Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Elsevier BV  

DOI： 10.1016/j.precisioneng.2023.08.004

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：MDPI AG  

Magnesium alloys are lightweight structural materials with excellent machinability. However, further development is seriously limited by their low strength and poor formability. Therefore, further decreasing the surface residual stress of the frame by post-process treatment is a key issue, such as for reducing the subsequent deformation due to the residual stress, improving the machining accuracy and corrosion resistance of the magnesium alloy frame products, and extending the service life of the magnesium alloy frame products. Using AZ31B magnesium alloy as the experimental subject, and by exploring the effects of milling parameters on the surface quality of frame parts, this study shows that the surface residual compressive stress, hardness, and roughness of frame parts decreased with the increasing of the milling speed and increased as the depth of cut and the feed per tooth increased. Using cutting fluid in the milling process can decrease the surface residual stress and roughness of the frame parts but increase the surface hardness. In accordance with the experimental results and analysis, the main reason affecting the residual stress on the surface layer of frame components is the thermal elastoplastic problem caused by thermal mechanical coupling during the milling process, resulting in varying stress states on the workpiece’s surface. The primary contributors to hardness are the work-hardening effect induced by milling forces and the thermal-softening effect of milling temperatures, which either augment or diminish the workpiece’s surface hardness. Furthermore, the primary factor impacting surface roughness is the magnitude of cutting forces. Excessive cutting forces lead to the ploughing phenomenon or tool vibrations, thereby causing varying degrees of surface roughness on the workpiece. Meanwhile, the influence of stress-relief annealing or cryogenic treatment on surface residual stress and hardness after the milling of the frame parts was researched. It shows that within the selected milling parameters, both stress-relief annealing and cryogenic treatment can reduce the surface residual stress and homogenize the residual stress distribution of frame parts. Stress-relief annealing leads to a reduction in the hardness of the machined surface, and the hardness of the machined surface increases slightly under cryogenic treatment. The effects of the two post-processing methods on surface quality vary, and in practical production, a rational selection can be made according to the different processing requirements to achieve the optimal standards.

DOI： 10.3390/met13101712

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Springer Science and Business Media LLC  

DOI： 10.1007/s12666-023-03028-7

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Other Link： https://link.springer.com/article/10.1007/s12666-023-03028-7/fulltext.html

Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Fuji Technology Press Ltd.  

The objective of this study was to determine the effect of vibration behavior on workpiece surface properties in low-frequency vibration cutting. The effects of the parameters that determine vibration behavior on surface roughness were quantitatively evaluated through a comparison with other cutting conditions. Furthermore, by clarifying how the surface properties of the workpiece, such as roughness, roundness, and cross-sectional curves, change depending on the vibration behavior, a search for optimal conditions for low-frequency vibration cutting was conducted. The best surface properties were obtained under the condition of spindle rotation per vibration E=4.5. By using a value close to the minimum possible spindle rotation R=0.5 when the workpiece is retracted, it is expected to be effective in suppressing the variation in surface roughness at each phase angle; this variation is characteristic of low-frequency vibration cutting. Workpieces machined under low-frequency vibration conditions such as (E=2.5, R=1.0) and (E=3.5, R=1.0) were found to form characteristic surface patterns on the workpiece surface owing to a phenomenon in which the depth of the cut to the workpiece changes.

DOI： 10.20965/ijat.2023.p0434

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Authorship：Last author   Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

The effects of internal and external heat generation on machine tools cause thermal deformation to lead to the reduction of machining accuracy. The internal heat generation on spindle, ball screws or motors has been studied and proposed the countermeasures in many reports. However, the heat generation by guiding is not studied enough so far. The demand for machining accuracy in machine tools are still getting higher, then we need to consider the effects of heat generation by guiding. In this study, using the 3-axis vertical type machining center that has the hybrid guiding system (with sliding and rolling elements), the temperature changes and the relative displacement between the spindle and the table are measured. By FEM based on the temperature change data, the thermal deformation is estimated. Then, the effects of heat generation by guiding are investigated and suggested the countermeasures on FEM. The results obtained in the study are as follows, (1) The simulation results based on the experimental data give close agreement with the experimental results. (2) Even if the heat generation of driving system can be suppressed, a certain level of relative displacement might be remained. In some cases, the relative displacement without the heat generation of the driving system is even greater than or equal to that with the heat generation. (3) The countermeasure that the effect of cooling of the guide rail or its circumference on the thermal deformations is simulated and the possibility that can decrease the thermal displacement is suggested.

DOI： 10.2493/jjspe.89.634

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Japanese Society of Tribologists  

DOI： 10.2474/trol.17.306

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Authorship：Last author   Language：Japanese   Publishing type：Research paper (scientific journal)  

DOI： 10.18914/tribologist.22-00011

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Authorship：Corresponding author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Corresponding author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Language：Japanese   Publisher：The Japan Society for Precision Engineering  

DOI： 10.11522/pscjspe.2022a.0_252

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Authorship：Last author   Language：Japanese   Publishing type：Research paper (scientific journal)  

DOI： 10.18914/tribologist.22-00003

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Elsevier BV  

In the cylindrical grinding process, the residual grinding allowance is left owing to the rubbing of the abrasive grains and the elastic deformation of the grinding system caused by the large normal grinding force. Therefore, a sizing gauge is generally used to monitor the workpiece diameter during the process. However, the sizing gauge disturbs the grinding operations, such as loading and unloading the workpiece. In this study, a new method for estimating the grinding stock of a ground workpiece is proposed. In the proposed method, the grinding stock can be estimated without a sizing gauge. The removed volume of the workpiece can be calculated from the power consumption of the wheel motor, which is easily measured. Before the grinding experiments, the specific grinding energy is determined from several grinding results. During the grinding process, the grinding stock of the ground workpiece was estimated using the determined specific grinding energy. It was confirmed that the grinding stock could be accurately estimated under several grinding conditions.

DOI： 10.1016/j.precisioneng.2021.08.012

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (international conference proceedings)  

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Authorship：Last author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Elsevier BV  

DOI： 10.1016/j.precisioneng.2021.07.002

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Language：English   Publishing type：Research paper (scientific journal)   Publisher：Japan Society of Mechanical Engineers  

In cylindrical traverse grinding, a slender workpiece is bent by the normal grinding force due to its low stiffness. Consequently, a form error is generated by the elastic deformation of the workpiece during the grinding process. To prevent such deformation of the workpiece, a steady rest is generally used. However, when the contact point between the workpiece and the steady rest is ground, the pushing force of the steady rest is lost, and the elastic deformation of the workpiece is increased immediately. As a result, a step shape error is generated at the contact point. To improve the use of the steady rest, the elastic deformation of the workpiece during the grinding process is simulated using the beam model considering the steady rest in this study. From the analysis results, it was determined that placing the steady rest outside the grinding part can reduce the elastic deformation of the workpiece. In addition, the traverse speed was controlled to maintain a constant elastic deformation. Through grinding experiments, it was confirmed that the form accuracy of the slender workpiece was improved by setting the steady rest outside the grinding part and adjusting the traverse speed.

DOI： 10.1299/jamdsm.2021jamdsm0049

Web of Science

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Language：English   Publishing type：Research paper (international conference proceedings)  

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Language：English   Publishing type：Research paper (international conference proceedings)  

In the cylindrical grinding process, the residual grinding allowance is left owing to the rubbing of the abrasive grains and the elastic deformation of the grinding system caused by the large normal grinding force. Therefore, a sizing gauge is generally used to monitor the workpiece diameter during the process. However, the sizing gauge disturbs the grinding operations, such as loading and unloading the workpiece. In this study, a new method for estimating the grinding stock of a ground workpiece is proposed. In the proposed method, the grinding stock can be estimated without a sizing gauge. The removed volume of the workpiece can be calculated from the power consumption of the wheel motor, which is easily measured. Before the grinding experiments, the specific grinding energy is determined from several grinding results. During the grinding process, the grinding stock of the ground workpiece was estimated using the determined specific grinding energy. It was confirmed that the grinding stock could be accurately estimated under several grinding conditions.

DOI： 10.1016/j.precisioneng.2021.08.012

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Language：English   Publishing type：Research paper (international conference proceedings)  

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© 2020 Elsevier Inc. In this study, we investigated thermal influence on surface layer of CFRP in grinding with heat conduction analysis using grinding temperature at wheel contact area on dry and wet condition. Moreover, the thermal affected layer was analyzed through an experiment to examine the temperature of glass transition and thermal decomposition of the matrix resin that composes the CFRP used in this study. The influence of thermal effect on grinding of CFRP was verified based on observation of ground surface finish after grinding using SEM and the measurement of surface roughness. From the measurement result of DSC (Differential Scanning Calorimetry)，TG-DTA (Thermogravimetry-Differential Thermal Analysis), It was found that the thermal affected layer of CFRP includes a layer in which the matrix resin is changed in quality by exceeding the glass transition temperature and a layer in which the matrix resin is thermally decomposed by exceeding the thermal decomposition temperature. In addition, it was found that the surface roughness was significantly reduced if the thermal affected layer with thermal decomposition was generated. In each grinding atmosphere, it tended to increase of grinding temperature at wheel contact area with increasing in the setting depth of cut. In the case of dry grinding, grinding temperature at wheel contact area increased up to t thermal decomposition temperature of the matrix resin. However, in the case of the wet grinding, grinding temperature at wheel contact area did not increase until thermally decomposition temperature. From the result of simulation about thermal affected layer, influence of grinding heat increased with increasing in the setting depth of cut. Ultimately, the thermal affected layer with thermal decomposition was generated in dry grinding. Moreover, from the results of SEM observation, it was confirmed that the surface finish properties deteriorated significantly due to thermal decomposition of the matrix resin in the case of Δ = 400 μm in the setting depth of cut at fiber angle θ = 0°. On the other hand, it was confirmed that the micro damage of carbon fiber was occurred in wet grinding at each setting depth of cut.

DOI： 10.1016/j.precisioneng.2020.04.005

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In the case of traverse grinding of a slender workpiece, the ground workpiece is easily deformed by the normal grinding force due to its low stiffness. To reduce the form error caused by the elastic deformation of the workpiece, a steady rest is widely used. Generally, a steady rest is set to push the ground area of the workpiece. However, the stepped shape error is generated at the contact point where a steady rest pushed the workpiece because the pushing force of a steady rest is decreased after the material of the contact point is removed. In this study, to reduce the stepped shape error of the ground workpiece, we proposed a new method to set a steady rest. In this method, the steady rest was set to push the area where was not ground. In addition, the traverse speed of the workpiece was adjusted to keep the elastic deformation of the workpiece constant. The suitable method to control the traverse speed was estimated by using a beam model that could simulate the elastic deformation of the workpiece during the grinding process. It was confirmed that the new method could improve the form accuracy of a slender workpiece through grinding experiments.

DOI： 10.1115/LEMP2020-8507

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In the case of internal grinding of a deep hole, the inner surface of the hole was ground by a slender grinding wheel that has a high aspect ratio. A slender grinding wheel is bent by the normal grinding force during the grinding process. Therefore, the form accuracy of the ground workpiece is decreased especially when the aspect ratio of a wheel is high. In our previous study, it was confirmed that the biggest factor that generated the form error of the workpiece was the elastic deformation owning to the normal grinding force. To reduce the form error of the ground workpiece, it is effective to expand the spark-out duration. However, the expansion of the spark-out duration leads to the low productivity. In this study, the form of the grinding wheel was modified by a diamond dresser to improve the form accuracy of the workpiece without expanding the spark-out duration. The modified form of a wheel was determined to compensate the form error of the workpiece generated by the elastic deformation of the grinding wheel. Thorough several grinding experiment, it was confirmed that the form accuracy of the ground workpiece was successfully improved by modifying the form of a slender grinding wheel without expanding the spark-out duration.

DOI： 10.1115/LEMP2020-8595

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© 2019 Inderscience Enterprises Ltd. The five factors (abrasive grain, grain size, grade, structure and bonding material) of the three main elements (abrasive grain, bonding material and pore) of a grinding wheel are important parameters affecting surface quality and grinding efficiency, however it is difficult to determine an optimal combination of grinding conditions for workpiece material. In previous research, we constructed a support system for effectively selecting an appropriate grinding wheel using decision tree technique. We also proposed a visualisation process to show how grinding wheel elements and factors correspond to the materials characteristics of the workpiece material. In this research, to evaluate the usefulness of prepared visualisation maps and their effectiveness in deciding grinding wheel elements, we performed comparison experiments applying the surface grinding technique to JIS SUS310S material using PA abrasive grain as recommended by the grain-type visualisation map and WA and GC abrasive grains for comparison purposes. We found that visualisation maps enable quick selection of a grinding wheel even for the grinding of difficult-to-cut materials for which grinding wheel selection is usually difficult.

DOI： 10.1504/IJAT.2019.106676

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© 2019, Fuji Technology Press. All rights reserved. Ring-shaped SiC ceramics used in sliding components were examined herein. Conventional lapping generates many shallow scratches in random directions in the surface of such SiC ceramics, and these starches extend from the inner circumference of the surface to its perimeter. The scratches affect the ability of the surface to prevent liquid from escaping from the perimeter side to the inner-circumference side of the SiC ring, and they can increase the friction force of the finished surface as a sliding material. We propose concentric mutual lapping to remove the scratches caused by conventional lapping. The surface topography of a SiC ring is evaluated quantitatively using a white light interferometer, and a vector and quantitative analysis of the surface profile is proposed. The results show that concentric mutual lapping can quickly remove the scratches caused by conventional lapping, and subsequently, circumferential scratches are generated along the lapping direction. We have also conducted sliding tests to analyze the effect of surface topography on the surface function as a sliding material. The results reveal that concentric mutual lapping suppresses the differences in surface function that occurred depending on the sliding direction.

DOI： 10.20965/ijat.2019.p0756

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© 2019, Fuji Technology Press. All rights reserved. During the cylindrical traverse grinding of a slender workpiece, the ground workpiece is easily bent by the normal grinding force owing to its low stiffness. Therefore, it is difficult to finish the slender workpiece with high accuracy. To prevent the elastic deformation of a workpiece during the grinding process, a steady rest is generally used. However, considerable skill of the worker is required to use a steady rest. Therefore, we developed a new traverse grinding method without any steady rest. In this method, the elastic deformation of a workpiece was kept constant by controlling the traverse speed of the workpiece. At the middle of the ground workpiece, where the elastic deformation increased easily, the traverse speed was slowed down. However, this method had a longer grinding cycle time because the average traverse speed decreased compared to that of the conventional method. To shorten the cycle time, the peripheral speed of the grinding wheel was increased to decrease the normal grinding force. Basic grinding experiments were carried out under several grinding conditions by changing the peripheral speed of the wheel. From these grinding experiments, it was confirmed that the normal grinding force and the form error of the ground workpiece decreased as the peripheral wheel speed increased. By using results obtained from basic experiments, grinding experiments involving changes in the traverse speed were carried out at two peripheral wheel speeds. The grinding cycle time was reduced successfully by increasing the peripheral wheel speed without an increment in the form error of the ground workpiece. Furthermore, a form error was observed at the end of the workpiece where the grinding wheel traveled away from the workpiece. The form error occurred because the normal grinding force decreased rapidly when the contact length between the workpiece and the wheel was decreased at the end of the workpiece. To prevent rapid changes in the normal grinding force, the traverse speed of the workpiece was increased at the end of the workpiece. By using this method, a ground workpiece with high form accuracy was obtained.

DOI： 10.20965/ijat.2019.p0728

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© 2019 Japan Society for Precision Engineering. All rights reserved. An internal surface of a deep hole is finished by internal grinding. Although the grinding wheel is fed to the axial direction of the workpiecc with oscillation in the conventional internal grinding, the end of the wheel wears out. To prevent the intensive wheel wear, we proposed a new internal grinding method. In this method, the grinding wheel was fed to the radial direction and the plunge grinding was carried out by a slender grinding wheel. In this method, the grinding wheel should be retracted at the suitable moment to reduce the internal form error of the ground workpiecc. The main cause of the form error is elastic deformation of the grinding wheel, and the wheel runout is also an error factor. The form error of the workpiece was improved with considering two kinds of error factor in the plunge internal grinding with a slender grinding wheel. Furthermore, the profile of the grinding wheel was modified to shorten the grinding cycle time.

DOI： 10.2493/jjspe.85.885

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Language：Japanese   Publishing type：Research paper (scientific journal)  

J-GLOBAL

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Language：English   Publishing type：Research paper (scientific journal)   Publisher：Fuji Technology Press  

DOI： 10.20965/ijat.2018.p0861

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© ISAAT 2018 - 21st International Symposium on Advances in Abrasive Technology. All rights reserved. In this study, the ring shaped SiC ceramics applied to sliding components are selected as specimens. In the surface of SiC ceramics, many scratches penetrating the inner edge to outer one are generated in random direction by conventional lapping. The scratches affect the surface functions in prevention of fluid exuding from the outer side to the inner side of SiC ring and have low friction force on the finished surface as a sliding material. In this study, the concentric mutual lapping is proposed to remove the scratches by conventional lapping. Then, the surface topography is evaluated quantitatively by the white light interferometer and proposed the vectorial and quantitative analysis of surface profile. As a result, the concentric mutual lapping can remove scratches quickly by the conventional lapping. And then circumferential scratches along a lapping direction were generated. In addition, we analyzed effect of surface topography on the surface function as a sliding material by sliding tests. From the investigation, it turned out that the concentric mutual lapping suppressed the difference in surface functions depending on the sliding direction.

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© ISAAT 2018 - 21st International Symposium on Advances in Abrasive Technology. All rights reserved. In cylindrical traverse grinding of a slender workpiece, the elastic deformation of the workpiece is caused by the normal grinding force. Due to the low stiffness of a slender workpiece, the workpiece shape error tends to increase especially at the end edge where the wheel draws away from the workpiece. This shape error observed at the end edge of the workpiece has great influence on the shape accuracy of the ground workpiece. Therefore, it is necessary to reduce the shape error at the end edge to improve the shape accuracy. The purpose of this study is to estimate the shape error at the end edge of the workpiece to explore appropriate grinding conditions. The shape error of the ground workpiece was estimated by calculating the elastic deformation of the ground workpiece based on the measured normal grinding force. The estimated shape error agreed well with the measured one of the actually ground workpiece. Investigation compared the shape error of the ground workpiece with the estimated one from the normal grinding force measured during the process.

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© ISAAT 2018 - 21st International Symposium on Advances in Abrasive Technology. All rights reserved. The recommended grinding conditions are described in five factors (abrasive grain, grain size, grade, structure, and bonding material) of the three main elements (abrasive grain, bonding material, and pore) in the grinding wheel catalog data-set. As systematic arrangement is not made, grinding conditions (cutting speed, table feed, depth of cut) have to be decided on the basis of an experienced engineer's information or experience. Moreover, although the setting of the five factors of the three elements of a grinding wheel is important parameter that affects the surface quality and grinding efficiency, it is difficult to determine the optimal combination of workpiece materials and grinding conditions. In this research, a support system for effectively deciding the desired grinding wheel was built by using a decision tree technique, which is one of the data-mining techniques. This system extracts a significant tendency of grinding wheel conditions from catalog data. As a result, a visualization process was proposed in correspondence to the action of the grinding wheel elements and their factors to the material characteristics of the workpiece material. In this report, we produced patterns to support selection of grinding wheels by visualizing the surface grinding wheel selection decision tendency from more amount of data, based on data mixed with JIS (Japan Industrial Standards) and maker's catalog data.

DOI： 10.1504/IJAT.2019.101399

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© 2018 CURRAN-CONFERENCE. All rights reserved. In the grinding wheel catalog data-set, the recommended grinding conditions are shown in reference to five factors (abrasive grain, grain size, grade, structure, and bonding material) of the three main elements (abrasive grain, bonding material, and pore). Since systematic arrangement is not made, grinding conditions (cutting speed, table feed, depth of cut) have to be decided on the basis of an experienced engineer's information or experience. Moreover, although the setting of the five factors of the three elements of a grinding wheel is important parameter that affects the surface quality and grinding efficiency, it is difficult to determine the optimal combination of workpiece materials and grinding conditions. In this research, a support system for effectively deciding the desired grinding wheel was built by using a decision tree technique, which is one of the data-mining techniques. This system extracts a significant tendency of grinding wheel conditions from catalog data. As a result, a visualization process was proposed in correspondence to the action of the grinding wheel elements and their factors to the material characteristics of the workpiece material.

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© ISAAT 2017.All right reserved. In dry grinding of hard carbon parts with micro-grit diamond wheels, carbon chips adhere to the wheel surface and the grindactivity of diamond wheel is remarkably lost in a short time. There blunt diamond wheels after wheel loading have an influence on the grinding results such as the stock removal, the surface roughness of workpiece. Generally, the grinding ability of diamond wheel in which the wheel loading occurs is recovered by the dressing. However, the dressing removes not only carbon chips but also abrasive grains under carbon chips, which have enough cutting performance. Since the dressing increases irrelevant wheel wear in this case, dressing is not desirable from the viewpoint of total life of grinding wheel and manufacturing cost. The carbon chips on wheel surface could be also removed by the organic solvent cleaning, however it is undesirable for working environments. The purpose of this research is to clean up carbon chips on wheel surface by dry ice blasting for dry grinding. In addition, the recovery of grindactivity after dry ice blasting was investigated. Dry ice hardly affects the environment and workers because dry ice sublimes to carbon dioxide. In this paper, the grindactivity of micro-grit diamond wheels clean up by dry ice blasting is investigated, analyzing surface roughness of workpiece, stock removal and tangential force in grinding tests. In addition, the grindactivity of wheels treated by other methods is investigated. As a result, the dry ice blasting can remove carbon chips accumulated on micro-grit diamond wheel enough to recover the grindactivity of wheel with normal surface roughness, stock removal and tangential force as before wheel loading.

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© ISAAT 2017.All right reserved. The shape error of the ground workpiece worsens in case of internal grinding with a slender grinding wheel. In this study, we propose a new grinding system to improve the shape accuracy of the ground workpiece, where the grinding force was estimated previously to minimize the shape error. Considering the effect of wheel wear and wheel run-out on the shape error, the optimized grinding force was obtained by simulating the wheel wear before grinding. Grinding experiments were carried out to verify the proposed system which successfully reduced shape error of the workpiece.

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In the grinding wheel catalog data-set, the recommended grinding conditions are shown in reference to five factors (abrasive grain, grain size, grade, structure, and bonding material) of the three main elements (abrasive grain, bonding material, and pore). Since systematic arrangement is not made, grinding conditions (cutting speed, table feed, depth of cut) have to be decided on the basis of an experienced engineer's information or experience. Moreover, although the setting of the five factors of the three elements of a grinding wheel is important parameter that affects the surface quality and grinding efficiency, it is difficult to determine the optimal combination of workpiece materials and grinding conditions. In this research, a support system for effectively deciding the desired grinding wheel was built by using a decision tree technique, which is one of the data-mining techniques. This system extracts a significant tendency of grinding wheel conditions from catalog data. As a result, a visualization process was proposed in correspondence to the action of the grinding wheel elements and their factors to the material characteristics of the workpiece material.

DOI： 10.1299/jsmelem.2017.9.009

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In cylindrical grinding, thermal deformation of a ground workpiece can reduce the size accuracy. To improve the size accuracy, it is necessary to consider the thermal deformation during grinding process. In this study, we develop an intelligent grinding system that can consider the thermal deformation of the ground workpiece. In this system the thermal deformation of the workpiece is simulated during grinding process. The thermal deformation is simulated from the measured grinding force. Grinding force is measured by the strain gauges mounted on the race center. The grinding heat conducted into the ground workpiece is estimated from the measured normal grinding force. The net stock removal, that is the stock removal measured after the workpiece is cooled, is estimated by adding the measured stock removal and simulated thermal deformation of the workpiece. To obtain the target stock removal, the grinding wheel is retracted as the net stock removal is reached to the target stock removal. With using the developed grinding system, grinding experiments were carried out. In these grinding experiments, the size error is reduced less than 1 micro meter in radius even though the thermal deformation is more than 2 micro meters in radius. With grinding experiments, it is confirmed that the developed grinding system can improve the size accuracy successfully.

DOI： 10.1299/jsmelem.2017.9.143

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J-GLOBAL

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In cylindrical plunge grinding, the dimensional accuracy of a workpiece is reduced due to its thermal deformation. Therefore, it is necessary to simulate the thermal deformation of a workpiece during grinding in order to obtain high accuracy. To calculate the thermal deformation of a workpiece, we propose a new simulation method, in this method, the thermal deformation of a workpiece is calculated with the tangential grinding force that can be estimated easily from the measured power consumption of the wheel motor. Grinding experiments were carried out in several grinding conditions to verify the proposed method. Good agreement was achieved between the simulated thermal deformation of the workpiece and the experimental results in each grinding condition.

DOI： 10.2493/jjspe.82.70

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In machining of CFRP, the delamination occurs at interfaces between matrix resin and carbon fibers due to the machining heat causes a deterioration of the surface quality because of poor heat resistance of matrix resin. However, the thermal environments of CFRP at the machining point haven't been made clear enough. In this study, the grinding temperature is measured in grinding of CFRP under dry and wet with vitrified bond diamond wheel. Furthermore, variations of the instantaneous heat transfer coefficients at the grinding point are calculated based on the grinding temperature data, and the effect of grinding atmosphere on the heat transfer characteristics at the grinding point is investigated experimentally.

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In cylindrical grinding for a long workpiece, the elastic deformation of the workpiece reduces the shape accuracy because of its low stiffness. Therefore, it is very important to analyze the elastic deformation of the workpiece during grinding process. In this study, an advanced analyzing method of the shape error in case of a long workpiece was proposed. In the proposed method, the normal grinding force, which is the important factor for the elastic deformation of the workpiece, was estimated from the power consumption of the wheel motor. To evaluate the proposed analysis method, the analyzed shape error was compared with measured shape error obtained by grinding experiment.

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Authorship：Lead author,　Corresponding author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Trans Tech Publications Ltd  

© (2015) Trans Tech Publications, Switzerland. In dry grinding of hard carbon parts, the grinding performance of wheel is remarkably lost by carbon chips loading on wheel surface. The deterioration in grinding performance of wheel affects the grinding accuracy and efficiency. Generally, the grinding performance of loading wheel recovers by dressing. However, the dressing is not suitable from a viewpoint of the wheel life and the production cost because many abrasive grains having sharp edges under loading carbon chips on wheel surfaces are lost by dressing. In this study, we propose the application of dry ice blasting as a removal method of loading carbon chips. The dry ice is little influence on the working environment because of the quick sublimation of dry ice particles to carbon dioxide. In addition, the dry ice blasting might be suitable for the chip removal method because the dry ice doesn't remain on wheel surfaces after blasting without the damage of wheel surfaces. The dry ice blasting tests of resinoid bond diamond wheel surface with no grinding performance by loading carbon chips are carried out, and the effects of dry ice blasting on removal of loading carbon chips are investigated, analyzing the protrusion height of abrasive grains, the impact pressure in the dry ice blasting and so on.

DOI： 10.4028/www.scientific.net/KEM.656-657.220

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© (2015) Trans Tech Publications, Switzerland. In surface grinding, the shape error is occurred by the thermal deformation of a ground workpiece. To finish the workpiece with high accuracy, it is necessary to understand the temperature distribution of the workpiece during grinding process. However there is no study to analyze the temperature distribution of a large workpiece during surface grinding process. In this study, an advanced simulation analysis method of the temperature distribution for a large workpiece was developed. In the developed simulation analysis method, the temperature distribution was calculated from the power consumption of the wheel motor. The power consumption can be obtained easily without any specialized equipment. To evaluate the developed simulation analysis method, in-process measurement of the temperature distribution of a large workpiece was also carried out. A large workpiece ground in this study weights about 1.3 tons. The temperature distribution was measured with thermistors mounted in many places of the ground workpiece. At the area close to the grinding surface, it was found that temperature rises immediately after the passage of grinding wheel with measuring the developed in-process measurement system. On the other hand, at the area far from the grinding point, temperature does not change quickly. The in-process measured temperature distribution agreed well with the simulated results.

DOI： 10.4028/www.scientific.net/KEM.656-657.353

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Authorship：Lead author,　Corresponding author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Trans Tech Publications Ltd  

© (2015) Trans Tech Publications, Switzerland. The grinding performance of wheel remarkably decreases by the wheel loading in dry grinding of precision hard carbon parts. When the wheel loading occurs, the dressing is carried out to remove loading chips for generation of the grinding performance. However, many abrasive grains, which have enough cutting ability under loading chips, are removed in dressing. We therefore have developed the wheel surface cleaning using adhesive films without dressing to remove loading carbon chips on wheel surfaces in our previous reports, and the cleaning could achieve the lean regeneration of grinding performance of fine grade diamond wheels. The removing ability of loading chips is improved by increasing the peeling speed of adhesive film, the pressing time of adhesive films or the number of pressing time. However the optimum cleaning condition has not been investigated. In this report, from the viewpoint of efficiency in the treatment, we therefore investigate the optimum rolling press process of adhesive film on loading disc wheel surfaces in dry grinding of carbon. The optimum treatment processes are experimentally made clear, analyzing SPa of cleaned wheel surfaces, which is one of surface roughness parameters having the correlation with the protrusion height of abrasive grains. Furthermore, the effect of the treatment on regeneration of grinding performance is experimentally verified by grinding tests of hard carbons.

DOI： 10.4028/www.scientific.net/KEM.656-657.283

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Authorship：Lead author,　Corresponding author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：Fuji Technology Press  

In mass production cylindrical grinding operations, the ground surface finish has never been measured in each grinding cycles because existing surface roughness testers take a relatively long time to measure surface finishes, and the introduction of a surface roughness tester in each grinding cycle would affect mass production processes. Therefore, the surface finish of all parts manufactured in a production lot is generally evaluated based on the measured results of only few parts by sampling checks. We have proposed a unique quick technique for measuring surface roughness. It uses electromotive force based on the slight frictional heat to evaluate the surface finish of cylindrical workpieces rotating on cylindrical grinding machines, and it can do this in a split second just after each grinding cycle, so it does not hamper mass production grinding processes. The proposed quick measurement system can capture the variations in surface finish in a set of repeated cylindrical grinding cycles without dressing. The possibility of accurate judging dressing time by using the quick measurement system in mass production grinding processes is shown experimentally.

DOI： 10.20965/ijat.2015.p0176

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© (2014) Trans Tech Publications, Switzerland. In superfinishing, a fine surface can be obtained by transiting the machining states from the cutting action to the finishing one. In this study, we propose an advanced machine control system in superfinishing. The superfinishing stone is retracted automatically when the proposed system detects improvement in the surface roughness of the workpiece. The suitable machining time is determined by monitoring the machining force ratio measured with a force sensor. With machining experiments, we confirm that the finished surface roughness can be controlled by adjusting the threshold value of the machining force ratio to retract the superfinishing stone during machining.

DOI： 10.4028/www.scientific.net/AMR.1017.515

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© (2014) Trans Tech Publications, Switzerland. Soft magnetic powder cores are made by pressurizing and molding pure iron powder covered with insulation film. The material is used as a component of electro-magnetic converter parts essential for automobiles, home electric appliances and electronic equipment. The material permits downsizing and higher performance of such equipment. The recent severer requirements for performance and dimensional accuracy need a new processing technology that warrants the required level of both magnetic performance and surface quality of the material. However in general, processing - grinding - soft magnetic powder cores can give rise to degradation of magnetic performance and/or chipping or plucking of the ground surface due to the mechanical damage of the insulation film and/or loss of structural particles from the material due to the increase in grinding resistance. The authors performed basic studies for various grinding conditions and wheels that could possibly affect the quality of the material with a view to eliminating these problems. As a result, factors that affect the surface quality were identified, and a method that warrants a higher surface quality was proposed.

DOI： 10.4028/www.scientific.net/AMR.1017.27

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© (2014) Trans Tech Publications, Switzerland. In order to establish a high performance grinding method of cemented carbide, the grinding force distribution on the working surface of the cup type electroplated diamond grinding wheel is experimentally analyzed with the grinding force variation of face grinding, which is carried out on the narrow workpiece. The grinding force distribution is obtained by the successive difference of the grinding force variation. The grinding state becomes steady as soon as beginning of the interference of grinding wheel in workpiece, because the edge profile of workpiece is formed as same as the envelope of the grinding wheel. Main conclusions obtained in this study are as follows. In the region of the front edge of the grinding wheel, relatively large grinding force occurs, then in the region of the rear edge of the grinding wheel, the grinding force becomes smaller. In the left right-side end of the wheel, the grinding forces are larger than the center of the wheel. It is made clear that the grinding force distribution shows the peak value near the outer part of the wheel, and the peak value is larger in the center part of the wheel, on the contrary, the peak width become broad in both the left and right-side end of the wheel.

DOI： 10.4028/www.scientific.net/AMR.1017.9

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© (2014) Trans Tech Publications, Switzerland. In cylindrical traverse grinding of a long workpiece with high aspect ratio, the shape accuracy of a workpiece worsens due to its low stiffness. In this study, the grinding force was measured during grinding process to calculate the elastic deformation of a workpiece caused by the normal grinding force. By comparing calculated elastic deformation with the measured shape error of ground workpiece, the cause for the shape error in case of grinding a long workpiece was investigated experimentally. From experimental results, it is confirmed that the main factor of the shape error of the long workpiece is its elastic deformation during grinding process.

DOI： 10.4028/www.scientific.net/AMR.1017.78

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© (2014) Trans Tech Publications, Switzerland. The micro patterning on a cylindrical surface is conventionally carried out by electrochemical machining, chemical etching, cutting and so on. However, there exists some problems in machining dimensional errors and tool lives. On the other hand, blasting is expected as one of micro fabrication methods and progresses to apply for machining of hard and brittle materials. The purpose of this study is to develop the micro blasting technique for patterning of micro herring-bone grooves on spindle surfaces of the fluid dynamic bearings. Then, machining characteristics in blasting of rotating workpieces are experimentally investigated, analyzing stock removals, burr heights and groove shapes. In addition, micro herring-bone grooves are patterned on spindle surfaces by blasting and the performance of herring-bone bearings are evaluated. The herring-bone bearings with micro grooves patterned on a spindle surface by blasting have enough performance, compared with conventional ones.

DOI： 10.4028/www.scientific.net/AMR.1017.205

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The surface finish is one of important evaluation items of grinding results as well as the form and size accuracy or the surface quality in grinding. The surface finish of the ground surface has never been measured after each grinding cycle because the measurement of the surface finish needs relatively a long duration by existing surface roughness testers and applications of surface roughness tester in each grinding cycle would affect mass-production processes. We propose a rapid on-machine measurement technique of the surface finish, which can check the surface finish of cylindrical workpieces rotating on cylindrical grinding machines in a split second just after each grinding cycle, and the usefulness without hampering mass-production grinding processes is shown in this study.

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In the NC machine tools for automatic mass production processing lines, it is demanded that high stable machining accuracy is maintained for a long time. The main factor of deterioration in machining accuracy depends on the thermal deformation of machine tool, and the measures are one of the most important issues in the machine tool design. The thermal deformation is practically estimated by the temperature changing state of machine tools based on obtained data of their thermal deformation chracteristics. The estimation accuracy of thermal deformation depends on the thermometry points of machine tool greatly. This study describes an approach to the most suitable thermometry points in machine tool to determine the effective thermal deformation measures experimentally. As a result, the existence of points where the temperature of components changed with relation to thermal deformation very closely was confirmed. © (2013) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.797.603

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Language：English   Publishing type：Research paper (scientific journal)   Publisher：TRANS TECH PUBLICATIONS LTD  

In cylindrical grinding, a sizing device is generally used to obtain the required dimension. However, the dimensional error can be caused by the thermal deformation of the workpiece even if grinding machine is controlled with the sizing device. To solve this problem, it is necessary to develop the grinding system that can consider the thermal deformation of the workpiece during grinding process. In this study, an advanced grinding system was developed, which can predict the net stock removal of ground workpiece immediately. The grinding experiment is carried out to verify the developed system. © (2013) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.797.609

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CFRP (Carbon Fiber Reinforced Plastics), which is increasingly applied to airplanes, automobiles, production equipment for electronic device, and so on, is machined after molding process. Grinding is often used for edge finishing of CFRP parts. This paper deals with the influence of grinding atmosphere on grinding characteristics of CFRP by the experimental investigation of ground surface characteristics, surface finish, grinding force, grinding temperature, etc. in surface grinding of unidirectional CFRP using a vitrified bond diamond wheel with the water soluble coolant and the liquid nitrogen in addition to dry grinding. The grinding temperature has been measured by a developed thermocouple system using carbon fibers being made up CFRP and a constantan wire setting between CFRP specimens. The grinding temperature at wheel contact area on CFRP is higher than the glass-transition temperature of CFRP at larger setting wheel depth of cut. The wet grinding prevents in worsening ground surface of CFRP and increasing grinding force that occur in dry grinding of CFRP. The liquid nitrogen makes some effect on prevention in wheel loading and delamination of carbon fibers in dry grinding of CFRP, however the grinding force supplying liquid nitrogen becomes larger than that in dry grinding because of an increase in hardness of CFRP by freeze up. The bending strength of ground CFRP, which suggests the scale of affected layer, is improved by supplying the water soluble coolant and the liquid nitrogen in grinding process. © 2013 The Japan Society of Mechanical Engineers.

DOI： 10.1299/kikaic.79.5068

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Authorship：Lead author,　Corresponding author   Language：English   Publishing type：Research paper (scientific journal)   Publisher：TRANS TECH PUBLICATIONS LTD  

Single-layered metal bond diamond wheels are useful to high efficient grinding of difficult-to-grind materials because of the high gripping force of abrasive grains and the controllable grain density. In this paper, fundamental information are obtained for an application of electrostatic force to setting of diamond grains into pasted metal bond slurry layer on wheel surface, investigating experimentally jumping phenomenon of diamond grains in an electrostatic field between a electrode plate and metal bond slurry layer. The SD grains and the SDC grains coated with Ti are selected. SDC grains jump into a metal bond layer as quick as making an electrostatic field, however SD grains jump with short time lags. The setting rate of SDC grains is larger than that of SD grains, and setting position accuracy of SDC grain array is better than SD grain array. The possibility of setting abrasive grains into single-layered metal bond diamond wheel surface using electrostatic force is obtained and SDC grains are suitable to the proposed abrasive setting method. © (2012) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.565.40

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The purpose of this study is a practical application of the cavitation aided abrasive machining (CAAM). This study shows the machining effect of the precision abrasive machining on injection molds using the cavitation in a suction flow of slurry, which can easily finish to a fine surface by a simple apparatus. The cavitation occurred above the workpiece surface downstream of the restrictor tip because of the rapid decompression and then the abrasive grains in the water interfere with the workpiece surface by the cavitation impact. In this report, the possibility of application of the cavitation aided abrasive machining to the precision manufacturing of micro air vents on the rib of injection molds are generated by using masks of a certain thickness that are made on a special masking equipment, and the machining characteristics of micro air vents are investigated by analyzing the depth of micro grooves and the surface finish in machining of injection molds. When the depth of the micro grooves is approximately 1μm in the machining of 30 minutes, the manufacture of molding parts without burrs or residual voids is carried out by CAAM. © (2012) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.565.597

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Authorship：Lead author,　Corresponding author   Language：Japanese   Publishing type：Research paper (scientific journal)  

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Language：English   Publishing type：Research paper (international conference proceedings)   Publisher：JAPAN SOC PRECISION ENGINEERING-JSPE  

In cylindrical plunge grinding, thermal deformation of a workpiece can cause its dimensional error. Therefore, it is necessary to investigate thermal deformation process of the workpiece based on the temperature distribution during grinding. To calculate the thermal deformation of the workpiece, advanced new simulation method is proposed in this study. The temperature distribution is calculated with the grinding energy that can be estimated from the measured power of grinding wheel motor. The results of these simulations were compared to experimental results obtained with in-process measurement system of internal temperatures and thermal deformation of the workpiece. Good agreement was achieved between the simulated thermal deformation and the experimental one.

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The purpose of this study is to develop the environment-friendly coolant. Cylindrical plunge grinding tests are carried out using alkaline electrolyzed water, high-frequency reduced water and alkali-reduced water as coolant. Most effective coolant is brought out in comparison with surface roughness, grinding force and workpiece surface temperature. Moreover, elemental analyses and measurements of contact angle of treated water are carried out in order to clarify the effect on grinding performance. Furthermore, elemental analyses and observation of evaporation residues in treated water are also carried out. As a result, grinding performance using alkali-reduced water is better than that using alkaline electrolyzed water or high-frequency reduced water. © (2012) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.565.16

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In cylindrical plunge grinding, a large amount of heat flows into the workpiece continuously, accumulates and remains even after the process, which causes dimensional error. Therefore it is necessary to investigate the temperature distribution in the workpiece during grinding and analyze the influence of grinding heat on the dimension. Such an investigation has not been done enough, because the technology to measure the temperature distribution in the rotating workpiece has not matured. Considering such background, an in-process measuring system has been developed, which makes it possible to detect the temperature distribution in a wide range from the outer surface to the inside of the rotating workpiece. The system consists of small temperature sensors which are embedded into the workpiece, a micro computer attached on the workpiece which acquires the data from the sensors and transmits to a personal computer by a wireless communication device. Furthermore the contact type thermocouple which enables to measure the rotating surface temperature is added to the system. Measurement experiments revealed that the grinding heat conducts from the workpiece surface toward the center, accumulates, and remains in the workpiece even after the process. Heat conduction simulation was also performed. Good agreement was achieved between the simulated temperatures and experimental measurements. © 2012 German Academic Society for Production Engineering (WGP).

DOI： 10.1007/s11740-012-0372-z

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In an internal grinding, the stiffness of wheel spindle is not so high because of its small diameter. So the elastic deformation of wheel spindle becomes large. In this reason, the dimensional accuracy of workpiece worsens in internal grinding with a high aspect-ratio. To solve this problem, in this study, the shape of the grinding wheel is modified by the single crystal diamond tool. A grinding test with the formed wheel is carried out and the shape of the workpiece is measured. It is conformed that the shape error of the workpiece ground with the formed wheel is significantly improved.

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Micro patterning on cylindrical surface, e.g. dynamic pressure bearings, is mainly carried out by chemical etching. However, there exist environmental problems in the waste etchant processing and safety ones in works using toxic chemical liquids. On the other hands, blasting is expected as one of micro patterning methods and comes into use for not only surface modification but also machining of hard and brittle materials. The purpose of this study is to develop the micro blasting technique for cylindrical parts. Therefore, machining characteristics in blasting of rotating workpieces are experimentally investigated, analyzing the stock removal and the surface roughness. In addition, the patterning of micro herringbone grooves are carried out on spindle surfaces based on the obtained characteristics. © (2011) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.325.570

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Abrasive Technology  

In cylindrical plunge grinding, the workpiece expands because most of the grinding heat is transmitted to the workpiece during grinding. After grinding, the workpiece diameter decreases as the coolant removes the accumulated heat, and the dimensional accuracy of the workpiece decreases because of thermal deformation. Therefore, it is necessary to understand thermal deformation behavior of the workpiece taking into consideration the temperature distribution during grinding. In this study, simulation analysis of temperature distribution and thermal deformation of the workpiece are proposed. The validity of these simulation results were verified by comparison with measurement results obtained with developed in-process measurement system of temperature distribution and thermal deformation in the workpiece.

DOI： 10.11420/jsat.55.161

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Authorship：Corresponding author   Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Abrasive Technology  

Dressing is frequently carried out in dry grinding of hard carbon because of loading over short grinding times. However, even if abrasive grains covered with loading chips on a wheel surface still have sharp cutting edges, they are removed with loaded chips by dressing. In this study, we propose the dressless restoration of grindactivity in which loaded chips are removed by peeling off the adhesive tape from the loaded wheel surface after pressing. The process of removing loaded chips in dressless restoration was clarified, and the effects of adhesive tape pressing load and peeling speed on removal characteristics of loaded chips were investigated.

DOI： 10.11420/jsat.55.102

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The purpose of this study is to develop an in-process of measurement technique of surface roughness using thermoelectric effect in cylindrical grinding. The electromotive force (EMF) generates depend on the surface roughness of workpiece and the variation of workpiece temperature when the sensor with thermocouple wires rubs on the workpiece surface in grinding process. In this paper, the in-process measurement technique of surface roughness in cylindrical plunge grinding is proposed, conceiving the cancellation of the EMF caused by the variation of workpiece temperature in the sensor output. Also a new type in-process sensor was developed for high accuracy to overcome the problem which was clarified in the cancellation method of the influence of workpiece temperature at a basic sensor © (2010) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/AMR.126-128.684

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The grindactivity of wheel is remarkably lost by the loading of wheel surface in dry grinding of hard carbon parts. In this report, we propose the dressless wheel treatment, in which loading chips are removed with adhesive tape, and experimentally investigate its effect on recovery of grindactivity, analyzing the stock removal, the grinding current and the surface roughness in repeat of grinding cycle with treated and non-treated wheels. The removal and finishing performances of loaded wheel are recovered by the dressless wheel treatment.

DOI： 10.4028/www.scientific.net/AMR.76-78.94

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DOI： 10.11420/jsat.53.566

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Other Link： http://id.nii.ac.jp/1399/00010266/

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The purpose of this study is to develop the cavitation aided abrasive machining which makes effective use of cavitation occurring in suction flow of slurry for fine machining. In this paper,a fundamental machining phenomenon of glass using the cavitation suction flow is clarified and machining characteristics are experimentally investigated by the observation of machined surface and surface roughness, stock removal and cavitation impact. Abrasive grains impinge on a workpiece surface to physically remove work material and generate fine surface in the machining. Then it can finish the polished glass surface of 9.3nmRz down to about 5.0nmRz by using abrasives of WA 4000. © (2009) Trans Tech Publications, Switzerland.

DOI： 10.4028/www.scientific.net/KEM.407-408.654

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The purpose of this study is to make clear the machining effect of the precision abrasive machining using the cavitation in reversing suction flow, which can easily finish to a fine surface by a simple apparatus. The machining fluid including loose micro abrasive grains is sucked by a pump, and the cavitation occurs ahead of the nozzle fixed in the suction chamber because of the rapid decrease of pressure of machining fluid. We use the cavitation impact to make the abrasive grains to interfere with the workpiece surface. In this report, the possibility of application of the new abrasive machining to the precision manufacturing is investigated by analyzing the behavior of machining fluid, the stock removal and the surface finish in machining of glass. The cavitation impact is strongest under the nozzle clearance of 20mm and restriction nozzle diameter of 4mm. Glass surface is finished up to several nanometers in Ry with slight stock removal by the proposed abrasive machining.

DOI： 10.4028/0-87849-364-6.223

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The grinding performance of wheel remarkably decreases by the loading of wheel surface in dry grinding of hard carbon parts. In this report, we propose the removal method of loaded carbon chips in which an adhesive tape is removed with carbon chips after putting on a loaded wheel surface by an elastic roller with the setting load . The removal characteristics are experimentally investigated by analyzing the projecting height of abrasive grains, removal force of adhesive tape and so on. The removal method results in the enough projecting height of abrasive grain.

DOI： 10.4028/0-87849-364-6.356

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In this study, the correlations between surface quality and contamination in coolant were investigated on the assumption that chips produced in grinding and abrasive grains released from a wheel affect the work surface. The number of scratches, which is one of the most important problems in production fields, in relation to sludge and abrasive contents was systematically summarized. The experimental results showed that the number of scratches increased monotonically with increasing sludge contents, and remained constant at 50×10⁷/l. Meanwhile, abrasive grains in coolant were dominantly involved in the formation of scratches, and had a 40-fold impact on the number of scratches rather than sludge. Moreover, optical microscopy indicated that configurations of scratches could be categorized as linear-type or curve-type. Whereas the former was observed with increasing sludge contents, the latter emerged with contamination of abrasive grains.

DOI： 10.11420/jsat.52.589

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DOI： 10.5956/jriet.37.274

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DOI： 10.11420/jsat.52.158

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Chromium aluminum nitride based films were synthesized by the cathodic arc method using an alloy cathode, and annealed in a vacuum chamber at 800, 900 and 1000 °C. XRD analyses showed that the (Cr,Al,Si,Y)N films maintained a cubic phase up to 800 °C, but changed to a mixed phase after post-annealing at temperatures of more than 900 °C. Cr2N segregation and partial transformation from a cubic to hexagonal phase at over 800 °C were confirmed for (Cr,Al,Si)N and (Cr,Al,Y)N. The lattice parameters for cubic (Cr,Al,Si)N and (Cr,Al,Y)N (0.416 nm) decreased to 0.411 nm and 0.413 nm, respectively, after annealing at 900 °C. The lattice parameter for (Cr,Al,Si,Y)N changed from 0.417 nm to 0.413 nm after annealing at 900 °C. The microhardness of (Cr,Al,Y)N was kept constant at 800 °C, whereas that of (Cr,Al,Si)N and (Cr,Al,Si,Y)N increased slightly between 800 and 900 °C. In this study, hardness, microstructure and lattice parameters were analyzed and discussed as a function of the annealing temperature. © 2007 Elsevier B.V. All rights reserved.

DOI： 10.1016/j.surfcoat.2007.05.050

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The elastic deformation of workpiece acted by grinding force is so large as to make the low machining efficiency and accuracy in the cylindrical grinding of micro parts of which the stiffness is extremely small because of their small diameter. In this study, the perpendicular axis type cylindrical traverse grinding is proposed for the manufacture of micro parts, and the undeformed chip shape in the grinding process is investigated comparing with that in the parallel axis type traverse grinding using generally for manufacture of over small-sized parts. The surface finish and the form accuracy of workpiece by the perpendicular axis type grinding are finer than those by the parallel axis type grinding with the developed micro cylindrical grinding machine.

DOI： 10.4028/0-87849-416-2.39

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The purpose of this study is to make clear the machining effect of a new technique of cavitation aided machining (CAM) by which the workpiece can be easily finished in a fine surface with a very simple apparatus. The machining fluid, that is mixture of abrasive grains and water as carrier, is sucked by a pump, and the flow of machining fluid is controlled by a restrictor. Then the cavitation phenomenon locally occurs by the rapid decrease of carrier pressure, so that abrasive grains in the mixed fluid come to interfere on the surface. In this report, the possibility of applying CAM to precision machining is investigated by analyzing the surface finish, the stock removal and the behavior of carrier. Main conclusions obtained in this paper are as follows: (1) Action of abrasive grains onto the surface is induced by very fine cavitation impact caused by cavitation occurred in the lower part from the center of restrictor in a flow. (2) At 2.0mm in clearance, the cavitation impact of carrier becomes strongest, so that the stock removal and the decrease of surface roughness have maximum. (3) CAM can be applied to an ultraprecision machining by which the surface finish of Al-Mg alloy is improved from 7.3nm Ra with ultraprecision cutting down to the surface finish at 6.6nm Ra.

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The polyvinyl alcohol (PVA) bond wheel is a typical elastic wheel using in precision finishing of a cylinder, a roll, a magnetic head and so on, but it can't allow using grinding fluid because of its too poor water resistance. So the super-soft grade resinoid wheel, of which the bonding material is prepared by the interaction of PVA and thermosetting plastics, is developed. The surface roughness decreases down to the minimum just after the start of plunge grinding. In this paper, the grinding method with the resinoid bond wheel is proposed to achieve the finest surface finish of workpiece, based on such minimizing phenomenon of surface roughness. Main conclusions obtained in this paper are as follows: (1) The finest surface finish can be obtained by spark-out grinding operation just at the right moment when the surface roughness of workpiece decreases down to the minimum. (2) The surface finish by this grinding operation decreases with decreasing the initial surface roughness, but the shrinkage in surface roughness during the spark-out grinding process increases with increasing initial surface roughness. (3) The repetition of this grinding operation without dressing makes the surface finish smaller than that by a general grinding operation with larger depth of cut before spark-out grinding.

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Abrasive Technology  

DOI： 10.11420/jsat.50.409

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DOI： 10.5956/jriet.35.452

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Abrasive Technology  

DOI： 10.11420/jsat.50.334

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DOI： 10.5956/jriet.35.371

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Language：English   Publishing type：Research paper (international conference proceedings)   Publisher：The Japan Society of Mechanical Engineers  

The electricity rust preventive machining method is proposed to effective prevents the workpiece from rusting in the cylindrical grinding only with water. The workpiece as a cathode is protected from rusting by supplying the electric current through the water. This method leads to the ecology machining because the water without extreme pressure agents, mineral oils and so on included in conventional machining fluid. Therefore, this method saves much work in a treatment of stale machining fluid. In this paper, the electric rust preventive machining method is developed and investigated its application to cylindrical grinding.

DOI： 10.1299/jsmelem.2005.2.653

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The electricity rust preventive machining method is proposed to effective prevent the workpiece from rusting in the cylindrical grinding only with water. The workpiece as a cathode is preserved from rusting by supplying the electric current through the water. This method leads to the ecology machining because the water without extreme pressure agents, mineral oils and the like is used as the machining fluid. Therefore, this method saves much work for a treatment of used machining fluid. Main conclusions obtained are as follows : (1) The effective prevention from rusting for 1 hour can be achieved by the electricity rust preventive machining method in cylindrical grinding. (2) The effective rust prevention conditions of electric supplying time and current are experimentally decided in cylindrical grinding and a very few electric power is necessary for rust prevention. (3) The supply current for the rust prevention increases with increasing the voltage, the nozzle-workpiece clearance or the exposed surface area. And the turbulent flow of water interferes with the supply of the current which increased with increasing the water flow rate.

DOI： 10.2493/jspe.71.337

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This report shows the practical educational effects of the design project to build up a jumping machine through PBL (Project-Based Learning) that trains students' inquisitiveness and creativity. Particularly, we report in detail that measuring the initial value of students' creativity is indispensable for them to realize the importance of inquisitiveness and creativity, ant that learning creative thinking methods wipes out students' perplexity and repulsion toward Open-ended problems and enhances educational effects. © 2005 SICE.

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The electricity rust preventive machining method is proposed to effective prevent the workpiece from rusting in the cylindrical grinding only with water. The workpiece as a cathode is preserved from rusting by supplying the electric current through the water. This method leads to the ecology machining because the water without extreme pressure agents, mineral oils and the like is used as the machining fluid. Therefore, this method saves much work for a treatment of used machining fluid. Main conclusions obtained are as follows: (1) The effective prevention from rusting for 1 hour can be achieved by the electricity rust preventive machining method in cylindrical grinding. (2) The effective rust prevention conditions of electric supplying time and current are experimentally decided in cylindrical grinding and a very few electric power is necessary for rust prevention. (3) The supply current for the rust prevention increases with increasing the voltage, the nozzle-workpiece clearance or the exposed surface area. And the turbulent flow of water interferes with the supply of the current which increased with increasing the water flow rate. © 2005, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.71.320

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The surface roughness decreases down to the minimum just after start of plunge grinding with a super-soft grade resinoid bond wheel, of which bonding material is prepared by the interaction of polyvinyl alcohol and thermosetting plastics. In this paper, the grinding method with the resinoid bond wheel is investigated for the finest surface finish of workpiece, based on such minimizing phenomenon of surface roughness. Main conclusions obtained in this paper are as follows : (1) The finest surface finish is obtained by spark-out grinding operation starting just at the moment on which the surface roughness of workpiece decreases down to the minimum. (2) The surface finish by this grinding operation decreases with decreasing the initial surface roughness, but the decrease in surface roughness during the spark-out grinding process increases with increasing initial surface roughness. (3) The repetition of this grinding operation without dressing makes the surface finish smaller than that by a general grinding operation with larger depth of cut before spark-out grinding.

DOI： 10.2493/jspe.70.1291

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

In the case of internal oscillation grinding of deep straight hole which is longer than a wheel width, a workpiece is finished in a taper shape because of a larger elastic deformation of wheel spindle in grinding process. In this paper, the controlled internal oscillation grinding technique for optimal form accuracy of a deep straight hole is developed, introducing retraction grinding method in which a grinding wheel head rapidly retracts a small amount against infeed direction at the beginning of spark-out grinding. Main conclusions obtained in this paper are as follows; (1) In internal grinding of a deep straight hole with retraction motion, the setting retraction amount is decided by the wheel spindle recovery which is almost in direct proportion to the retraction amount. (2) At the optimal retraction amount finishing a workpiece to a minimum taper error, the elastic deformation of wheel spindle just after retraction motion is constant decided by the grinding system even if the plunge speed or the speed ratio are different. (3) The optimal retraction amount is decided by subtracting the above own elastic deformation of wheel spindle from the elastic deformation of wheel spindle just before the beginning of spark-out grinding process without retraction motion.

DOI： 10.2493/jspe.70.263

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Language：English   Publishing type：Research paper (international conference proceedings)   Publisher：The Japan Society of Mechanical Engineers  

In this paper, the retraction grinding method, in which the grinding wheel head gets rapidly back by very small amount immediately after the beginning of spark-out state, is proposed for improving the taper error in the deep hole oscillation internal grinding. Main conclusions obtained are as follows : (1) It is made clear that by the retraction grinding method the taper error of workpiece can remarkably be improved with the fine surface roughness condition. (2) In the retraction grinding the taper generation mechanism is affected just by extending of spark-out grinding time due to a decrease of the residual stock on the stiffness of the grinding wheel and workpiece spindles. (3) By taking into account the periodic change of the normal grinding force linking to the oscillation movement, the measured taper can sufficiently be predicted.

DOI： 10.1299/jsmelem.2003.263

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In this study, the characteristics of grain boundary step generation in practical ultraprecision cutting opreration of Al-Mg alloy are experimentally made clear by analyzing height of grain boundary step, crystal direction, surface finish, residual stress and so on. Especially, crystal direction of each crystal grain of Al-Mg alloy appearing on finished surface is decided by ECP (Electron channeling pattern) method, and relationships between crystal orientation and height of grain boundary step are investigated. Main conclusions obtained in this study are as follows : (1) The height of grain boundary step on finished surface increases with a closen crystal orientation to (1 2 4) on the stereographic projection of crystal direction of Al-Mg alloy. (2) The height of grain boundary step or the surface finish decrease with a decrease of clearance angle of cutting tool. So a cutting tool with a smaller clearance angle results in finer machined surface.

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

A softened affected layer generated in electrolytic grinding at higher electrolytic voltage could not be removed by a spark-out grinding without electrolysis in the previous report. In this report, the electrolysis controlled spark-out grinding is developed in order to remove completely an affected electrolytic ground layer at any electrolytic voltage. Effects of the electrolysis controlled spark-out grinding on finished surface characteristics are experimentally proved by investigating ultra micro hardness on machined surface, surface finish and so on. Main conclusions obtained in this report are as follows: (1) The electrolysis controlled spark-out grinding can prevent the finished surface hardness from decreasing at higher electrolytic voltage in which affected layer is remained after spark-out grinding without electrolysis. (2) A surface finish and an effective spark-out grinding time decrease by the spark-out grinding with an optimum electrolyze-out time. (3) An optimum electrolyze-out time decreases with increasing electrolytic voltage and becomes negative at electrolytic voltage over 7V.

DOI： 10.2493/jjspe.69.1590

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The purpose of this study is to minimize affected layer generated by electrolytic grinding which results in deterioration of gloss or decrease of hardness on machined surface. In this paper, a reduction process of affected electrolytic ground layer by a spark-out grinding process without electrolysis, in which electrolytic effect stops just in the moment of stopping infeed of grinding wheel, is experimentally investigated by analyzing characteristics of electrolytic ground surface with a glossiness meter or an ultra micro hardness tester. Main conclusions obtained in this paper are as follows: (1) The depth of affected layer decreasing hardness is nearly 2.5 times as large as that deteriorating gloss, and both depths of affected layer increase with increasing electrolytic voltage. (2) In the case of higher electrolytic voltage, the stock removal in spark-out grinding process without electrolysis is less than the depth of affected layer decreasing hardness generated in steady electrolytic grinding process. So after finish of spark-out grinding, an affected layer decreasing hardness is remained on finished surface on which glossiness is recovered up to that of mechanical ground surface.

DOI： 10.2493/jjspe.69.1129

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

In this paper, an improving process of surface roughness in cylindrical plunge grinding with a super-soft grade resinoid bond wheel, whose bonding material is prepared by the interaction of polyvinyl alcohol and thermosetting plastics, is discussed, analyzing the ground surface profile, the topography of acting wheel surface and so on. Main conclusions obtained in this paper are as follows: (1) Minimizing phenomenon of surface roughness in which surface roughness decreases down to the minimum after start of grinding is remarkably occurred in plunge grinding process with a super-soft grade resinoid bond wheel. And the phenomenon is useful for improving surface roughness by grinding. (2) Decrease of number of simultaneously acting cutting edge by a rapid increase of wheel wear leads to worsen the surface finish just after the point of minimizing surface roughness. (3) The number of simultaneously acting cutting edge is obtained by ground surface profile, topography of acting wheel surface and interference wheel arc length.

DOI： 10.2493/jjspe.69.803

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：Japanese Society for Engineering Education  

This paper reports the concrete educational effects in the process of constructing "the straw leaning tower" and "the jumping machine", both of which need some specialized knowledge of the mechanical engineering. Although building up the practical objects is necessary for bringing up the students inquiry ability and creativity, the first year trial shows that it often fails without enough preparation and that constructing the ideas with the creative thinking way and the precise plan to realize them are indispensable. In the second year the practice of FD(Faculty Development) remarkably improves the both creativity of the straw leaning tower and jumping machine.

DOI： 10.4307/jsee.50.6_51

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：Japanese Society for Engineering Education  

This report shows the practical educational effects of the design project to. build up the jumping machine through PBL(Project-Based Learning): that is the project to train the students' inquiry ability and creativity. Practically, we report in detail that the measure of the students' creativity initial value is indispensable for the students to realize the importance of the inquiry ability and creativity, and that the learning of the creative thinking way wipes out the students' perplexity and repulsion to Open-Ended Problem and improve the educational effects.

DOI： 10.4307/jsee.50.5_71

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

In ultraprecision cutting by which surface finish is nano-meter order, the problems which are not necessary to consider in ordinary cutting occur. One of these is the step at grain boundary on machined surface which is generated by the difference of elastic recovery of crystal grains after cutting edge passing because of mechanical characteristics of crystal grain affected by crystal direction. In this study, in order to make clear the mechanism of the surface finish generation in ultraprecision cutting of Al-Mg alloy, the relationship between clearance angle of tool and surface finish is analyzed quantitatively taking notice of step at grain boundary. As a result, it is confirmed that burnishing effect with clearance of cutting tool, which strengthen with a decrease of clearance angle, improves surface finish in ultraprecision cutting of Al-Mg alloy.

DOI： 10.2493/jjspe.68.1221

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Language：English   Publishing type：Research paper (international conference proceedings)   Publisher：AVIATION INDUSTRY PRESS  

Form dressing of poreless resinoid bonded wheel is carried out by scanning a Q-switched YAG laser beam on the wheel surface and the form dressing mechanism is experimentally investigated by analyzing initial profile of dressed wheel, variation of wheel tip profile in form grinding process, density and height of cutting edge and the like, and by comparing with those by a traditional dressing with PVA wheel. Irradiation of YAG laser beam on Wormed or circular formed resinoid wheel surface leads to the available dressing effect and higher form accuracy in grinding process. Especially the scanning of a YAG laser beam on Wormed resinoid bond wheel surface results in about 10 mum in radius of wheel tip which is better form dressing effect than that by a traditional dressing with PVA wheel.

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

The purpose of this research is to develop a cavitation aided machining which positively makes use of cavitation occurring in fluid for machining phenomenon. In this paper, a fundamental ultraprecision machining phenomenon of glass surface is made clear and its machining characteristics is experimentally investigated by analyzing surface finish, stock removal and cavitation impact. Then an efficiency of applying the cavitation aided machining as an ultraprecision machining is proved by carrying out ultraprecision surface machining on glass surface based on the machining phenomenon. Main conclusions obtained in this paper are as follows; (1) Cavitation aided machining can be applied to an ultraprecision machining by which the surface finish of glass is improved down to the surface finish at about 5.0nmRy by using abrasives of WA 4000. (2) WA abrasive grains generate finer machined surface than GC abrasives which is harder or AZ abrasives which is heavier. (3)Ultraprecision machined glass surface with 60mm in length is generated by applying a fundamental machining phenomenon of cavitation aided machining along flowing direction of machining fluid continuously. © 2001, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.67.2000

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

In this paper, the material removal mechanism in electrolytic grinding process is experimentally investigated by analyzing the stock removal due to electrolytic phenomenon and to grinding phenomenon in electrolytic grinding process, taking the inevitable accumulation phenomenon of interference depth of wheel into consideration. The material removal effect in electrolytic grinding is also discussed from the viewpoint of machining energy. Main conclusions obtained in this paper are as follows: (1) The electric current in electrolytic grinding process increases from beginning of wheel interference because of the momentary short circuit or electric discharge through generated chips at smaller concentration of electrolyte or applied voltage. Therefore all electric current isn't always consumed for the electrolytic effect. (2) There exists the critical electrolytic conditions from which the electrolytic effect in electrolytic grinding process intensifies. (3) The total consumed energy reduces with the increase of concentration of electrolyte or the applied voltage, but the effective energy rate for material removal decreases at about 7V in applied voltage. © 2001, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.67.120

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

Form dressing of V-formed resinoid bond wheel by scanning a Q-switched YAG laser beam on the wheel surface is carried out and the form dressing mechanism is experimentally investigated by analyzing initial profile of dressed wheel, variation of wheel tip profile in form grinding process, density and height of cutting edge and so on, comparing with those by a traditional dressing with PVA wheel. Main conclusions obtained in this paper are as follows; (1) Scanning YAG laser beam on V-formed resinoid bond wheel surface results in the better form dressing effect concerning form accuracy or projecting height of cutting edge than a traditional dressing with PVA wheel. (2) Radius of wheel tip decreases with increasing peripheral wheel speed in form dressing because a heat effect on wheel surface by laser beam decreases with an increase of peripheral wheel speed. (3) Laser dressing of V-formed wheel at higher peripheral wheel speed represses a reduction of form accuracy in form grinding process. (4) Radius of dressed wheel tip increases with increasing formed angle and is much affected at larger formed angle by peripheral wheel speed in laser dressing.

DOI： 10.2493/jjspe.65.1633

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Language：English   Publishing type：Research paper (international conference proceedings)   Publisher：WORLD PUBLISHING CORPORATION  

Aramid fiber reinforced rubber (AFRR) is one of advanced composite materials, which have some excellent characteristics for a transmission belt. V-ribbed belt, which is used as an automobile engine part, is formed by grinding to generate not only the required shape but also the suitable frictional characteristics. The frictional characteristics of V-ribbed belt of AFRR are significantly affected by form grinding conditions because of much lower coefficient of friction of aramid fiber and higher one of matrix rubber. In this paper, an in-process measuring system of coefficient of friction of V-ribbed belt in form grinding process is developed based on quantitative analysis of coefficient of friction. Furthermore, a form grinding technique of V-ribbed belt for controlling coefficient of friction is proposed by investigating coefficient of friction in spark-out grinding process of V-ribbed belt.

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

The purpose of this research is to develop a new technique of CAH (cavitation aided honing) by which the workpiece can be easily finished in a fine surface with a very simple apparatus. The machining fluid, that is mixture of abrasive grains and water as carrier is sucked by a pump, and the flow of machining fluid is controlled by a restrictor, and then the cavitation phenomenon locally occurs by the rapid decrease of carrier pressure, so that abrasive grains in the mixed fluid come to interfere on the surface. In this report, the possibility of applying CAH to precision machining is investigated by analyzing surface finish, stock removal and behavior of carrier. Main conclusions obtained in this paper are as follows ; (1) Action of abrasive grains onto the surface in CAH is induced by very fine vibratory impact caused by cavitation occurred in the lower part from the center of restrictor in a flow. (2) At 2.0mm in clearance, cavitation impact of carrier becomes strongest, so that the stock removal and the decrease of surface roughness have maximum. (3) CAH can be applied to an ultraprecision machining by which the surface finish of Al-Mg alloy is improved from 7.3nm R_a with ultraprecision cutting down to the surface finish at 6.6nm R_a.

DOI： 10.2493/jjspe.64.913

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

Frictional characteristics of V-ribbed belt of aramid fiber reinforced rubber are significantly affected by form grinding conditions because of much lower coefficient of friction of aramid fiber and higher one of matrix rubber. In this paper, an in-process measuring system of coefficient of friction of V-ribbed belt in form grinding process is developed based on quantitative analysis of coefficient of friction in the previous report. Furthermore, a form grinding technique of V-ribbed belt for controlled coefficient of friction is proposed by investigating coefficient of friction in spark-out grinding process of V-ribbed belt. Main conclusions obtained in this paper are as follows ; (1) The in-process measuring system of coefficient of friction of V-ribbed belt which can exactly predict its wide variation in form grinding process is developed. (2) In spark-out grinding process of V-ribbed belt, generation of V-groove is finished in a while from starting of spark-out grinding, and projecting length of aramid fiber continues to decrease gradually until the end of spark-out grinding process. (3) V-ribbed belt which has the required coefficient of friction can be finished by stopping grinding of V-ribbed belt when the measuring system points at the required coefficient of friction in spark-out grinding process after finishing to generate V-groove.

DOI： 10.2493/jjspe.63.1469

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

Aramid fiber reinforced rubber (AFRR) is one of advanced composite materials, which have some excellent characteristics transmission belt. V-ribbed belt is formed by grinding to generate not only the required shape but the suitable frictional characteristics on contacting rubber surface with a pulley. The frictional characteristics of AFRR V-ribbed belt is sensitively affected by projecting condition of aramid fiber whose coefficient of friction is much lower than that of matrix rubber. In this paper, form grinding mechanism of AFRR V-ribbed belt with diamond wheel is experimentally investigated by analyzing form accuracy of V-groove and projecting length of aramid fiber. Furthermore, an estimating method for the coefficient of friction of AFRR V-ribbed belt is proposed by clearing up effects of each factor on the coefficient of friction of V-ribbed belt. Main conclusions obtained in this paper are as follows: (1) Coefficient of friction of AFRR V-ribbed belt is decided by V-groove angle and projecting fiber length on the surface generated in form grinding, and it decreases with increases of V-groove angle or projecting fiber length. (2) Coefficient of friction of V-ribbed belt can be estimated by subtracting the decrease from coefficient of friction caused by projecting aramid fiber from the coefficient of friction decided by V-groove angle of matrix rubber belt without projecting fiber. (3) Both V-groove angle and projecting fiber length increase with an increase of curvature of V-ribbed belt in form grinding process.

DOI： 10.2493/jjspe.63.1295

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

The purpose of this study is to establish a new dressing technique of resinoid bond wheel by scanning the point of heat source on wheel surface. Dressing effect with CW YAG laser is testified in previous report. In this paper, Q-switched YAG laser is selected as a dressing tool for making more improvement of dressing effect with YAG laser, and dressing mechanism and grinding characteristics of dressed resinoid bond wheel with Q-switched YAG laser are experimentally discussed by observing the acting wheel surface and analyzing some grinding results with dressed wheel. Furthermore, dressing effect with Q-switched laser is verified by comparing with that with CW laser. Main conclusions obtained in this paper are as follows : (1) Scanning Q-switched YAG laser beam on resinoid bond wheel surface results in better dressing effect than that with CW laser beam. (2) Dressing with Q-switched laser of 2kHz in Q-switch frequency brings out best grinding characteristics of resinoid bond wheel in those of all Q-switch frequency. (3) In lower Q-switch frequency, heat affected structure generated on dressed wheel surface is completely removed as soon as laser beam is irradiated because of radical and frequent variation of heat energy supplied with laser beam.

DOI： 10.2493/jjspe.63.1153

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The purpose of this paper is to get fundamental informations for estimating depth of crack layer under ground surface of sintered silicon nitride which is one of typical engineering ceramics. This paper proposes a estimation method of the depth of crack layer generated in a transitional cutting process, which is a fundamental phenomenon in grinding process, with a single point diamond, as a function of normal cutting force, generated groove depth, Poisson's ratio, fracture toughness and a characteristic parameter of affected structure zone based on linear fracture mechanics. And the rule of the characteristic parameter, which is decided by interference type of cutting edge, is experimentally found out. The characteristic parameter decreases with increasing groove depth in conformity with the exponential function determined by indentation characteristic and nose radius of cutting edge in spherical interference region, and it turns to constant at critical interference depth according to vertical angle of cutting edge. By applying the method in each cutting phenomenon of a cutting edge in grinding of silicon nitride, the depth of remained crack layer in a grinding process can be estimated and grinding conditions or stock removal in successive grinding process can reasonably be determined.

DOI： 10.2493/jjspe.62.1330

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Language：Japanese   Publishing type：Research paper (scientific journal)   Publisher：The Japan Society for Precision Engineering  

There is a possibility that resinoid bond wheel may thermally be dressed by scanning the heat source on the wheel surface, because bonding material is lower heat resistance than other ones. In this paper, the dressing effect on resinoid bond wheel with YAG laser beam is discussed, observing the acting wheel surface and investigating the grinding characteristics of the wheel dressed by scanning YAG laser beam. Main conclusions obtained in this paper are as follows: (1) Irradiation of YAG laser on resinoid bond wheel surface results in the dressing effect. (2) The effective dressing conditions concerning the peripheral wheel speed and the feed rate of laser beam are determined by the heat energy provided on wheel surface, the transitional characteristic of heating and the width of affected region by scanning of laser beam during one revolution of wheel. (3) Resinoid bonding material become brittle and weak and/or abrasive grains are damaged by irradiation of YAG laser on the wheel surface. (4) Under the same heat energy provided on wheel surface, surface finish increases with a decrease of the peripheral wheel speed in dressing and an increase of the feed rate of laser beam. © 1995, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.61.556

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Frictional characteristics of ground surface of aramid fiber reinforced rubber (AFRR), which is one of the advanced composite materials for transmission belt, are dominated by grinding conditions, and form and size of aramid fibers which aren't removed projecting on the surface of matrix rubber in grinding. In this paper, the coefficient of static friction is analytically described based on Hertz's theory of elastic contact in terms of arrangement of aramid fiber in matrix rubber, occupying ratio of fiber on contact surface of AFRR with pulley and so on, and the validity of this analysis is also discussed by comparing the theoretical coefficient with the measured one. It is pointed out that the coefficient of static friction on ground surface of AFRR can be predicted by fiber diameter, fiber content, length of projecting fiber, width of fiber end and coefficient of static friction of matrix rubber and aramid fiber. Though the coefficient of static friction on ground surface of AFRR is analyzed for four ideal conditions of projecting fiber, the measured coefficient agrees well with the analyzed one for the case that fibers are uniformly arranged in hexagonal form and ground in the direction of a central diagonal of this hexagonal fiber arrangement. Furthermore, the validity of this analysis is shown by investigating effects of pressure on contact conditions between pulley and ground surface of AFRR. © 1994, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.60.1637

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Aramid fiber reinforced rubber (AFRR) is a new composite material developed for transmission belt. Transmissibility of belt is considerably dominated by frictional characteristics of belt surface contacting with pulley. Transmissibility of belt just like as V-ribbed belt made of AFRR, which is finished by grinding, is influenced by grinding conditions as well as its material. In this paper, by investigating the surface generation process in grinding AFRR with diamond wheel, a grinding technique for a required transmissibility which is represented by coefficient of friction on ground surface of AFRR, is made clear. Main conclusions in this paper are as follows : (1) The coefficient of friction on ground surface of AFRR, which is determined by a projecting length of aramid fiber from matrix surface, increases as the projecting fiber length decreases. (2) In the steady grinding state, a required projecting fiber length of AFRR is given by controlling grinding conditions with grinding force ratio. (3) There exist the matrix removal region for lower initial length of projecting fiber or the fiber removal region for higher one, than cutting depth of grinding wheel, and therefore both projecting fiber length and matrix size can be adjusted by either grinding of the two regions. © 1994, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.60.1299

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The purpose of this study is to establish a thermal dressing technique with moving heat source for resinoid bond wheel, in which heat resistance of bonding material is markedly lower than that of vitrified bond. In this paper, a single pulse of CW : YAG laser introduced as a heat source is irradiated on resinoid bond abrasive stick to make clear a fundamental phenomenon of laser dressing, analyzing transformation, profile of resinoid surface, stiffness of grain mounting and so on. Main conclusions obtained in this paper are as follows : (1) Transformation of resinoid bond, releasing abrasive grain and vaporization of bonding material take place with laser irradiation. (2) The depth and diameter of heat affected structure increases with increasing power density and irradiating time of a laser beam. (3) A stiffness of grain mounting decreases as a distance to an abrasive grain from a beam center decreases in heat affected surface. © 1993, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.59.1967

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In this paper, superfinishing mechanism of sintered silicon nitride (SSN) is experimentally investigated, analyzing superfinishing force, surface roughness, stock removal, finished surface and so on. Work surface is ground before superfinishing. Cutting ability influenced by superfinishing conditions is quantitatively evaluated by means of obtaining the equivalent depth of removal considering an oscillation locus of stone on work surface. Main conclusions obtained in this study are as follows : (1) In superfinishing process of SSN with metal bond diamond stone, equivalent depth of removal is decided by pressure of a grain and ratio of surface contact. (2) Finished surface roughness decreases with an increase of work speed but is hardly influenced by stone pressure. (3) Equivalent depth of removal is hardly influenced by superfinishing conditions which take part in an oscillation locus of stone on work surface, and increases with an increase of stone pressure in addition to a decrease of ratio of surface contact. © 1993, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.59.1483

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In this report grinding characteristics of chloroprene rubber (CR, matrix material) are experimentally investigated in order to obtain fundamental information as to grinding mechanism of aramid fiber reinforced rubber. Main conclusions obtained in this report are as follows: (1) Regular pattern just as file is generated on ground surface of CR, and generative mechanism of the pattern is classified into two distinct types. (2)Tangential force is larger than normal one because of severe friction between bonding material on diamond wheel surface and CR which make much elastic recovery before and after a contact of cutting edge. (3)Height and spacing of the pattern decrease with an increase of mean contact stiffness between surface of grinding wheel and CR by varying setting depth of cut, speed ratio and radius ratio. © 1992, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.58.1539

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Grinding process and surface generation of GFRP (Glass Fiber Reinforced Plastic) are experimentally investigated for the purpose of obtaining the fine surface finish. Especially fracture of glass fiber on surface that lead to inferiority of machined surface characteristic is observed from the microscopic point of view. Main conclusions obtained in this study are as follows: (1) Wheel wear in grinding GFRP is not much more drastic than tool wear in cutting. (2) The surface in grinding GFRP is generated by the plastic deformation of plastic material in matrix and by the fracture and also the plastic deformation of glass fiber. (3) Fracture of glass fiber on surface, that depends on the distribution angle of fiber, is a main cause of inferiority on ground surface and is divided into three distinct types. (4) Surface roughness in grinding GFRP decrease with a decrease of fiber contents, a miniaturization of undeformed chip shape and an increase of grinding speed. © 1991, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.57.1253

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In order to describe quantitatively the grinding process of partially stabilized zirconia (PSZ) with metal bonded diamond wheel, the analytical method established for metal grinding is applied to the grinding process of fine ceramics, and the theoretical values are compared to the experimental values. It is made clear that the plunge grinding process of PSZ with metal bonded diamond wheel can be represented by five independent characteristic parameters such as the size generation acceleration, the wheel wear rate, the grinding system stiffness, the contact stiffness and the cutting stiffness. By the characteristic parameters, variations of the grinding force, the stock removal, the residual stock through a grinding cycle and the grinding cycle time can be predicted. © 1989, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.55.167

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The circular cutting with a single point diamond cutting edge, in which the depth of cut is very small and takes maximum at some point, is carried out for making clear a cutting process of partially stabilized zirconia under conditions similar to practical grinding, investigating sliding phenomenon of a diamond cutting edge, normal cutting force, groove profile, stock removal and so on. Main conclusions obtained in this study are as follows : 11) There are three different regions with depth of cut ; elastic, plastic and cutting region. (2) There are critical depths and critical normal forces at the beginning point of plastic deformation and cutting. (3) In the transitional cutting process, there are following three types of interference with maximum depth of cut ; (i) elastic region through the contact length, (ii) elastic-plastic-elastic, (iii) elastic-plastic-cutting-plastic-elastic. (4) Surface generation of a groove is performed by plastic deformation as well as brittle fracture. © 1988, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.54.1544

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Cylindrical plunge grinding process and surface generation process of Sialon are experimentally investigated with bronze bond diamond wheel, analyzing grinding force, surface roughness, wheel wear, ground surface and so on. Main conclusions obtained in this study are as follows: (1) In a cylindrical plunge grinding process of Sialon with bronze bond diamond wheel, there are three distinct grinding processes such as spark-in, steady and spark-out. (2) Ground surface is formed by plastic deformation as well as brittle fracture in grinding Sialon. (3) Diamond grain primarily wears in attrition. (4) Grinding force increases with an increase of setting depth of cut, while surface roughness is hardly influenced by setting depth of cut. © 1988, The Japan Society for Precision Engineering. All rights reserved.

DOI： 10.2493/jjspe.54.1298

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Total pages：vi, 242p   Language：Japanese

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Total pages：234p   Language：Japanese

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Authorship：Lead author,　Corresponding author   Language：Japanese   Publishing type：Article, review, commentary, editorial, etc. (trade magazine, newspaper, online media)  

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Language：Japanese   Publisher：The Japan Society of Mechanical Engineers  

In the lapping of sintered SiC with diamond slurry, many scratches are generated to the directions at random. The surface texture of SiC depends on its mechanical functions. When the motion of workpieces is controlled in the mutual lapping, the unidirectional texture generated on the lapped surface having the special characteristics. Most evaluations of machined surface are carried out based on some surface roughness parameters except Angular Spectrum in ISO25178. The new evaluation of finished surface of SiC by lapping is proposed based on the surface topography in this study. As a result, the proposed evaluation method of surface has correlation with a surface function rather than practical geometric evaluation parameters.

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Language：Japanese   Publisher：The Japan Society of Mechanical Engineers  

The micro patterning on cylindrical surface is conventionally carried out by the electrochemical machining, the chemical etching, the cutting and so on. However, there exist some problems in machining dimensional errors and tool lives. On the other hands, blasting is expected as one of micro fabrication methods and progress to apply for machining of hard and brittle materials. The purpose of this study is to develop the micro blasting technique for patterning of micro herringbone grooves on cylindrical parts. Then, machining characteristics in blasting of rotating workpieces are experimentally investigated, analyzing the stock removals, the burr heights and the groove shapes. In addition, micro herring-bone grooves are patterned on spindle surfaces by blasting and the performance of herring-bone bearing is investigated.

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The purpose of this study is to confirm the performance of grinding coolant using alkaline water with plant ash. Cylindrical plunge grinding tests are carried out using alpinia zerumbet alkaline water and alpinia zerumbet alkali-reduced water as coolant. Alpinia zerumbet alkaline water by running tap water though the plant ash show high pH. Most effective alkaline coolant is brought out, comparing with surface roughness, grinding force and workpiece surface temperature. As a result, grinding performance using alpinia zerumbet alkaline water and alpinia zerumbet alkali-reduced water is better than that using tap water.

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Language：Japanese   Publisher：一般社団法人 日本機械学会  

DOI： 10.1299/jsmemag.114.1113_620_3

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DOI： 10.2493/jjspe.75.817

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Language：Japanese   Publisher：The Japan Society for Precision Engineering  

DOI： 10.2493/jjspe.73.507

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Language：English   Publishing type：Research paper, summary (international conference)   Publisher：AVIATION INDUSTRY PRESS  

The Ti-Ni alloy is one of the difficult-to-machine materials and its grinding mechanism has not yet been made clear. In this study, the grinding characteristics of Ti-Ni alloy is experimentally investigated, analyzing the transition of form accuracy in cylindrical plunge grinding process with a cBN wheel. The form accuracy of Ti-Ni alloy decreases in the cylindrical plunge grinding and is improved by spark-out grinding. But the form error of Ti-Ni alloy remains even if a spark-out grinding finishes.

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In this paper, the electricity rust preventive machining method has been developed to perfectly prevent the rust of workpiece using only the water in the surface grinding. The surface grinding can be performed under the condition of rust prevention, in which a negligible current is applied between the workpiece, connected with the cathode, and the cooling water, connected with the anode. This method can be an ultimate zero emission ecology machining, because only the water is used as the working fluid without the extreme pressure additive, the mineral oil, and the surface active agent.

DOI： 10.4028/www.scientific.net/kem.257-258.483

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DOI： 10.2493/jspe.70.1291

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An improving process of surface roughness in cylindrical plunge grinding with a super-soft grade resinoid wheel is discussed, analyzing the ground surface profile, the topography of acting wheel surface and so on. Minimizing phenomenon of surface roughness, in which surface roughness decreases down to the minimum just after beginning of grinding, occurs remarkably in plunge grinding process with a super-soft grade resinoid wheel. And the phenomenon is useful for improving surface roughness by grinding. The number of simultaneously acting cutting edge is obtained by ground surface profile, topography of acting wheel surface and interference wheel arc length.

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Language：Japanese   Publisher：山陽放送学術文化財団  

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Language：Japanese   Publisher：Japanese Society for Engineering Education  

DOI： 10.20549/jseejaarc.2004.0_605

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Language：Japanese   Publisher：The Japan Society of Mechanical Engineers  

This report shows the systematic teaching method of design subject : that is the project to train the students' inquiry ability and creativity. Practically, we report in detail that the measure of the students' creativity initial value is indispensable for the students to realize the importance of the inquiry and creativity, and that the learning of the creative thinking way wipe out the students' perplexity and repulsion to Open-Ended Problem and improve the educational effects.

DOI： 10.1299/jsmemecjo.2003.5.0_193

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Language：Japanese   Publisher：The Japan Society of Mechanical Engineers  

DOI： 10.1299/jsmecs.2003.41.365

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DOI： 10.20549/jseejaarc.2003.0_445

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