Prediction of cutting forces and machining error in ball end milling of curved surfaces -II experimental verification

This paper presents the results of a series of experiments performed to examine the validity of a theoretical model for evaluation of cutting forces and machining error in ball end milling of curved surfaces. The experiments are carried out at various cutting conditions, for both contouring and ramping of convex and concave surfaces. A high precision machining center is used in the cutting tests. In contouring, the machining error is measured with an electric micrometer, while in ramping it is measured on a 3-coordinate measuring machine. The results show that in contouring, the cutting force component that influences the machining error decreases with an increase in milling position angle, while in ramping, the two force components that influence the machining error are hardly affected by the milling position angle. Moreover, in contouring, high machining accuracy is achieved in “Up cross-feed, Up cut” and “Down cross-feed, Down cut” modes, while in ramping, high machining accuracy is achieved in “Left cross-feed, Downward cut” and “Right cross-feed, Upward cut” modes. The theoretical and experimental results show reasonably good agreement.     

Whole-Body Force Sensation by Force Sensor With Shell-Shaped End-Effector

This paper proposes a tactile-sensing mechanism for a robot. The mechanism is composed of a force-sensor device and an end-effector of shell shape. Since the end-effector plays the role of an outer shell, a force can be sensed at any position on the body. Due to the aspect of its intrinsic contact sensing, position of the single contact point is calculable without any sensor array. Another advantage is that the six-axis resultant force is measurable. This paper shows that the mechanism is also available for the end-effector with an angulated shape. The only condition for the shape is to be a convex hull. Some experimental results evaluate sources of error in practical measurement and show the validity of the proposed mechanism.     

A useful method for observing intracellular structures of free and cultured cells by scanning electron microscopy

Scanning electron microscopy (SEM) using osmium-maceration methods has been used for analyzing the three-dimensional structure of cell organelles in tissue samples, but it has been quite difficult to observe free and cultured cells with this technique. The present study was performed to develop a method that can be applied to free and cultured cells for SEM studies of intracellular structures after osmium maceration. The method was also applied to light microscopy (LM) and to transmission electron microscopy (TEM). HeLa cells and human leukocytes were fixed with a mixture of 0.5% paraformaldehyde and 0.5% glutaraldehyde followed by an additional fixation with 1% osmium tetroxide. These cells were embedded in low-melting-point agarose. A temperature-responsive dish was also used for collection of cultured cells before embedding. For LM and TEM, the cell-embedded agarose was further embedded in epoxy resin, and semi- and ultrathin sections were examined conventionally. For SEM, the agarose was freeze-fractured in 50% dimethyl sulfoxide, processed for osmium maceration and observed in a high-resolution SEM. Low-melting-point agarose was useful as an embedding medium for SEM, because it was well preserved during prolonged osmication for SEM. Thus, the fine structure of cell organelles was clearly analyzed by SEM after osmium-maceration treatment. These SEM images could also be compared with those of LM and TEM of the agarose-embedded tissues.     

Resonance stub effect in a transition from a through via hole to a stripline in multilayer PCBs

We present results of study of the resonance stub effect occurring in a transition from a through via hole to a stripline in a multilayer printed circuit board (PCB). This effect for via structures including ground vias is estimated by numerical simulations and measurements in the frequency band up to 20 GHz. Ways to alleviate problems in the design of interconnections embedded in multilayer PCBs due to the resonance stub effect and possible applications of the effect in microwave filtering are traced.     

Quantum Effects on Hydrogen Isotopes Adsorption in Nanopores

We have investigated the applicability of simulations and theoretical techniques for exploring the selectivities of hydrogen isotopes. We have simulated the adsorption isotherms of H₂ in an idealized carbon slit pore at 77 K by using the grand canonical Monte Carlo simulations with the Feynman-Hibbs effective potential (FH-GCMC) and the rigorous path integral method (PI-GCMC), and we obtained good agreement between the isotherms from both simulations. This suggests that FH-GCMC, which uses the approximative Feynman-Hibbs treatment, is as useful as PI-GCMC for exploring H₂ adsorption at 77 K. Moreover, we show that the ideal adsorption solution theory (IAST) can predict the selectivity of D₂ over H₂ in the interstices of single-wall carbon nanotube (SWNT) bundles at 77 K (below 0.1 MPa) very well by comparing the obtained results with the mixture adsorption FH-GCMC simulations. This indicates that IAST is also applicable to the estimation of the selectivity of D₂ over H₂ at moderate pressures and at 77 K from experimental single-component adsorption isotherms. We also demonstrate that the FH-GCMC simulation can reproduce the experimental adsorption isotherms of H₂ and D₂ in aluminophosphate AlPO₄-5 at 77 K. Finally, we analyze the selectivity of D₂ over H₂ by IAST with the experimental single-component adsorption isotherms of H₂ and D₂ at 77 K for a variety of adsorbents: AlPO₄-5, activated carbon fibers (ACFs), HiPco SWNT, and SWNHs. The selectivities predicted by the experimental adsorption data based on the results from the FH-GCMC simulations are presented and discussed.     

Two-way ESR cavity for magnetic- and electric-dipole transitions

A two-way ESR cavity for magnetic dipole transition (MDT) and electric dipole transition (EDT) was manufactured. There are two openings to fit the sample cell for MDT or EDT in the cylindrical TE(011) mode. One opening is located on the axis of the cavity and the other is located away from the axis. The ESR spectra of the mixture of oxygen and nitrogen oxide obtained when the sample cell was inserted in each of the openings showed the selective transition of the MDT or of the EDT of the species.     

Insulation characteristics and its evaluation method of N2 gas for nonstandard lightning impulse waveforms

Until recently, SF₆ gas has widely been used as the best insulating medium in substation equipment. However, SF₆ gas was specified to be a greenhouse gas at COP3 in 1997 because of its high global warming potential (GWP), and alternative insulation gases to SF₆ have been sought for a long time. Alternatives using the natural gases are considered to be suitable, but none of them show better properties for insulation as well as good environmental compatibility. Therefore, it is necessary to rationalize the equipment insulation level and reduce the test voltage of electric power apparatus to as low a level as possible. The actual lightning surge waveform (so‐called nonstandard lightning impulse waveform) occurring in the actual field is different from the standard lightning impulse waveform (1.2/50 μs). There are many cases in which the actual lightning surge waveform has a steep rise and large decay of overvoltage, and the insulation requirements are not as severe as those for the standard lightning impulse waveform. In this paper, we focused our research on N₂ gas as an SF₆ substitute and investigated the insulation characteristics of N₂ gas for a single‐frequency oscillatory waveform with various frequencies from 2.7 to 20.0 MHz and damping ratios. Based on the experimental results, it might be possible to reduce the test voltage of N₂ gas insulation by evaluating the crest value of the actual lightning surge waveform that has been converted into an equivalent standard lightning impulse waveform. © 2009 Wiley Periodicals, Inc. Electr Eng Jpn, 167(2): 10–20, 2009; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20754     

Flow fields with vortex in a small semi-open axial fan

In order to clarify the effect of tip clearance (TC) size on fan performance and the flow field at rotor outlet in a small semi-open axial fan, the experimental investigation was carried out. The tip diameter of test fan rotor was 180mm and test TC sizes were 1mm (TC=1mm) and 4mm (TC=4mm). Fan characteristics tests were carried out for two cases of TC size and three-dimensional velocity fields at rotor outlet were measured using a single slant hot-wire probe at four flow-rate conditions. As a result, it was found that the pressure — flow-rate characteristics curves for two cases showed almost the same tendency. However, the ensemble averaged velocity profiles along radial measurement stations of TC=4mm largely changed compared with that of TC=1mm in cases of small flow-rate condition. From the phase-locked averaging results, it was also found that the vortex existed in the rotor outlet flow field of high flow-rate condition for each TC case. Compared with the vortices for TC=1mm and TC=4mm, the vortex for TC=4mm was stronger than that for TC=1mm.     

Optimization of interface structures in crystalline silicon heterojunction solar cells

In heterojunction solar cells consisting of hydrogenated amorphous silicon (a-Si:H) and crystalline silicon (c-Si), suppression of epitaxial growth at the heterointerface is found to be crucial to achieve high solar cell efficiencies. In order to avoid the epitaxial growth, wide-gap hydrogenated amorphous silicon oxide (a-SiO:H) has been applied to the heterojunction solar cells. We have fabricated a-SiO:H/c-Si solar cells using n-type and p-type c-Si substrates and demonstrated that incorporation of the a-SiO:H i layer prevents the harmful epitaxial growth at the heterointerface completely.