Decision methodology of end-milling conditions using data-mining

The purpose of the present study is to apply data-mining methods to support the decision of reasonable cutting conditions. Although an enormous amount of information is listed in a catalog, it is not possible to know all of it. Seen from the viewpoint of the user, this enormous amount of information becomes a hindrance. For example, even if an expert worker does not look at a catalog, in end-mill processing, he can decide the appropriate processing condition efficiently from experience; however, this type of situation creates difficult problems for an unskilled worker or a skilled worker with little experience. The recommended cutting condition for every type of material is listed in a catalog together with the appropriate tool, but it takes much time and labor to search and examine the catalog to find the right tool, and this process is inefficient. The main subject of our research was to support the processing condition of the end-mill for each precision tool efficiently based on end-mill clusters. Our research applied the techniques of data mining, in particular, non-hierarchy clustering and hierarchy clustering, to catalog data. With these techniques, we applied multiple regression analysis and reached the following main conclusions. As a first step, we paid attention to the shape element of catalog data. In addition to using conventional mining processes, we grouped end-mills from the viewpoint of tool shape, which meant the ratio of dimensions, visually by applying the K-means method. We applied variable cluster analysis next to each cluster and extracted an predictor variable to represent each cluster, and we performed multiple regression analysis and derived a cutting condition decision formula. The cutting condition decision formula provided high accuracy. The accuracy was higher than the results achieved through mining of all data. A more highly precise processing condition decision formula was derived by doing mining again, excluding the peculiar data clusters such as small diameter end-mill. We understood what was effective for cutting condition decision to be factors related to blade length and the ratio of the full length, factors which have not been singled out through background knowledge or expert knowledge, but were noticed as an effect of catalog mining.     

Effect of pulse-modulated microwaves on fullerene ion production with electron cyclotron resonance ion source

Fullerene plasmas generated by pulse-modulated microwaves have been investigated under typical conditions at the Bio-Nano electron cyclotron resonance ion source. The effect of the pulse modulation is distinct from that of simply structured gases, and then the density of the fullerene plasmas increased as decreasing the duty ratio. The density for a pulse width of 10 μs at the period of 100 μs is 1.34 times higher than that for CW mode. We have studied the responses of fullerene and argon plasmas to pulsed microwaves. After the turnoff of microwave power, fullerene plasmas lasted ～30 times longer than argon plasmas.     

Electron cyclotron resonance plasma production by using pulse mode microwaves and dependences of ion beam current and plasma parameters on the pulse condition

We measure the ion beam current and the plasma parameters by using the pulse mode microwave operation in the first stage of a tandem type ECRIS. The time averaged extracted ion beam current in the pulse mode operation is larger than that of the cw mode operation with the same averaged microwave power. The electron density n(e) in the pulse mode is higher and the electron temperature T(e) is lower than those of the cw mode operation. These plasma parameters are considered to cause in the increase of the ion beam current and are suitable to produce molecular or cluster ions.     

A single-solenoid pulsed-magnet system for single-crystal scattering studies

We present a pulsed-magnet system that enables x-ray single-crystal diffraction in addition to powder and spectroscopic studies with the magnetic field applied on or close to the scattering plane. The apparatus consists of a single large-bore solenoid, cooled by liquid nitrogen. A second independent closed-cycle cryostat is used for cooling samples near liquid helium temperatures. Pulsed magnetic fields close to ~30 T with a zero-to-peak-field rise time of ~2.9 ms are generated by discharging a 40 kJ capacitor bank into the magnet coil. The unique characteristic of this instrument is the preservation of maximum scattering angle (~23.6°) on the entrance and exit sides of the magnet bore by virtue of a novel double-funnel insert. This instrument will facilitate x-ray diffraction and spectroscopic studies that are impractical, if not impossible, to perform using split-pair and narrow-opening solenoid magnets. Furthermore, it offers a practical solution for preserving optical access in future higher-field pulsed magnets.     

Preparation of fine polymer particles containing metallocene derivatives

This article deals with preparations of fine particles of metallocene copolymers by emulsifierfree emulsion polymerization of vinylferrocene (VFc), ferrocenylmethyl methacrylate (FMMA), 1-ferrocenylethyl methacrylate (1-FEMA), 2-ferrocenylethyl methacrylate (2-FEMA), and 1-ruthenocenylethyl methacrylate (1-REMA) with acrylonitrile (AN), styrene (St), and methyl methacrylate (MMA) in water/ethanol medium. As a result, spherical copolymer particles containing metallocene derivatives have been successfully synthesized in the particle size of ca. 120 to 600 nm. The contents of ferrocenyl or ruthenocenyl groups in copolymer particles increased with increasing concentration of charged metallocene derivatives, while the amounts of metallocene derivatives incorporated into particles are much lower than the charged ratio. © 1994 John Wiley & Sons, Inc.     

Design of electrofusion joints and evaluation of fusion strength using fusion simulation technology

Fusion simulation is one of the key techniques in designing and producing electrofusion (EF) joints for gas distribution and in evaluating fusion joint integrity. This paper describes the result of a numerical simulation of a thermal fusion process, using the finite element method. A nonlinear heat transfer computer program was used to obtain the temperature profile of a large electrofusion joint at fusion. The effects of applied voltage, heating time, wire pitch, and ambient temperature were examined for designing a 150-mm EF joint. A method to shorten the cooling time was also investigated. The fusion condition range suitable for a 150-mm EF joint was found to be slightly narrower than that suitable for a 50-mm EF joint. Examination of the effect of wire pitch revealed that if the pitch is extremely large, thermal degradation starts in the resin close to the wire before the fusion-interface strength reaches the maximum value. We have developed a program to simulate the process of closing the gap between the pipe and the joint due to resin expansion and melting after the power is supplied.     

Improving the Anti-seizure Ability of SiC Seal in Water with RIE Texturing

The demand for higher pressure and higher speed of sealing systems is currently increasing due to stricter standards for permissible emissions. Silicon carbide (SiC) is thought to be a promising material for sealing systems operating in water, since the combination of SiC and water is both environmentally friendly and energy saving. The purpose of this study is to improve the anti-seizure ability of SiC seals working in water by means of surface texturing. The texture pattern of micro-pits evenly distributed in a square array is formed on one of the contact surfaces by reactive ion etching (RIE). Experiments which simulate the working condition of mechanical seals were carried out to evaluate the effect of micro-pits on the critical seizure load. It is found that micro-pit texturing is an effective way to stabilize friction, to reduce the friction coefficient, and to expand the low-friction range ( < 0.05) of SiC seals working in water.     

Measurement on the shear properties of liquid nanomeniscus bridge

The shear properties of liquid nanomeniscus bridge were measured by a nanorheometer which was developed recently. The meniscus bridges of PFPE (Perfluoropolyether) Z-dol were formed between two glass spheres. One was mounted on a piezo actuator and moved sinusoidally in the shear direction against the other which was mounted on a rectangular-type microcantilever. The diameters of the spheres were 90 μm and 20 μm, respectively. The induced oscillatory motions of the cantilever-sphere assembly were detected via a two phase lock-in amplifier with respect to the modulation frequency and the surface separation. The amplitude response was interpreted as elastic characteristics and phase shift as damping characteristics of the liquid meniscus bridge. The experimental results were qualitatively compared to those of the normal oscillatory experiments.The lateral meniscus force was much smaller than the normal case, which affected directly the amplitude ratio and phase shift of the system. In results, the system showed more viscous behavior compared to the normal case. However, the system still showed the excess stiffness and excess damping at low frequencies and large surface separations, which was originated from the existence of the liquid meniscus bridge. The excess stiffness was directly attributed to the lateral meniscus force and the excess damping to the moving contact line.     

Microfabricated silicon dioxide cantilever with subwavelength aperture

We have developed a microfabricated SiO₂ cantilever with subwavelength aperture for scanning near-field optical microscopy (SNOM), to overcome the disadvantages of conventional optical fibre probes such as low reproducibility and low optical throughput. The microcantilever, which has a SiO₂ cantilever and an aperture tip near the end of the cantilever, is fabricated in a reproducible batch process. The circular aperture with a diameter of 100–150 nm is formed by a focused ion-beam technique. Incident light is directly focused on the aperture from the rear side of the cantilever using a focusing objective, and high optical throughput (10⁻² to 10⁻³) is obtained. The microcantilever can be operated as a SNOM probe in contact mode or in dynamic mode.