Outline:
General or Specialized : Specialized
Field of learning : Design and production / management
Foundational academic disciplines : Engineering／Mechanical engineering／Production Engineering/Processing Studies
Relationship with Educational Objectives : This class is equivalent to (2) Acquire knowledge in specialized technical fields such as materials and structure, motion and vibration, energy and flow, information and measurement / control, design and production / management, and machines and systems, and can be used for designing, manufacturing, and operating machines and systems.
Relationship with JABEE programs The main : The main goals of learning / education in this class is (A), Ａ－２ .
Course outline : Precision and ultra-precision machining technologies play an important role in modern science and technology, and are evolving and developing complementarily with other peripheral technologies. In this lecture, we will give an overview of the features and mechanisms of precision and ultra-precision machining technologies, mainly for cutting and abrasive machining, and learn about their roles in advanced technologies.
Style:
Course method :
Classes will be conducted using a projector. We will proceed with the lessons while confirming the knowledge about machining and machine tools that we have acquired so far. In addition, in order to deepen understanding, exercises will be imposed at appropriate times while considering the progress of the lesson.
Grade evaluation method :
The results of the two regular exams are evaluated equally (70%). For each examination, textbooks are allowed. Students who score less than 60 points in each examination may have their scores changed if their understanding is confirmed through make-up exams and retests. However, the score after the change will not exceed 60 points. Evaluation is also based on exercises and reports (30%).
Notice:
Precautions on the enrollment :
Students must be completed (no more than 1/3 of the required numbers of class hours may be missed).
This subject is a "subject that requires study outside of class hours". Classes are offered for 15 credit hours per credit, but 30 credit hours are required in addition to this. Follow the instructions of your instructor for these studies.
Course advice :
This is a subject that requires knowledge of machining and machine tools that have been learned so far. Therefore, as a preparatory study to be conducted in advance, it is recommended to look back on the knowledge about machining and machine tools learned in your department. Students from other than Mechanical Systems are required to review mechanics and self-learn what students gratuated from Mechanical Systems have learned in Manufacturing Technology, Mechanical Design, and Strength of Materials.
Foundational subjects : Design of Mechanical Elements I, II (Mechanical 3rd, 4th year),Manufacturing Technology (Mechanical 2nd), Instrumentation Engineering (Mechanical 4th)), Material Processing (Mechanical 5th), etc.
Related subjects : Experiments of Mechanical and Control Systems (Advanced Course 1st), Advanced Design Engineering (Advanced Course 1st), etc.
Attendance advice :
Based on the knowledge learned in this department, comprehensively consider the knowledge of element technology in machine tools, cutting tool technology, machining technology, control / measurement technology for improving machining accuracy.
You can be late for up to 25 minutes, and if you exceed this, you will be considered absent.
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Theme |
Goals |
| 1st Semester |
| 1st Quarter |
| 1st |
Guidance, Products to which the ultra-precision machining method is applied
Learning contents outside class hours [Items] (Instructions): ○ Precision and accuracy, three elements of accuracy, functional compatibility, dimensional tolerance and fits, geometrical tolerance, surface texture (for those who are not from Mechanical Systems) |
Describe the fields of application of ultra-precision machining and micromachining and their social implications.
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| 2nd |
Background of ultra-precision machining 1 [What is ultra-precision machining?]
Learning contents outside class hours [Items] (Instructions): ・ Technical trends of machine tools from the viewpoint of function / machining accuracy (for all students), ○ Outline of removal process, shape of workpiece and tool motion relationships, cutting mechanisms and processes, machinability, cutting tools and machine tools |
Understand how to cut machine materials and the basics of machine tools.
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| 3rd |
Background of ultra-precision machining 2 [Types of ultra-precision machining]
Learning contents outside class hours [Items] (Instructions): ・ Ultra-precision machining technology from the viewpoint of transferability and resolution of machining, ○ Machining principle, abrasive machining, fixed abrasive machining and free abrasive machining, self-sharpening, grinding, grinding wheel / grinding fluid |
Explain the characteristics of various machining methods by viewing and classifying them from the viewpoint of changes in the mass of the workpiece.
Explain the characteristics of cutting / grinding / polishing from the viewpoint of transferability and resolution.
Understand and classify the difference between normal machining / ultra-precision machining / micromachining.
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| 4th |
Background of ultra-precision machining 3 [Basic technology of ultra-precision machining system]
Learning contents outside class hours [Items] (Instructions): ・ Reproducibility and basic technology of ultra-precision machining machine, ○ Hooke's law, rigidity, residual stress, coefficient of thermal expansion of cast iron / steel (linear expansion coefficient), self-excited vibration, vibration isolation and vibration control, numerical control (NC), feedback |
Understand the elemental technologies of machine tools / cutting tools technologies / machining technologies and consider measures for precision machining.
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| 5th |
Ultra-precision machine tools 1 [Structure of machine tools, roles of components, structural elements]
Learning contents outside class hours [Items] (Instructions): ・ Basic components of machine tools and shape-creating motion, ・ Relationship between mechanical properties and rigidity of structural materials, ○ Line of force, flexural rigidity, torsional rigidity, equation of motion of 1 degree of freedom lumped constant system model, material characteristic value and structural material |
Explain the structure of the machine tool body.
Explain the principles and ideas necessary to realize high-precision machining.
Understand the elemental technologies of machine tools / cutting tools technologies / machining technologies and consider measures for precision machining.
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| 6th |
Ultra-precision machine tools 2 [Machine tool components and technical ingenuity-spindle]
Learning contents outside class hours [Items] (Instructions): ・ Rigidity of spindle (bearing structure) and rotation accuracy, rigidity of guidway and motion accuracy, technical ingenuity for speedup, ○ Rolling bearing / hydrodynamic bearing (dynamic pressure) / hydrostatic bearing (static pressure), Newton's law of viscosity, pressure flow and shear flow,equation of continuity |
Explain the structure of machine tools and the drive system of the spindle.
Explain the principles and ideas necessary to realize precision machining.
Understand the elemental technologies of machine tools / cutting tools technologies / machining technologies and consider measures for precision machining.
Explain the principle of fluid lubrication of plain bearings and journal bearings.
Explain the difference between hydrostatic bearings and dynamic pressure bearings and the principle of hydrostatic bearings.
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| 7th |
Ultra-precision machine tools 3 [Machine tool components and technical ingenuity-linear motion mechanism]
Learning contents outside class hours [Items] (Instructions): ・ Rigidity and motion accuracy of linear motion mechanism ・ technical ingenuity for speedup, ○ Servo system elements: servomotor, coupling, ball screw / nut, encoder, linear scale |
Explain the structure of machine tools and the drive system for guidway.
Explain the principles and ideas necessary to realize precision machining.
Understand the elemental technologies of machine tools / cutting tools technologies / machining technologies and consider measures for precision machining.
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| 8th |
1st semester mid-term exam |
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| 2nd Quarter |
| 9th |
Return and commentary of exam answers. Tools for ultra-precision cutting [ultra-precision cutting tools and tool holders]
Learning contents outside class hours [Items] (Instructions): ・ Items required for cutting tools, ○ Chuck, machine vise, collet chuck, single point tool, ceramics / cemented carbide / high-speed tool steel, hardness / toughness, wear |
Understand the elemental technologies of machine tools / cutting tools technologies / machining technologies and consider measures for precision machining.
Acquire basic knowledge about machine tools / cutting tools / machining processes, and be able to consider ultra-precision machining techniques and issues.
Explain the properties that cutting tools should have and the conditions and types of cutting tool materials.
Explain the phenomenon caused by the wear of the cutting tool edge and the cutting tool life.
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| 10th |
Metal cutting mechanism 1 [Cutting model and chips]
Learning contents outside class hours [Items] (Instructions): ・ Phenomenon of cutting, ○ Decomposition and composition of force, equilibrium of forces / moments, ductile fracture and brittle fracture, stress and strain, normal stress and shear stress, elasticity and plasticity, work hardening |
Explain the mechanism of cutting, the form of chips, the generation of heat due to cutting, and the build up edge.
After understanding the phenomenon of removal processing, the model can be explained.
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| 11th |
Metal cutting mechanism 2 [Cutting resistance and machining with a single shear plane model]
Learning contents outside class hours [Items] (Instructions): ・ Cutting resistance and single shear plane model, ○ Friction angle, material defects (point defects, line defects (dislocations), surface defects (grain boundaries)), crystal slip (yield) |
Acquire basic knowledge about machine tools / cutting tools / machining processes, and be able to consider ultra-precision machining techniques and issues.
Explain the mechanism of cutting, the form of chips, the generation of heat due to cutting, and the build up edge.
After understanding the phenomenological theory of removal processing, the model can be explained.
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| 12th |
Metal cutting mechanism 3 [Roughness of finished surface, method of obtaining high quality finished surface roughness by cutting and ultra-precision cutting mechanism] ・ Abrasive machining [Model for grinding, problems of grinding, conventional grinding and Its features]
Learning contents outside class hours [Items] (Instructions): ・ Relationship between cutting conditions / tool conditions and surface roughness, ○ Real contact, adhesion, heat treatment (annealing, recovery and recrystallization), austenite, ○ Probability density function, (cumulative) distribution function, upward / downward cutting |
It is possible to describe the precision cutting technology and its social implications.
Explain how to devise cutting tools to improve machining accuracy and productivity.
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| 13th |
Ultra-precision grinding [ultra-precision grinding]
Learning content outside class hours [Items] (Instructions): ・ Characteristics of abrasive machining and technical ingenuity for higher accuracy |
Explain the 3 elements and 5 factors of the grind wheel, and explain how to select the grind wheel from the relationship between these and the grinding performance.
Explain the similarities and differences between grinding and polishing.
Abrasive machining can be classified into machining using fixed abrasive grain tools and free abrasive grain tools.
Explain the mechanism and features of grinding
It is possible to describe the high precision grinding technology and its social implications.
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| 14th |
Ultra-precision polishing [conventional polishing method and ultra-precision polishing]
Learning contents outside class hours [Items] (Instructions): ・ Characteristics of processing with fixed and free abrasive grains, ・ Processing mechanism for super smooth surface creation |
Polishing can be classified according to how the abrasive grains are fixed.
It is possible to describe the high-precision polishing technology and its social implications.
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| 15th |
(1st semester final exam) |
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| 16th |
Return and commentary of exam answers. |
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