International Journal of Automation Technology最新文献

{"title":"Special Issue on Recent Advanced Manufacturing Science and Technology","authors":"Takashi Matsumura, Norikazu Suzuki","doi":"10.20965/ijat.2024.p0461","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0461","url":null,"abstract":"Recently, manufacturing technologies have progressed owing to high industrial demand. For example, in the automobile and aircraft industries, manufacturing processes require technologies that allow for high machining rates of lightweight and/or difficult-to-cut materials. Fabricating medical equipment involves the machining of biocompatible materials with high mechanical strength. Information devices require high-quality ultraprecision manufacturing processes. Furthermore, measurement and characterization technologies are also essential for manufacturing. Along with the evolution of manufacturing technologies, scientific studies have been performed on manufacturing phenomena and process control based on physical and/or mathematical aspects.\u0000 This special issue was promoted by the International Conference on Leading Edge Manufacturing/Materials & Processing (LEM&P2023) held from June 12, 2023 to June 16, 2023 at Rutgers University in New Brunswick, sponsored by the Japan Society of Mechanical Engineers. This conference was co-located with the Manufacturing Science Engineering Conference (MSEC), ASME, and North American Manufacturing Research Conference (NAMRC), SME.\u0000 This special issue includes nine papers that describe the innovations and detailed progress in the following areas:\u0000 - Characterization of materials\u0000 - Fundamental study and modeling of material removal process\u0000 - Manufacturing control and optimization\u0000 - Manufacturing processes for new hard materials\u0000 - Micro-/Nano-scale manufacturing\u0000 - Tool manufacturing and performance\u0000 - Metrology and evaluation\u0000 - Surface characterization\u0000 This special issue includes technical and scientific discussions that suggest new key technologies for future manufacturing. We hope that this will help readers understand manufacturing processes and improve their operations.\u0000 We thank the authors and reviewers for their generous cooperation and the editing staff for their contributions.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141674155","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of Noise on Accuracy of Grain Size Evaluation by Magnetic Barkhausen Noise Analysis","authors":"Kanna Omae, T. Yamazaki, Kohya Sano, C. Oka, J. Sakurai, Seiichi Hata","doi":"10.20965/ijat.2024.p0528","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0528","url":null,"abstract":"Magnetic Barkhausen noise (MBN) is a magnetic signal caused by domain wall motion and is used for non-destructive testing and evaluation of ferromagnetic materials because of its sensitivity to both mechanical and magnetic properties. Recently, machine learning models have been employed to evaluate materials based on MBN; however, the application of material evaluation to low-volume targets is challenging because of their low signal-to-noise ratio, which is due to their low volume. Therefore, understanding the influence of the signal-to-noise ratio is important, particularly for low-volume objects. However, very few reports have quantitatively assessed the influence of noise in MBN analysis. In this study, we focused on noise to improve the accuracy of MBN analysis using machine learning, investigated its impact on the prediction accuracy of machine learning models, and explored methods to mitigate its effects. A method for grain size evaluation based on MBN analysis was adopted and performed for Fe-Co alloy wires with different grain sizes. After the measurement of MBN, the relationship between the extracted features from the analysis of MBN by fast Fourier transform and grain size was learned using a gradient boosting decision tree to create a grain size evaluation model, and the coefficient of determination was used to evaluate the prediction accuracy of the grain size evaluation. The machine learning model demonstrated high prediction accuracy (R2 = 0.926) across the entire grain size range. Using the model to assess the effect of signal-to-noise ratio, experiments were also conducted using MBN time-series data with artificially applied Gaussian noise. Additionally, from the insight of the distribution of predicted grain sizes, we confirmed that a noise reduction method by averaging the MBN prediction results can improve the prediction accuracy by reducing the effect of noise as expected. This research will lead to the adoption of MBN applications, which are simple and practical methods of material evaluation, for the micro–nano discipline.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141676479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tool Path Design of Metal Powder Extrusion in Additive Manufacturing for Suppressing Shape Error Caused During Sintering","authors":"Tomoya Suzuki, T. Tateno","doi":"10.20965/ijat.2024.p0493","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0493","url":null,"abstract":"Metal Additive manufacturing (AM) can produce mechanical parts of complex structures such as lattice structures and hollow structures that are difficult to fabricate by subtractive processing. The main AM methods using metal materials are powder bed fusion (PBF), directed energy deposition (DED), and material extrusion (ME). The ME method is acknowledged as being inexpensive and convenient for manufacturing parts. However, the ME method using metal material requires a sintering process using a furnace after the AM process. Sintering generates shape errors in parts with a hollow structure, which is a characteristic of AM. Various factors cause shape errors, including the temperature control parameters in sintering. In this study, we investigated the effect of tool paths on shape errors caused in sintering and proposed a tool path that suppresses shape error. Experiments on the effect of the infill structure on shape error revealed that a smooth contact between the contour path and infill path can suppress shape errors in sintering. It was also determined that the overlap of infill paths decreases shape errors in sintering. These results demonstrate that the dominant factor causing shape errors is the tool path, rather than the kind of the infill structure. Based on this result, another experiment was conducted to investigate the effect of tool paths on shape errors in sintering. Among the tool path features, we focused on the material amount instability caused by retraction and excessive self-overlapping at the contact points between the contour and infill paths. The results demonstrated that the unstable feeding of material at the contact points owing to retraction and excessive self-overlapping caused a non-uniform filling rate and thickness variations in the specimens. This, in turn, affected the shape error in sintering.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141675423","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Scrap Float Detection in a Blanking Die Set with Multiple Retrofit Accelerometers Using the Mahalanobis–Taguchi System","authors":"Takahiro Ohashi","doi":"10.20965/ijat.2024.p0537","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0537","url":null,"abstract":"Detection of scrap floating for a stamping die with 0.8 mm-thick A1050 aluminum sheets was conducted with multiple retrofit accelerometers attached to the outside of the stamping die-set. The accelerometers were attached to three locations on the side of the stripper plate and one location on the side of the punch plate of a 3-ϕ30 hole blanking die using a magnet-based jig. Anomaly detection technique using the Mahalanobis–Taguchi system was conducted with the gravity analysis of the waveform of the accelerometers’ signal. A total of 106 experiments without foreign objects (i.e., a scrap) were conducted to collect instances of the signal profile for the normal samples. In addition, 24 error samples with a foreign object were fabricated for anomaly detection tests. Only one of the four locations achieved 100% accuracy in detection using only one sensor. In detection using only one sensor, only one of the four locations achieved 100% accuracy. We attempted to improve the accuracy by increasing the amount of learning. However, the accuracy did not improve by increasing the amount of training except for the one sensor mentioned above. This result implies that machine learning, in which features are predefined by the user, cannot compensate for the disadvantage of sensor location by the amount of training. Then, combinations of the sensors were examined. Learning with all features of all 4 sensors (i.e., with 12 features) resulted in a still imperfect separation between normal and error samples. However, even if a single sensor causes false positives, it was possible to combine the influential features of multiple sensors, that were chosen by SN ratio analysis, to detect all anomalies without false positives. In future work, we would like to consider the detection of anomalies with multi-discipline features and combine anomaly detection systems with design and quality control systems.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141675754","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Advanced Sensing and Machine Learning Technologies for Intelligent Measurement in Smart and Precision Manufacturing","authors":"Ryo Sato, Kuangyi Li, M. Michihata, Satoru Takahashi, Wei Gao","doi":"10.20965/ijat.2024.p0545","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0545","url":null,"abstract":"This paper provides an overview of state-of-the-art sensing and machine learning technologies for intelligent measurement in smart and precision manufacturing. Length, angle, and force are identified as the fundamental quantities for production quality management based on process monitoring as well as geometrical metrology in optical lithography and mechanical machining. Advancements in length-based measurement technologies such as laser interferometers and optical encoders, as well as advancements regarding depth and thickness measurements, are presented. Various types of optical microscopes, such as evanescent field microscopes, structured illumination microscopes, and confocal microscopes, are also described. For angle-based measurement technologies, in addition to the conventional continuous-wave laser autocollimators, the newly developed Fabry–Pérot angle sensor and nonlinear optics angle sensor using an ultrashort pulse laser are presented. Finally, on-machine and in-process force sensing and machining learning techniques for dimensional and machining process monitoring are reviewed.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141675878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fabrication of Rose Petal Surface Using Release-Coated UV-Curable Resin via Ultraviolet Nanoimprint Lithography","authors":"Takuto Wakasa, Kazuki Fujiwara, Jun Taniguchi","doi":"10.20965/ijat.2024.p0521","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0521","url":null,"abstract":"Organisms often have superior abilities. For example, the moth’s eyes block the reflection of light, preventing even the slightest light from escaping. Morpho butterflies have vivid colors despite their lack of pigmentation. The superhydrophobicity of lotus leaves is another example, which is attributed to their characteristic surface structure. We have recreated an interesting property by mimicking the structure of rose petals. When a drop of water falls on a rose petal, it adheres to the petal like a sphere. The droplets stay in place when the petals are inverted in this state. This phenomenon is called the rose petal effect. The surface of the petals is lined with microscale hemispherical structures, and each surface has additional nanoscale grooves. The effect is due to the hierarchical structure of nano- and microstructures. When water is dropped onto these structures, the surfaces of the nanostructures become air pockets, preventing water from entering the grooves. This results in stronger water repellency compared to that of the same material with a smooth surface. In contrast, when water penetrates the microstructure, the surface area becomes larger than that of a smooth surface, increasing adhesion. This is called the Wenzel mode. Here, we attempted to reproduce this structure on film using a combination of high-throughput techniques; ultraviolet nanoimprint lithography (UV-NIL) and roll pressing. The manufacturing process comprises two main steps. First, a nanopillar structure called a moth-eye structure is fabricated over the entire surface using UV-NIL. This serves the same purpose as the nanoglobe structure. Next, microscale holes are drilled on the surface using a roll press method. The resulting depressions immobilize water droplets and improve adhesion. Despite the strong water repellency obtained through this method, with a contact angle of more than 140±b°, up to 9 µL of water droplets remained attached to the film even when the film was turned over. Because this method can impart adhesion at any position on the water-repellent surface, it can be applied to microdroplet transport.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141676942","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Prototype of Parallel Plate Type Fast Atom Beam Source and its Improvement of Irradiation Characteristics","authors":"Taisei Kato, R. Morisaki, T. Yamazaki, C. Oka, J. Sakurai, Seiichi Hata","doi":"10.20965/ijat.2024.p0513","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0513","url":null,"abstract":"Fast atom beam (FAB) source is used for surface activated bonding. This process is attracting attention as an essential process for next-generation semiconductor manufacturing. Traditional wafer direct bonding processes require annealing or cannot be directly bonded at room temperature. Therefore, there are restrictions on the materials that can be bonded and the combinations of materials that can be bonded. However, surface activated bonding has made it possible to directly bond dissimilar materials at room temperature. This technology is expected to be applied to the manufacturing of various MEMS and three-dimensional stacking of semiconductors. This bonding process involves bombarding the wafer surface with fast argon atom beam in a vacuum chamber. Irradiation removes oxide layer and contaminants, exposing dangling bonds. By pressing the wafers together, the dangling bonds are bonded together, and a strong bond is achieved. The device that generates this fast argon atom beam is FAB source. This device has been of the type that generates a saddle field electric field. However, this FAB source had a narrow beam irradiation area and was unable to support the recent increase in wafer diameter. Therefore, it was necessary to perform irradiation using multiple FAB sources. At production sites, there is a need to develop new FAB sources that can irradiate large areas. In this study, we developed FAB source in which the beam is generated by parallel plate electrodes. We performed a comparison with the saddle field type FAB source and found that the performance was inferior in initial experiments. Next, we improved the design to operate at higher voltages and increased the aperture area. Through these improvements, we have achieved performance superior to the saddle field type FAB source.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141675844","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Initial Wear of Fixed Diamond Wire Tool –Effect of Slurry Assisted Slicing on Machining Mechanism—","authors":"Shinya Moriyama, Takanori Yazawa, T. Otsubo, K. Harada","doi":"10.20965/ijat.2024.p0483","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0483","url":null,"abstract":"In this study, we investigated the effect of adding cerium oxide (CeO2) particles to the cutting fluid on the machining mechanism when slicing sapphire wafers using an electrodeposited diamond wire tool. The results showed that the added CeO2 acted to suppress wire tool deflection and promote initial wear of the nickel plating to rapidly expose the abrasive grains. In addition, elemental analysis of the shed wear particles suggested that they were adsorbed particles of nickel plating and sapphire. It was statistically confirmed that the CeO2 slurry reduced the size of the wear particles. In addition, the machining force was measured, and it was found that the CeO2 slurry reduced the machining force. Based on these results, it is the CeO2 slurry likely changed the wear mode from severe to mild and suppressed the lifting of the tool because smaller wear particle were formed. This suppressed wire tool deflection and stabilized the machining pressure to make the abrasive grains uniformly contact and remove material from the workpiece. Therefore, the number of cutting grains increased and the depth of cut per grain was kept small, which likely resulted in a transition to the crack-free ductile mode.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141674490","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Continuous Representation of Machining Processes Using 4-Dimensional Geometric Models –Cutter-Workpiece Engagement Analysis and Processing Surface Estimation in Spatio-Temporal Space—","authors":"Tong Zhang, M. Onosato, Fumiki Tanaka","doi":"10.20965/ijat.2024.p0463","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0463","url":null,"abstract":"The study proposes strategies for conducting cutter-workpiece engagement (CWE) analysis and representation based on 4-dimensional (4D) geometric models. To achieve the CWE condition, two 4D models representing the workpiece and the machinable volume of the tool are introduced for Boolean subtraction and CWE calculation. However, performing set operations and mesh transformations on high-accuracy 4D mesh models can be complex and time-consuming. Therefore, a simplified CWE analysis process between the time-invariant workpiece-occupied region (WOR) and the tool-occupied region (TOR) has been implemented to illustrate the validity of the set operation algorithm. The results demonstrate the effectiveness of the proposed 4D Set operation algorithm and its application in CWE analysis to a certain extent.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141676372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of Different Feed Rates on Chip Evacuation in Drilling of Lead-Free Brass with a Small-Diameter Drill","authors":"Tadaaki Naruki, Kenichi Suzuki, Hideharu Kato, Shigehiko Sakamoto, Masahiro Seto, Jin Katayama, Takayuki Oka","doi":"10.20965/ijat.2024.p0503","DOIUrl":"https://doi.org/10.20965/ijat.2024.p0503","url":null,"abstract":"Free-cutting brass is a material whose machinability is improved by the addition of lead. It is used in a wide range of applications because of its high electrical conductivity and antibacterial properties. However, the use of lead is restricted by laws and regulations to reduce environmental damage. Therefore, the lead in free-cutting brass is being replaced by bismuth or silicon. The machinability of lead-free brass, improved by these additives, has been confirmed to be sufficient for milling and turning. However, when drilling deep small-diameter holes in leadless brass, the problem of premature drill breakage occurs due to chips clumping and clogging in the drill flutes. In a previous study, drilling of holes with an aspect ratio of nine was performed using a 1.0 mm diameter cemented carbide drill, and it was confirmed that the addition of trace elements improved the chip breaking and chip evacuation. However, the waveform of thrust force during machining demonstrated a decreasing trend, and the original machining conditions were not attained. In this study, the effect of feed rate on chip evacuation was investigated using a 0.5 mm diameter twist drill, which is subject to severe chip evacuation at high cutting speeds. As a result of examining chip evacuation by varying the feed rate, the chip evacuation exhibited good performance; where bellows-like chips were evacuated under a slow feed rate, and long-pitch chips were evacuated under a high feed rate. In the drilling process using these feed rates with good chip evacuation, 10,000 holes could be drilled, but the shape of the top of the hole was distorted and the straightness was poor at a slow feed rate. In contrast, hole accuracy was good at a high feed rate, further indicating that a high feed rate with long-pitch-shaped chip evacuation is effective for high efficiency when drilling deep holes of small diameters.","PeriodicalId":43716,"journal":{"name":"International Journal of Automation Technology","volume":null,"pages":null},"PeriodicalIF":0.9,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141673636","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}