term decision and therefore subject to high dynamics and
uncertainties. Furthermore the evaluation of different network configurations has to be done with
respect to the underlying multidimensional target systems. This paper describes an integrated concept
for the evaluation of network configurations using a discrete-event simulation tool with an integrated
Monte-Carlo-Simulation to include dynamics and uncertainty and the PROMETHEE approach for the
consideration of multidimensional target systems. The concept leads to robust network designs, which
are adjusted to the companies needs. |
| Data Mining based Configuration of Cyclically Interlinked Production Systems |
| L. Overmeyer, J. Dreyer, D. Altmann / H.K. Toenshoff (1) |
| STC O, 59/1/2010, P.493 |
| Keywords: Planning, Production, System |
|
Abstract : Cyclically interlinked production systems are commonly used production facilities. During the bidding
phase manufacturers of these systems assure customers about the performance and operating efficiency
despite numerous uncertainties. Up to now, there has been no planning approach that could hedge these
results. Recently however, a method for configuring cyclically interlinked production systems during the
bidding phase has been developed in order to resolve this deficit. Data mining models are built to predict
performance figures of production systems, whereas, characteristic curves are used to predict the
operating efficiency of a system configuration. This paper introduces the challenge of bid proposal
management and explains the developed method. |
STC P |
| Metrological performance of optical coordinate measuring machines under industrial conditions |
| S. Carmignato, A. Voltan, E. Savio (2) |
| STC P, 59/1/2010, P.497 |
| Keywords: Coordinate measuring machine (CMM), Uncertainty, Intercomparison |
|
Abstract : An increasing number of manufactured parts are measured in industry using non-contact measuring
systems. The paper describes an industrial comparison of coordinate measuring machines (CMMs)
equipped with optical sensors, performed in Europe from August 2007 to January 2009 involving 21
optical CMMs. Participants, mainly small–medium size industrial companies, were asked to measure a
set of calibrated artefacts with measurement tasks of different complexity. They include both 1D/2D
standards (glass scale and optomechanical hole plate) and 3D injection moulded workpieces of different
colours (four plastic Lego bricks).
In addition to the evaluation of actual metrological performances of optical CMMs in industry, an
important aim of the comparison was to investigate the validity of measurement uncertainty statements
provided by participants. The focus of this investigation was on the additional error sources that emerge
when using optical CMMs. Results demonstrate that: (i) the interactions of optical sensors with material
and surface of parts are among the most important error sources; (ii) the users of optical CMMs in most
cases are not aware of the magnitude of these effects; (iii) specific uncertainty evaluation procedures,
suitable for industrial users of optical coordinate measurements, are needed. |
| Error compensation of cylindrical coordinate measuring machines |
| G.X. Zhang (1), H.Y. Zhang, J.B. Guo, X.H. Li, Z.R. Qiu, S.G. Liu |
| STC P, 59/1/2010, P.501 |
| Keywords: Measurement, Error compensation, Cylindrical coordinate measuring machine |
|
Abstract : A method for measuring bodies of rotation in the cylindrical coordinate system is considered. This
method possesses many advantages such as high efficiency and high reliability. However cylindrical
CMMs suffer from some specific problems due to their complexity in construction and long structural
loops. Error compensation gains special importance in cylindrical CMMs. To limit these deficiencies, new
techniques for compensating the parallelism errors between the measuring column axes and the rotary
axis, and for compensating thermal errors utilizing reference object measurements and bidirectional
measurements have been developed. The effectiveness of the proposed techniques is proven by
experiment and practice. |
| A fast evaluation method for pitch deviation and out-of-flatness of a planar scale grating |
| W. Gao (2), A. Kimura |
| STC P, 59/1/2010, P.505 |
| Keywords: Measurement, Optical, Interferometry |
|
Abstract : A planar scale grating with a pitch of 1 mmused in an interferential scanning-type planar encoder, which
produces multi-axis position signals based on interference between first-order diffracted beams from the
grating, is evaluated by a 100 mm-aperture Fizeau interferometer. The out-of-flatness of the grating is
first evaluated from the wavefront of the zero-order diffracted beam from the grating. The grating is then
tilted to align the axes of the first-order diffracted beams with that of the interferometer so that the Xand
Y-directional pitch deviations of the grating can be evaluated from the wavefronts of the first-order
diffracted beams. |
| Correlation uncertainty and Gear conformity assessment |
| J.Y. Dantan, J.P. Vincent, G. Goch (1), L. Mathieu (1) |
| STC P, 59/1/2010, P.509 |
| Keywords: Metrology, Decision making, Uncertainty |
|
Abstract : Metrology always aims at providing reliable information as a basis for decisions of the conformity
assessment. These decisions are affected by the measurement uncertainty (The Guide to the Expression of
Uncertainty in Measurement describes the measurement uncertainty evaluation) and the correlation
uncertainty, which characterizes the fact that the Intended Functionality and the Specified
Characteristics may not be perfectly correlated. To evaluate the risk of a wrong decision concerning
the conformity assessment due to the correlation uncertainty, this contribution proposes a model for the
expression and an evaluation method of the correlation uncertainty based on the Axiomatic Design
matrix and the Monte Carlo Simulation. |
| New Concept of a 3D- probing system for micro – components |
| T. Liebrich, W. Knapp (1) |
| STC P, 59/1/2010, P.513 |
| Keywords: Metrology, Sensor, Interferometry |
|
Abstract : The results of a feasibility study with the aim to demonstrate the applicability of a Fizeau interferometer
for tactile dimensional metrology are presented. The concept is based on a Fizeau interferometer for
detecting the deflection of an internal measuring plane at which the probing stylus is attached. The
mechanical setup is dimensioned for small probing forces and an isotropic probing behaviour. Results
and experience during building up the probing system and evaluating the interference images are
presented. Furthermore, the advantages and disadvantages of the new 3D-probing concept with a
theoretical resolution of 0.1 µm (X-/Y-direction) and 0.04 µm (Z-direction) are discussed. |
| A high-resolution, self-sensing and self-actuated probe for micro- and nano coordinate metrology and scanning force microscopy |
| K. Hidaka (3), H.U. Danzebrink, H. Illers, A. Saito, N. Ishikawa / P.H.J. Schellekens (1) |
| STC P, 59/1/2010, P.517 |
| Keywords: Probe, Ultrasonic, Sensor |
|
Abstract : This paper presents a sensor head for micro- and nano-coordinate metrology and scanning force
microscopy (SFM) which has an ultrasonic vibration sensor working in a longitudinal oscillationmode. In
this head several important aspects are involved. One is the structure of the stylus sensor which is based
on unequal, vibratingmasses, with an exchangeable stylus part. Another is the combination of the stylus
and the microscope objective. For metrological reasons the longitudinal axis of the stylus and the optical
axis of the objective are co-linear. This structure of the sensor head allows the measurement of the target
area with the stylus after finding it using the optical microscope. The detailed structure and several
results, for instance, step height measurements, are presented. |
| A novel resist surface profilometer for next-generation photolithography using mechano-optical arrayed probe system |
| S. Takahashi, K. Watanabe, K. Takamasu / T. Masuzawa (1) |
| STC P, 59/1/2010, P.521 |
| Keywords: Measuring instrument, Profile, Photoresist surface |
|
Abstract : We propose a novel mechano-optical arrayed probe system, allowing a resist surface profile evaluation,
which can be applied to on-machine measurement for a next-generation photolithography process of the
semiconductormanufacturing. An experimental system, consisting of a white light interferometer and an
arrayed probe unit supported on a SiC thin membrane, was newly developed, and fundamental
experiments were carried out for verifying the feasibility of the new system. The experimental results
suggest the proposed method is an effective resist surface profile evaluation technology with a vertical
resolution of 10 nm over a horizontal range of tens of millimeters. |
| A Newly Developed Three-dimensional Profile Scanner with Nanometer Spatial Resolution |
| H. Shinno (2), H. Yoshioka, T. Gokan, H. Sawano |
| STC P, 59/1/2010, P.525 |
| Keywords: Control, Measuring machine, Probe |
|
Abstract : Demands for characterization of three dimensional (3D) micro-geometries and surface topographies over
a large area have recently increased in many industries. This paper presents a newly developed 3D profile
measuring machine with a nanometer spatial resolution. The machine developed is composed of an
active vibration isolating system, a planar nano-motion table system driven by voice coil motors, a
vertical nano-motion platform driven by a hybrid actuator, and a probing system based on the scanning
tunneling microscopy principle. Performance evaluation results confirm that the machine can be
successfully conducted the characterization of micro-geometries and surface topographies. |
| On-Axis Self-Calibration of Angle Encoders |
| X.-D. Lu, R. Graetz, D. Amin-Shahidi, K. Smeds / W.T. Estler (1) |
| STC P, 59/1/2010, P.529 |
| Keywords: Calibration, Spindle, Encoder |
|
Abstract : Angle encoder calibration is needed to improve the accuracy of rotary position feedback in manufacturing
equipment. Although several self-checking methods have been developed, the fundamental problem of
calibrating angle encoders remains unsolved. Existing methods require an encoder to be calibrated on
specially designed angle comparators, but the process of transferring the encoder from the comparator to
the encoders application axis typically introduces arc-sec level error. This paper presents the Timemeasurement
Dynamic Reversal (TDR) method to calibrate encoders on their application axes. The TDR
method has demonstrated 0.006 arc-sec uncertainty (2o), including the first 500 harmonic components. |
| Submicron Functional Surfaces Generated by Diamond Machining |
| E. Brinksmeier (1), O. Riemer, R. Gläbe, B. Lünemann, C. von Kopylow, C. Dankwart, A. Meier |
| STC P, 59/1/2010, P.535 |
| Keywords: Ultra-precision, Nano manufacturing, Nano Fast Tool Servo |
|
Abstract : The application of a fast tool servo assisted diamond turning process enables the generation of structured
optical surfaces. To realize a high machining accuracy, two nano Fast Tool Servos (nFTS) have been
developed featuring strokes of 500 nm and 350 nm at frequencies up to 5 kHz and 10 kHz respectively.
This process enables the generation of microstructures with nanometer precision which can be used as
diffractive optical elements. The quality of these diffractive optical elements depends on various aspects,
such as the design of holograms, the nFTS data pre-processing, the piezo actuator and the workpiece
material. |
| A Cluster Analysis Applied to Volumetric Errors of Five-Axis Machine Tools Obtained by Probing an Uncalibrated Artefact |
| T. Erkan, J.R.R. Mayer / L. Kops (1) |
| STC P, 59/1/2010, P.539 |
| Keywords: Machine tool, Error, Metrology |
|
Abstract : This paper presents a cluster approach to the analysis of volumetric error for five-axis machine tools. The
probed artefact is uncalibrated so the analysed volumetric errors exclude isotropic scale errors. First, a
simultaneous model based estimation of machine and artefact geometric parameters enhances the
estimation of the artefact. Then, a point-to-point least squares adjustment is performed between the
measured and the predicted ball centre clusters. Information about the volumetric impact of both
the linear and rotary axes as separate groups is obtained by analysing the position measurement error of
the artefact as a whole and of each ball individually. Simulation is conducted for the validation of the
method supported by experiments. |
| Nano Photomask Fabrication using Focused Ion Beam Direct Writing |
| F.Z. Fang (2), Z.W. Xu, X.T. Hu, C.T. Wang, X.G. Luo, Y.Q. Fu |
| STC P, 59/1/2010, P.543 |
| Keywords: Ion beam machining (IBM), Nano-manufacturing, Photomask |
|
Abstract : A novel nano-photomask fabricationmethod using focused ion beam direct writing (FIBDW) is proposed
to normalize the dwell time of each pixel of the ion beamlocation with respect to the contrast of designed
bitmaps. The removal mechanism is studied to develop the fabrication process. It has been confirmed that
beam dwell time, astigmation and overlap are the most effective parameters for achieving the features in
nanoscale. An approach for dot array milling is proposed also for inspecting and correcting the beam
astigmatism. Photomasks with line width of 32 nm are employed for the purpose of successful
application of this novel method in this study. |
| Subaperture stitching interferometry of high-departure aspheres by incorporating a variable optical null |
| M. Tricard (2), A. Kulawiec, M. Bauer, G. DeVries, J. Fleig, G. Forbes, D. Miladinovic, P. Murphy |
| STC P, 59/1/2010, P.547 |
| Keywords: Interferometry, Metrology, Asphere |
|
Abstract : Originally, subaperture stitching interferometry enabled full-aperture measurement of large-aperture
spheres and flats using 400 or 600 interferometers and transmission elements. Later, mild aspheric surfaces
could be measured using the same fundamental principles. In both cases, stitching algorithms
automatically compensate for systematic reference wavefront and distortion errors. Aspheres with up to
1000 waves of departure from best-fit sphere can be measured without dedicated null lenses using a
variable optical null (VONTM) device which generates an optical wavefront that closely matches the
surface of the asphere within a local subaperture. This paper presents the principles of subaperture
stitching interferometry incorporating VON technology. |
| Development of the automatic positioning system of micro tool edge in micromachining of glass plate for micro fluidic chips |
| T. Aoyama (2), N. Takahata |
| STC P, 59/1/2010, P.551 |
| Keywords: Micromachining, Positioning, Tool |
|
Abstract : A microfluidic chip is a microscale chemical laboratory, and a glass substrate is used for the material of
the chip. Micromachining is an effective process to produce a 3D micropattern on such a glass plate. In the
micromachining process, however, the positioning of the contact point of the tool edge on the surface of
the glass workpiece is technically difficult. In this study, a new automated positioning system for the
microtool edge is developed using the total internal reflection of a laser beam. The developed system is
also applied to detect the change in the cutting mode from ductile to brittle. |
| Absolute Distance Measurement using the Frequency Comb of a Femtosecond Laser |
| S. Hyun, Y-J. Kim, Y. Kim, S.-W. Kim (2) |
| STC P, 59/1/2010, P.555 |
| Keywords: Interferometry, Optical, Metrology |
|
Abstract : We describe a multi-wavelength interferometer that performs absolute distance measurements by
exploiting the frequency comb of a femtosecond pulse laser as the precision wavelength ruler. An
external-cavity laser diode is locked to the frequency comb and used as the tunable light source
producing multiple wavelengths in discrete hopping and continuous scanning modes. This method
enables high speed absolute distance metrology for industrial applications with improved measurement
precision directly traceable to the Rb clock of an rf time standard. |
STC S |
| Mechanism of ring crack initiation in Hertz indentation of monocrystalline silicon analyzed by controlled molecular dynamics |
| T. Inamura (2), Y. Shishikura, N. Takezawa |
| STC S, 59/1/2010, P.559 |
| Keywords: Simulation, Fracture analysis, Molecular dynamics |
|
Abstract : The mechanism of ring crack initiation in the Hertz indentation of monocrystalline silicon with no
preexisting defect has been analyzed by controlled molecular dynamics. It has been found that
microvoids that develop into a ring crack can be generated outside the outer periphery of the contact area
between the silicon and an indenter, such that the static stress and dynamic stress associated with
acoustic waves locally transform the monocrystal structure to a polycrystal one, and then the static stress
causes cross slips at grain boundaries to cause microvoids. |
| Replication and dimensional quality control of industrial nanoscale surfaces using calibrated AFM measurements and SEM image processing |
| G. Tosello, H.N. Hansen (1), F. Marinello, S. Gasparin |
| STC S, 59/1/2010, P.563 |
| Keywords: Metrology, Atomic force microscopy, Nano-structured surface |
|
Abstract : Ultra-high precision manufacture of nanoscale structured polymer surfaces poses the highest challenges
in terms of tooling and replication. This paper introduces new procedures for quality control of nickel
stampers and polymer moulded discs for CD, DVD and HD-DVD manufacture: quantitative application of
AFM to calibrate height, depth and pitch of sub-micrometer features and SEM image processing to detect
replication accuracy in terms of number of replicated features. Surface replication is analyzed using a
metrological approach: nano-features on nickel stampers and injection–compression moulded
polycarbonate substrates are measured, measurement uncertainty calculated, replication fidelity
assessed quantitatively, and dimensional tolerances at the nanometre scale verified. |
| Using Quantum Dots to Evaluate Subsurface Damage Depths and Formation Mechanisms in Glass |
| W. Williams, B. Mullany (3), W. Parker, P. Moyer, M. Randles / S. Smith (1) |
| STC S, 59/1/2010, P.569 |
| Keywords: Polishing, Surface integrity, Subsurface damage |
|
Abstract : Subsurface damage (SSD) is a layer of fractured and stressed material that remains beneath an apparently
well polished surface. It is detrimental to the quality and performance of high end optical components
and laser crystals. While many methods exist to detect SSD none offer insights into damage formation
mechanisms and few estimate damage depths. The technique of tagging lapping and polishing slurries
with quantum dots (nano-sized fluorescent crystals) does both. Fluorescence was detected at depths up
to 10 µm beneath the surface of glass slides processed with tagged slurries. The dots are introduced to the
subsurface through brittle fracture mechanisms. |
| Robust Solution for the Evaluation of Stratified Functional Surfaces |
| X. Jiang (2) |
| STC S, 59/1/2010, P.573 |
| Keywords: Evaluation, Surface, Stratified functional property |
|
Abstract : In the 1990s ISO published a set of empirical specifications for micro-nano surface manufacture, however,
how to characterize stratified functional surfaces is still in debate. The structure of these specifications
had not been designed for consistency and stability, which has led to many different instrumental
software having seriously divergent parametric results. This paper aims to present a robust solution for
the assessment of surfaces with stratified functional properties. It intends not only to provide
unambiguous specifications and deterministic numeric algorithms, but also to demonstrate illustrative
evaluation examples derived from stratified functional surfaces. |
| Milled Die Steel Surface Roughness Correlation with Steel Sheet Friction |
| J. Berglund, C.A. Brown (2), B.-G. Rosen, N. Bay (1) |
| STC S, 59/1/2010, P.577 |
| Keywords: Surface topography, Friction, Metal forming |
|
Abstract : This work investigates correlations between the surface topography ofmilled steel dies and friction with
steel sheet. Several die surfaces were prepared by milling. Friction was measured in bending under
tension testing. Linear regression coefficients (R2) between the friction and texture characterization
parameters were tested. None of the height, spacing, material volume, void or segmentation parameters
showed good correlations. Developed area, rms surface gradient, relative area and complexity showed
strong correlations (R2 > 0.7). For area-scale fractal complexity the correlation increases markedly at
scales below 200 µm2, with a maximum R2 of 0.9 at 50 µm2. |
| Parallelization of rigorous light scattering simulation algorithms for nanostructured surfaces |
| A. Tausendfreund, S. Patzelt, G. Goch (1) |
| STC S, 59/1/2010, P.581 |
| Keywords: In-process measuring, Simulation, Algorithm |
|
Abstract : Measuring processes based on scattered light can be investigated and designed using numerical
simulation. Unfortunately, the classical scalar diffraction theory fails to simulate light scattering from
sub-wavelength nanostructures. Therefore, new simulation algorithms are required. Existing approaches
based on the rigorous diffraction theory lead to accurate results. However, because of the high
computation efforts they are not applicable in practice. For example, the discrete dipole approximation
leads to systems with millions of coupled linear equations, which are solvable only by time consuming
calculations. The paper investigates a fast procedure, which decouples the equations and calculates the
developed subsystems in parallel on different computers. |
| Electrochemical etching using laser masking for multilayered structures on stainless steel |
| H.S. Shin, M.S. Park, C.N. Chu (2) |
| STC S, 59/1/2010, P.585 |
| Keywords: Micromachining, Electro chemical machining (ECM), Laser masking |
|
Abstract : This paper proposes a novel process for electrochemical etching ofmetal without a need for photo-mask.
Electrochemical etching using laser masking (EELM) process includes laser masking and anodic
dissolution. In the laser masking step, a patterned layer on a stainless steel surface was formed by laser
marking using a pulsed fiber laser. This patterned surface was selectively dissolved during the
electrochemical etching step because the laser marked area temporarily acted as a protective mask. To
fabricate microstructures, the appropriate conditions for stable EELM process were determined.
Consequently, multilayered structures were successfully achieved by recursive EELM process without
any requirement for a photo-lithography process. |
| Ultra-Precision Surface Grinding of PMN-PT Relaxor-Based Ferroelectric Single Crystals |
| Y. Namba, H. Takahashi / T. Hoshi (1) |
| STC S, 59/1/2010, P.589 |
| Keywords: Ultra-precision grinding, Surface, Piezoelectric |
|
Abstract : Lead magnesium niobate-lead titanate (PMN-PT) single crystals with high piezoelectric coefficients,
extremely large piezoelectric strains and very high electromechanical coupling factors are expected to be
used in various new sensors and actuators of high performance, instead of lead zirconate titanate (PZT).
PMN-PT (0 0 1) planes were ground with various resinoid-bonded diamond wheels in order to obtain thin
plates. The features of the ground surfaces change with crystallographic orientation and machining
conditions. A surface roughness of 0.44 nm Ra was obtained under adequate grinding conditions. Thin
PMN-PT crystals of less than 10 µm thickness were obtained by this grinding process. |
| Modification of surface properties on a nitride based coating films through mirror-quality finish grinding |
| K. Katahira, H. Ohmori (2), J. Komotori, D. Dornfeld (1), H. Kotani, M. Mizutani |
| STC S, 59/1/2010, P.593 |
| Keywords: Coating, Grinding, Tribology |
|
Abstract : In this study, we performed a specific precision grinding process in an attempt to improve the mirrorquality
finish and tribological characteristics of titanium nitride based coating films (TiN, TiCN, and
TiAIN). The ground surfaces were highly smooth with no evidence of cracking, chipping, or peeling,
demonstrating that the hard coating films were finished uniformly. For the TiAIN coating, a significant
high level mirror-quality finish was achieved with an average roughness Ra of 4 nm. In addition, for all
films, the employed grinding process led to superior tribological characteristics. In the case of the TiN
film, the precision grinding process produced a carbon- and copper-rich surface layer, as well as higher
compressive residual stress. |
| Improving anti-adhesive properties of cutting tool surfaces by nano/micro textures |
| T. Enomoto, T. Sugihara / T. Matsuo (1) |
| STC S, 59/1/2010, P.597 |
| Keywords: Cutting tool, Surface, Texture |
|
Abstract : Demand for aluminum alloy composites has rapidly increased, especially in the transport industry. This
demand is due to such key advantages as a high strength to mass ratio and high corrosion resistance.
However, aluminum chips readily adhere to the cutting edge of the tool used, often leading to tool
breakage. To address this problem, we have developed cutting tools with nano-/micro-textured surfaces
formed using femtosecond laser technology. Face-milling experiments on aluminum alloys showed that
the textured surface significantly improves the lubricity and anti-adhesive properties at the tool–chip
interface. |
| Surface Integrity of Selective-Laser-Melted Components |
| E. Brinksmeier (1), G. Levy (1), D. Meyer, A.B. Spierings |
| STC S, 59/1/2010, P.601 |
| Keywords: Machining, Surface integrity, Rapid prototyping |
|
Abstract : Selective-laser-melting (SLM) is an emerging rapidmanufacturing technology allowing the production of
components with complex geometries. Though the produced components dimensions are close to the
final dimensions, subsequent machining steps might be necessary. Therefore the resulting surface
integrity of SLM-produced and subsequently machined components is crucial. In this study the surface
integrity of ground and milled SLM-samples (18 Maraging 300) was analyzed, taking into account the
layer orientation. By assessing depth profiles for hardness and residual stresses as well as by measuring
the surface roughness, a first time comprehensive view of the correlations between layer orientation,
machining process and surface integrity of SLM-samples was obtained. On the basis of these findings, the
future potential of SLM can be revealed. The experiments were performed within the framework of the
CIRP collaborative working group on ‘‘Surface Integrity and the Functional Performance of Components. |