Showing papers in "International Journal of Precision Engineering and Manufacturing in 2008"

On the Development of Digital Radiography Detectors : A Review

Abstract: This article reviews the development of flat-panel detectors for digital radiography based on amorphous materials. Important design parameters and developments are described for the two main components of flat-panel detectors: the X-ray converter and the readout pixel array. This article also introduces the advanced development concepts of new detectors. In addition, the cascaded linear systems method is reviewed because it is a very powerful tool for improving the design and assessment of X-ray imaging detector systems.

A Nano-particle Deposition System for Ceramic and Metal Coating at Room Temperature and Low Vacuum Conditions

Abstract: A new nano-particle deposition system (NPDS) was developed for a ceramic and metal coating process. Nano-and micro-sized powders were sprayed through a supersonic nozzle at room temperature and low vacuum conditions to create ceramic and metal thin films on metal and polymer substrates without thermal damage. Ceramic titanium dioxide (TiO₂) powder was deposited on polyethylene terephthalate substrates and metal tin (Sn) powder was deposited on SUS substrates. Deposition images were obtained and the resulting chemical composition was measured using X-ray photoelectron spectroscopy. The test results demonstrated that the new NPDS provides a noble coating method for ceramic and metal materials.

Fabrication of Large-area Micro-lens Arrays with Fast Tool Control

Abstract: This paper describes a fast tool control (FTC)-based diamond turning process for fabricating large-area high-quality micro-lens arrays. The developed FTC unit has a stroke of 48 ㎛ and a resonance frequency of 4.9 kHz. Micro-lens arrays were fabricated using a micro-cutting tool with a nose radius of 50 ㎛. The FTC unit was integrated 'with a force sensor so that the initial position of the micro-cutting tool with respect 10 the workpiece surface could be detected through monitoring the contacting force. The length and depth of the designed parabolic micro-lens profile were 190 ㎛ and 20㎛, respectively. A micro-lens array was fabricated on a cylinder surface over an area of φ 55 ㎜ × 40 ㎜.

Time-dependent Optimal Heater Control in Thermoforming Preheating Using Dual Optimization Steps

Abstract: Thermoforming is one of the most versatile and economical processes available for shaping polymer products, but obtaining a uniform thickness of the final product using this method is difficult. Heater power adjustment is very important because the thickness distribution depends strongly on the distribution of the sheet temperature. In this paper; the steady-state optimum distribution of heater power is first ascertained by a numerical optimization to obtain a uniform sheet temperature. The time-dependent optimal heater input is then determined to decrease the temperature difference through the direction of the thickness using the response surface method and the D-optimal method. The optimal results show that the time-dependent optimum heater power distribution gives an acceptable uniform sheet temperature in the forming temperature range by the end of the heating process.

Robotic Automation Technologies in Construction: A Review

Abstract: Robot technology is a remarkably interdisciplinary research area, one that can be employed in various industrial fields as well as higher value-added fields. The construction industry, on the other hand, has been known as one of the most difficult research fields to apply robotic schemes. Therefore, applying robot technologies in the construction industry is quite a challenging topic. This paper aims to introduce the progress of automated robotic systems in construction fields, namely with respect to construction robots. While construction robots have a very wide range of application depending on the huge market size of the construction industry, there still exist a lot of problems such as highly risky working environment and inefficiency due to the labor intensive characteristic. In order to solve these problems, a variety of construction robots have been developed and, in this paper, the current state of the robotic systems for construction works and the vision of future robot technology in the construction field are introduced.

Parametric NURBS Curve Interpolators

Abstract: Free-form shapes which were once considered as an aesthetic feature are now an important functional requirement. CNC industries are looking for a compact solution for reproducing free-form shapes as conventional interpolation models are inadequate. The parametric curve interpolator developed in the last decade has clearly emerged as favorite among its contemporaries in recent years. At present intense research has been done on parametric curve interpolators and interesting developments are reported. Out of the various parametric representations for curves and surfaces, NURBS has been standardized and widely used in free-form shape design. This paper presents a review of various methods of parametric interpolation for NURBS and discusses the salient features, problems and solutions. Recent approaches on variable feedrate interpolation, parameter compensation are also reviewed and research trends are addressed finally.

An Intelligent Nano-positioning Control System Driven by an Ultrasonic Motor

Abstract: This paper presents a linear positioning system and its control algorithm design with nano accuracy/resolution. The basic linear stage structure is driven by an ultrasonic motor and its displacement feedback is detected by a LDGI(Laser Diffraction Grating Interferometer), which can achieve nanometer resolution. Due to the friction driving property of the ultrasonic motor, the driving situation differs in various ranges along the travel. Experiments have been carried out in order to observe and realize the phenomena of the three main driving modes: AC mode (for ㎜ motion), Gate mode (for ㎛ motion), and DC mode (for ㎚ motion). A proposed FCMAC(Fuzzy Cerebella Model Articulation Controller) control algorithm is implemented for manipulating and predicting the velocity variation during the motion of each mode respectively. The PCbased integral positioning system is built up with a NI DAQ Device by a BCB (Borland C?? Builder) program to accomplish the purpose of an intelligent nano-positioning control.

Effects of Nanopowder Additives in Micro-electrical Discharge Machining

Abstract: The use of electrical discharge machining(EDM) for micro-machining applications requires particular attention to the machined surface roughness and discharge gap distance, as these factors affect the geometrical accuracy of micro-parts. Previous studies of conventional EDM have shown that selected types of semi-conductive and nonconductive powder suspended in the dielectric reduced the surface roughness while ensuring a limited increase in the gap distance. Based on this, an extension of the technique to micro-EDM was studied. Such work is necessary since the introduction of nanopowders suspended in the dielectric is not well understood The experimental results showed that a statistically significant reduction in the surface roughness value was achieved at particular concentrations of the powder additives, depending on the powder material and the machining input energy setting. The average reduction in surface roughness using a powder suspended dielectric was between 14-24% of the average surface roughness generated using a pure dielectric. Furthermore, when these additive concentrations were used for machining, no adverse increase in the gap distance was observed.

Development of a Modular Structure-based Changeable Manufacturing System with High Adaptability

Abstract: Today, manufacturers are forced to acknowledge that the life cycles of products are becoming shorter. In the case of the door trim assembly field, the highly frequent introduction of new products and the continuous increase in product varieties leads to the demand for redesigning assembly systems more often. Modular manufacturing systems can be an important issue in helping to overcome these problems. This paper presents the development of a modular assembly system for the door trim, and because it takes the change drives into consideration, this system is highly flexible in adapting to changes in the environment.

Numerical Design Method for Water-Lubricated Hybrid Sliding Bearings

Abstract: This paper presents a new water-lubricated hybrid sliding bearing for a high speed and high accuracy main shaft system, along with the numerical method used for its design. The porous material for the restrictor and the restriction parameter were chosen based on the special requirements of the water-lubricated bearing. Subsequent numerical calculations give the load capacity, stiffness, and friction power of different forms of water-lubricated bearings. The pressure distribution of the water film in a 6-cavity bearing is shown, based on the results of the numerical calculations. A comparison of oil-lubricated and water-lubricated bearings shows that the latter benefits more from improved processing precision and efficiency. An analysis of the stiffness and friction power results shows that 6-cavity bearings are the preferred type, due their greater stiffness and lower friction power, The average elevated temperature was calculated and found to be satisfactory. The relevant parameters of the porous restrictor were determined by calculating the restriction rate, All these results indicate that this design for a water-lubricated bearing meets specifications for high speed and high accuracy.

Self-assembly of Fine Particles Applied to the Production of Antireflective Surfaces

Abstract: We introduce a new fabrication process for antireflective structured surfaces. A 4-inch silicon wafer was dipped in a suspension of 300-㎚-diameter silica particles dispersed in a toluene solution. When the wafer was drawn out of the suspension, a hexagonally packed monolayer structure of particles self-assembled on almost the complete wafer surface. Due to the simple process, this could be applied to micro- and nano-patterning. The self-assembled silica particles worked as a mask for the subsequent reactive ion etching. An array of nanometer-sized pits could be fabricated since the regions that correspond to the small gaps between particles were selectively etched off. As etching progressed, the pits became deeper and combined with neighboring pits due to side-etching to produce an array of cone-like structures. We investigated the effect of etching conditions on antireflection properties, and the optimum shape was a nano-cone with height and spacing of 500 ㎚ and 300 ㎚, respectively. This nano-structured surface was prepared on a 30 × 10-㎚ area. The reflectivity of the surface was reduced 97% for wavelengths in the range 400-700 ㎚.

A Comparative Study of Transistor and RC Pulse Generators for Micro-EDM of Tungsten Carbide

Abstract: Micro-electrical discharge machining (micro-EDM) is an effective method for machining all types of conductive materials regardless of hardness. Since micro-EDM is an electro-thermal process. the energy supplied by the pulse generator is an important factor in determining the effectiveness of the process. In this study, an investigation was conducted on the micro-EDM of tungsten carbide (WC) to compare the performance of transistor and resistance/capacitance (RC) pulse generators in obtaining the best quality micro-hole. The performance was measured by the machining time, material removal rate, relative tool wear ratio, surface quality, and dimensional accuracy. The RC generator was more suited for minimizing the pulse energy, which is a requirement for fabricating micro-parts. The smaller-sized debris formed by the low-discharge energy of RC micro-EDM could be easily flushed away from the machined zone, resulting in a surface free of burrs and resolidified molten metal. The RC generator also required much less time to obtain the same quality micro-hole in We. Therefore, RC generators are better suited for fabricating micro-structures, producing good surface quality and better dimensional accuracy than the transistor generators, despite their higher relative tool wear ratio.

Practical Ultraprecision Positioning of a Ball Screw Mechanism

Abstract: This paper describes the problem of ultra precision positioning with a ball screw mechanism in the microdynamic range, along with its solution. We compared the characteristics of two ball screw mechanisms with different table masses. The experimental results showed that the vibration resulting from the low stiffness of the ball screw degraded the positioning performance in the microdynamic range for the heavyweight mechanism. The proposed nominal characteristic trajectory following (NCTF) controller was designed for ultra precision positioning of the ball screw mechanism. The basic NCTF control system achieved ultra precision positioning performance with the lightweight mechanism, but not with the heavyweight mechanism. A conditional notch filter was added to the NCTF controller to overcome this problem. Despite the differences in payload and friction, both mechanisms then showed similar positioning performance, demonstrating the high robustness and effectiveness of the improved NCTF controller with the conditional notch filter. The experimental results demonstrated that the improved NCTF control system with the conditional notch filter achieved ultra precision positioning with a positioning accuracy of better than 10 ㎚, independent of the reference step input height.

Development of an In-process Confocal Positioning System for Nanostereolithography Using Evanescent Light

Abstract: A novel stereolithography method using evanescent light has been proposed as a means to realize 100-nanometer resolution. An in-process measurement system with high accuracy has been introduced to the nanostereolithography apparatus. Specifically, an optical microscopic system was developed to monitor the exposure process and a confocal positioning system was established to improve the longitudinal positioning accuracy in the layer-by-layer process. A high-power objective lens, a tube lens, and a charge coupled device (CCD) were included in the optical microscopic system, whereas a laser; a high-power objective lens, a piezoelectric (PZT) stage, a condenser lens, a pinhole, and a photomultiplier (PMT) made up the confocal microscopic system. Two verification experiments were conducted, and the results indicated that the optical microscopic system had a horizontal resolution of 200 ㎚ and that the confocal positioning system provided a depth resolution of 30.8 ㎚. These results indicate that nanostereolithography can be successfully performed with this system.

Multi-axis Milling for Micro-texturing

Abstract: The surface texture of a product is generally produced by etching or sandblasting However, these techniques have problems related to repeatability and environmental pollution. Since current milling machines can produce small parts at the micrometer or nanometer level, the resolution of milling exceeds the manufactured dimensions of the surface texture produced by etching or sand-blasting. A method for generating surface texture by milling is proposed and demonstrated. The proposed method was demonstrated by actual milling using a three- or five-axis control machine, and the machined surface texture was measured with an interferometer to allow comparison with the designed shape. The measurement results demonstrate that the proposed method can generate a wide-area surface texture with good machining repeatability.

An Inner-spherical Continuously Variable Transmission for Electric Bicycles

Abstract: A new continuously variable transmission (CVT) for electric bicycles was developed using a traction drive mechanism with inner and outer spherical rotors. This electric bicycle CVT permits three propulsion modes: human-power only, motor-power only, or a combination of motor power and human power. In addition, the electric bicycle CVT has high power efficiency, large torque capacity, improved drivability, and good packageability. A prototype was manufactured based on a conceptual design, a performance analysis, and a detailed design. This prototype has a rated power of 250 W and input motor speed of 20 rad/s for an overall speed ratio in the range 0.3-1.2. A bench test was conducted to measure the power transmission performance of the prototype.

Fabrication of Composite Drug Delivery System Using Nano Composite Deposition System and in vivo Characterization

Abstract: The Rapid Prototyping (RP) technology has advanced in many application areas. In this research, two different types, cylinder and scaffold. of implantable Drug Delivery System (DDS) were fabricated using Nano Composite Deposition System (NCDS), one of the RP systems. The anti-cancer drug (5-fluorouracil, 5-FU), biodegradable polymer (PLGA(85:15)), and bio ceramic (Hydroxyapatite, HA) were used to form drug-polymer composite material. Both types of DDS were evaluated in vivo environment for two weeks. For evaluation, the cumulative drug release and shape stability were measured. Test results showed that the scaffold DDS provide higher cumulative drug release and has better stability than cylinder DDS.

Development of a Miniature Air-bearing Stage with a Moving-magnet Linear Motor

Abstract: We propose a new miniature air-bearing stage with a moving-magnet slotless linear motor. This stage was developed to achieve the precise positioning required for submicron-level machining and miniaturization by introducing air bearings and a linear motor sufficient for mesoscale precision machine tools. The linear motor contained two permanent magnets and was designed to generate a preload force for the vertical air bearings and a thrust force for the stage movement. The characteristics of the air bearings, which used porous pads, were analyzed with numerical methods, and a magnetic circuit model was derived for the linear motor to calculate the required preload and thrust forces. A prototype of a single-axis miniature stage with dimensions of 120 (W) × 120 (l) × 50 (H) ㎜ was designed and fabricated, and its performance was examined, including its vertical stiffness, load capacity, thrust force, and positioning resolution.

Fuel Cell End Plates

Abstract: The end plates of fuel cell assemblies are used to fasten the inner stacks, reduce the contact pressure, and provide a seal between Membrane-Electrode Assemblies (MEAs). They therefore require sufficient mechanical strength to withstand the tightening pressure, light weight to obtain high energy densities, and stable chemical/electrochemical properties, as well as provide electrical insulation. The design criteria for end plates can be divided into three parts: the material, connecting method, and shape. In the past, end plates were made from metals such as aluminum, titanium, and stainless steel alloys, but due to corrosion problems, thermal losses, and their excessive weight, alternative materials such as plastics have been considered. Composite materials consisting of combinations of two or more materials have also been proposed for end plates to enhance their mechanical strength. Tie-rods have been traditionally used to connect end plates, but since the number of connecting parts has increased, resulting in assembly difficulties, new types of connectors have been contemplated. Ideas such as adding reinforcement or flat plates, or using bands or boxes to replace tie-rods have been proposed. Typical end plates are rectangular or cylindrical solid plates. To minimize the weight and provide a uniform pressure distribution, new concepts such as ribbed-, bomb-, or bow-shaped plates have been considered. Even though end plates were not an issue in fuel cell system designs in the past, they now provide a great challenge for designers. Changes in the materials, connecting methods, and shapes of an end plate allow us to achieve lighter, stronger end plates, resulting in more efficient fuel cell systems.

The Levitation Mass Method

Abstract: The present status and future prospects of the levitation mass method(LMM), a technique for precision mass and force measurement, are reviewed. In the LMM, the inertial force of a mass levitated using a pneumatic linear bearing is used as the reference force applied to the objects being tested, such as force transducers. materials, or structures. The inertial force of the levitated mass is measured using an optical interferometer. We have modified this technique for dynamic force calibration of impact, oscillation, and step loads. We have also applied the LMM to material testing. providing methods for evaluating material viscoelasticity under an oscillating or impact load. evaluating material friction, evaluating the biomechanics of a human hand, and generating and measuring micro-Newton-level forces.

Fuel Cell End Plates :A review

Abstract: The end plates of fuel cell assemblies are used to fasten the inner stacks, reduce the contact pressure, and provide a seal between Membrane-Electrode Assemblies (MEAs). They therefore require sufficient mechanical strength to withstand the tightening pressure, light weight to obtain high energy densities, and stable chemical/electrochemical properties, as well as provide electrical insulation. The design criteria for end plates can be divided into three parts: the material, connecting method, and shape. In the past, end plates were made from metals such as aluminum, titanium, and stainless steel alloys, but due to corrosion problems, thermal losses, and their excessive weight, alternative materials such as plastics have been considered. Composite materials consisting of combinations of two or more materials have also been proposed for end plates to enhance their mechanical strength. Tie-rods have been traditionally used to connect end plates, but since the number of connecting parts has increased, resulting in assembly difficulties, new types of connectors have been contemplated. Ideas such as adding reinforcement or flat plates, or using bands or boxes to replace tie-rods have been proposed. Typical end plates are rectangular or cylindrical solid plates. To minimize the weight and provide a uniform pressure distribution, new concepts such as ribbed-, bomb-, or bow-shaped plates have been considered. Even though end plates were not an issue in fuel cell system designs in the past, they now provide a great challenge for designers. Changes in the materials, connecting methods, and shapes of an end plate allow us to achieve lighter, stronger end plates, resulting in more efficient fuel cell systems.

Assessment and Optimization of Cutting Parameters while Turning AISI 52100 Steel

Abstract: This investigation deals with machining AISI 52100 steel using a carbide-coated tool. The machining cutting force and tool tip temperature are measured online while turning using different cutting parameters. The surface roughness is also measured, but off-line after each cut. The obtained data are analyzed and the influence of the Cutting parameters on the machining variables is determined in the form of plots. Regression models obtained from the results are tested using additional experimental data.

Advanced Process Control of the Critical Dimension in Photolithography

Abstract: This paper describes two run-to-run controllers, a nonlinear multiple exponential-weight moving-average (NMEWMA) controller and a dynamic model-tuning minimum-variance (DMTMV) controller, for photolithography processes. The relationships between the input recipes (exposure dose and focus) and output variables (critical dimensions) were formed using an experimental design method, and the photolithography process model was built using a multiple regression analysis, Both the NMEWMA and DMTMV controllers could update the process model and obtain the optimal recipes for the next run Quantified improvements were obtained from simulations and real photolithography processes.

Fabrication of EDM Electrodes by Localized Electrochemical Deposition

Abstract: The fabrication of complex three-dimensional electrodes for micro electrical discharge machining (micro-EDM) is an important issue in the field of micromachining. Localized electrochemical deposition (LECD) is a simple and inexpensive technique for fabricating micro-EDM electrodes. This study presents a new process for manufacturing electrodes with complex cross-sections using masks of different shapes. In this process, a non-conductive mask is placed between an anode and cathode that are immersed in a plating solution of acidified copper sulfate. The LECD is achieved by applying a pulsed voltage between the anode and cathode, which are separated by a small distance. In this setup, the cathode is placed above the anode and the mask, so that the deposited electrode can be used directly for EDM without changing the tool orientation. We found that the microstructure of the deposited electrode is influenced by the concentration of the plating solution and organic additives. Moreover, the values of the voltage, frequency, and duty cycle of the pulsed input have significant effects on the microstructure of the fabricated electrode. Finally, the optimum values of the voltage, frequency, and duty cycle were determined for the most effective fabrication of complex-shaped electrodes.

Analysis of Factors Impacting Atmospheric Pressure Plasma Polishing

Abstract: Atmospheric pressure plasma polishing (APPP) is a noncontact precision machining technology that uses low temperature plasma chemical reactions to perform atom-scale material removal. APPP is a complicated process, which is affected by many factors. Through a preliminary theoretical analysis and simulation, we confirmed that some of the key factors are the radio frequency (RF) power, the working distance, and the gas ratio. We studied the influence of the RF power and gas ratio on the removal rate using atomic emission spectroscopy, and determined the removal profiles in actual operation using a commercial form talysurf. The experimental results agreed closely with the theoretical simulations and confirmed the effect of the working distance. Finally, we determined the element compositions of the machined surfaces under different gas ratios using X-ray photoelectron spectroscopy to study the influence of the gas ratio in more detail. We achieved a surface roughness of Ra 0.6 ㎚ on silicon wafers with a peak removal rate of approximately 32 ㎣/min.

Hydroforming Simulation of High-strength Steel Cross-members in an Automotive Rear Subframe

Abstract: Hydroforming is a forming technology in which a steel tube is set in a die and formed to fit a specified shape by applying hydraulic pressure from inside the tube while also applying force in the tube axial direction (axial feed). In present study, the entire design process chain for an automotive cross-member was simulated and developed using hydroforming technology on high-strength steel. The part design stage required a feasibility study. The process was designed using computer-aided design techniques to confirm the actual hydroformability of the part in detail. The possibility of using hydroformable cross-member parts was examined using cross-sectional analyses, which were essential to ensure the formability of the tube material for each forming step, including pre-bending and hydroforming. The die design stage included all the components of a prototyping tool. Press interference was investigated in terms of geometry and thinning.

Performance Analysis of an Industrial Inkjet Printing Head Using the 1D Lumped Model

Abstract: A design approach using a one-dimensional (1D) lumped model was studied and applied to an industrial inkjet printing head design for micro patterning on printed circuit boards. For an accurate analysis, a three-dimensional piezoelectric-driven actuator model was analyzed and its jetting characteristics were applied to 1 Danalysis model. The performance of the 1 D lumped model was verified by comparing measured and simulated results. The developed 1 D model helped to optimize the design and configuration of the inkjet head and could be implemented in the design of multi-nozzle inkjet printing heads to improve the jetting frequency and minimize crosstalk.

Fatigue Properties of Copper Foil and the Evolution of Surface Roughness

Abstract: The aim of this investigation was to extract the fatigue properties at the designated fatigue life of copper foil and observe the mean stress and stress amplitude effects on both the fatigue life and the corresponding surface morphology Tensile tests were performed to determine the baseline monotonic material properties of the proportional limit and ultimate tensile strength. Constant amplitude fatigue tests were carried out using a feedback-controlled fatigue testing machine. The mean stress and the stress amplitude were changed to obtain the complete nominal stress￢life curves. An atomic force microscope was utilized to observe the relationship between the fatigue damage and the corresponding changes in surface morphology. A Basquin's exponent of-0.071 was obtained through the fatigue tests. An endurance limit of 122 MPa was inferred from a Haigh diagram. The specimen surface became rougher as the number of fatigue cycles increased, and there was a close relationship between the fatigue damage and the surface roughness evolution.

Evaluation of Ultrasonic Vibration Cutting while Machining Inconel 718

Abstract: Hard and brittle materials, such as Ni-and Ti-based alloys, glass, and ceramics, are very useful in aerospace, marine, electronics, and high-temperature applications because of their extremely versatile mechanical and chemical properties. One Ni-based alloy, Inconel 718, is a precipitation-hardenable material designed with exceptionally high yield strength, ultimate tensile strength, elastic modulus, and corrosion resistance with outstanding weldability and excellent creep-rupture properties at moderately high temperatures. However, conventional machining of this alloy presents a challenge to industry. Ultrasonic vibration cutting (UVC) has recently been used to cut this difficult-to-machine material and obtain a high quality surface finish. This paper describes an experimental study of the UVC parameters for Inconel 718, including the cutting force components, tool wear, chip formation, and surface roughness over a range of cutting conditions. A comparison was also made between conventional turning (CT) and UVC using scanning electron microscopy observations of tool wear. The tool wear measured during UVC at low cutting speeds was lower than CT. UVC resulted in better surface finishes compared to CT under the same cutting conditions. Therefore, UVC performed better than CT at low cutting speeds for all measures compared.

An Integrated Approach to the Improvement of Stability Lobes

Abstract: Redundant spurious loops and overlapping segments in stability lobe diagrams cannot be removed easily by regular methods. A programmatic approach is presented to detect multiple spurious loops occurring within the lobes. They are identified by reorganizing the numerical lobe data into speed-depth corners for subsequent removal. The same principle is then extended to remove overlapping segments of adjacent lobes to obtain a final continuous stability map. Unlike existing methods, the proposed methodology requires no interface with additional editing software, and can also yield stability lobe diagrams more quickly. The methodology is presented with lobe diagrams constructed using milling and turning models.