Morishige KOICHI (森重 功一)

Offer Organization: Japan Society for the Promotion of Science, System Name: Grants-in-Aid for Scientific Research, Category: Grant-in-Aid for Scientific Research (B), Fund Type: -, Overall Grant Amount: - (direct: 12100000, indirect: 2160000)
日本の機械製造業を強化するためには, 金型製造の工程設計自動化や知能化が重要である. このような高度な工程設計を実現するには, 加工方法や工具選択などに影響する特徴的な形状を自動的に抽出し, 工程設計者にビジュアルに示す機能を用意する必要がある. 本研究では, このようなフィーチャ抽出に関する, 以下の技術の実現に成功した.
(1) 加工に関する特徴抽出に適した3方向デクセルに基づく立体形状の表現.
(2)製品の加工領域を最適な加工方向ごとに分割する技術.
(3)設計ミスに起因する金型上の加工困難形状の自動抽出とその改善技術.
(4)5軸加工に関する特徴抽出に欠かせない幾何シミュレーション技術.

Offer Organization: Japan Society for the Promotion of Science, System Name: Grants-in-Aid for Scientific Research, Category: Grant-in-Aid for Scientific Research (B), Fund Type: -, Overall Grant Amount: - (direct: 12400000, indirect: 1200000)
The study is concerned with the e^3-PLM (Product Lifecycle Management). The e^3-PLM is a kind of PLMs, and it is an "ecology-oriented", "enduser-oriented", and "electronic ICT (Information Communication Technology) based system. In the PLM the importance of end-users is insisted and product use history data are utilized to realize environment friendly product management. The obtained results are follows.
(1) The structure of e^3-database for the PLM is designed. The database consists of a global database and local databases. The global database contains product design information, product handling information, product use history, and communication information, and it can be accessed by manufacturer, end-users, and recyclers. On the other hand, the local database is maintained by each sector and it contains internal information of the sector such as facility information, process plans, sales plans, etc.
(2) For the important scenes in product lifecycle, the value of information in e^3-database is evaluated and the methods to utilize the information are developed.
(a) The framework of PLM is developed and products management policies for products maintenance, renewal, and replacement are analyzed. Especially, environmental impacts related with products refurbishment are analyzed in detail.
(b) A database structure is developed to utilize product use history data. Then, an algorithm is developed to determine the effective handling method of post-consumer products.
(c) Processing and environment related attributes are added to products 3D-CAD models, and a design system is developed so that the environmental impacts of product over its lifecycle can be reduced at the product design stage.
(d) Operation planning is a vital activity in manufacturing, remanufacturing, and recycling operations. Then, an operation planning support system using the standardized machining information is developed.
(e) A method to calculate the economic value of the information in e^3-database is developed. Further investment decision problem with emissions trading is analyzed.

Offer Organization: Japan Society for the Promotion of Science, System Name: Grants-in-Aid for Scientific Research, Category: Grant-in-Aid for Scientific Research (B), Fund Type: -, Overall Grant Amount: - (direct: 11700000, indirect: -)
The study deals with the creation method of ultraprecision micro parts with high aspect ratio and complex shape, i.e. tall, small and complex shape, by making use of a multi-axis control ultraprecision machining center. The shape with high aspect ratio is usually difficult to create. The possibility of creating such a shape may lead to the application to new fields. In the previous year, the fundamental shape creation technology such as micro trapezoid groove, cylinder and prismatic parts of 1 mm in length with aspect ratio of 40, etc. was established by use of various kinds of diamond tools. This year, the following shapes were created; (1) micro pin array consisting of several cylinders and prismatic parts with high aspect ratio, (2) mirror segments array as an optical system for the next generation stepper and (3) micro Buddha head with complex shape. With regard to each item, the study is summarized as follows:
(1) Micro pin array with 9 needles could be machined with a rotational diamond tool, based on the tool path generated by the way of not making contact any more with already machined portions. The metal molding technology is required to produce such a shape since it takes much time to create it. Thus, the electro plating was tried for molding, however the uniform electro plating was difficult to achieve.
(2) Mirror segments array, whose surface roughness is 1 nm, consists of a series of 1mm* 15mm segment being cut from different positions of the sphere of 660 mm in radius. With 5-axis control machining, the segments of about 660mm in radius were machined, however the surface roughness was 10 nm. Farther improvement is required.
(3) Based on the shape data of Buddha bead, 5-axis control machining of Buddha head of about 3 mm in diameter was carried out, taking account of tool collision. The shape was successfully completed, however has overcut parts on the surface due to the difficulty of tool setting.

Offer Organization: Japan Society for the Promotion of Science, System Name: Grants-in-Aid for Scientific Research, Category: Grant-in-Aid for Scientific Research (B), Fund Type: -, Overall Grant Amount: - (direct: 2700000, indirect: -)
The demand for efficient and accurate machine tools and machining technology is rapidly increasing in recent years. The intensive manufacturing technology capable of the whole machining at one setup allows machine tools to realize the efficient and accurate machining. The study proposes a new machining method of combining sophisticated. 5-axis control machining with 6-axis control, one using non-rotational cutting tools. However, the cutting speed of 6-axis control machining is low, which causes the deterioration of machined surface quality. Thus, the ultrasonic vibrational cutting was employed to solve the problem. The study is summarized as follows :
1. The-main processor to generate cutter path (CL) data for 6-axis control machining, based on workpiece shapes defined by 3D-CAD system, was developed, especially for character line machining and asymmetric grooving, taking account of collision avoidance between tool and workpiece.
2. Cutting experiments by use of a vibration tool were carried out on a 6-axis control machining center with NC data converted from CL data by use of our own post processor. As a result, the workpiece with fine surface quality can be obtained.
3. A part of the integrated multi-axis control CAM system was achieved to perform the efficient machining ,by unifying the effective 5-axis control CAM system and the 6-axis control one developed in the study.

Offer Organization: Japan Society for the Promotion of Science, System Name: Grants-in-Aid for Scientific Research, Category: Grant-in-Aid for Scientific Research (B)., Fund Type: -, Overall Grant Amount: - (direct: 10000000, indirect: -)
The study proposes a new method of bonding two small parts without the use of any adhesive by making use of ultraprecision V-shaped microgrooves on the surfaces of each part. These V-shaped microgrooves allow small parts to be bonded together with high positioning accuracy due to a wedge effect and an adhesion phenomenon between the mating surfaces. Ultraprecision V-shaped microgrooves are created by using an ultraprecision machining center having 1 nm positioning resolution and a diamond milling cutter. The study is summarized as follows :
1. It is found that the bonding strength in general increases with decreasing wedge angle. The effect of the wedge length on bonding strength though varies with the wedge angle where the strength increases with increasing length for wedge angles greater than 8 degrees but increases with decreasing length for wedge angles less than 8 degrees.
2. These V-shaped microgrooves, whose depth and angle are 20 μm and 13.5 degree respectively, allow small parts to be tightly bonded together with high positioning accuracy due to a wedge effect and an adhesion phenomenon between two mating surfaces.
3. Small parts of 4 mm * 4 mm * 4 mm that have V-shaped microgrooves in two direction could be tightly bonded with 0.380 μm positioning accuracy.
4. The new method has a possibility to bond different materials each other. Two small parts with V-shaped microgrooves that are made of oxygen-free copper and aluminum are subjected to bonding test. As a result, the proposed bonding method is found to be effective to connect small parts accurately.
5. It is experimentally found that the microgrooving technology is also applicable to manufacture various Fresnel lenses and optical elements.