Details of a Researcher - Kakinuma, Yasuhiro

Papers - Kakinuma, Yasuhiro

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山田宗一郎, 青山藤詞郎, 柿沼康弘

精密工学会誌 (The Japan Society for Precision Engineering) 81 ( 3 ) 264 - 269 2015

Research paper (scientific journal), Accepted, ISSN 0912-0289

Electro adhesive gel (EAG) shows a unique characteristic changing its surface adhesive property according to the applied electric field, which is named as electro-adhesive effect (EA effect). Our recent research results indicated that the EAG is feasible to be applied to fixture, clutch, damping, and brake mechanisms. While the performance of EAG has been dramatically enhanced over the past decade, the individual difference caused by the production process has been still problem. In other word, adhesive area of EAGs under the same electric filed is non-uniform and uncontrollable. In this research, to ensure stable EA effect, an electro-adhesive surface (EAS) applying 3-dimensional micro structure alternative to the EAG is proposed. The proposed EAS is composed of the 3-D micro-mesh structure fabricated by the photolithography and silicone gel. The prototype of the EAS was developed and its characteristic was experimentally investigated by microscopic observation and shear test. The result obviously shows that the EAS generates larger adhesive force in higher intensity of electric filed. Furthermore, a uniform and regular pattern of adhesion area is clearly observed. From these results, EAS has a strong possibility to improve the stability of EA effect and enhance the performance of its application devices.

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エンドミル加工における外乱オブザーバを用いたセンサレスびびり振動検知技術の開発（第2報）－移動分散値と移動離散フーリエ変換を併用したびびり振動の種類別検知－

小池綾, 柿沼康弘, 青山藤詞郎, 大西公平

精密工学会誌 (The Japan Society for Precision Engineering) 81 ( 7 ) 692 - 698 2015

Research paper (scientific journal), Accepted, ISSN 0912-0289

Chatter vibration deteriorates the machining accuracy and shortens the tool life. Thus, In-process monitoring methods have been proposed by using additional sensors such as dynamometers and acceleration sensors. However, introducing additional sensors leads to high cost and reduction of machine-tool stiffness. To solve these problems, a sensor-less monitoring method applying the disturbance observer theory was proposed in our previous research which has experimentally shown that chatter vibration can be detected only from the servo information in milling. For further demand, because chatter vibration can be classified into self-excited vibration and forced vibration, an assorted detection method is required. In this study, we propose a novel frequency analysis method combining moving variance and moving Fourier transform algorithms, which can obtain the power spectrum density of each chatter vibration type separately with small computational load. The validity of the proposed method is evaluated through milling tests with different rotational speeds.

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Sensorless tool stiffness monitoring in buffing

Koike Ryo, Kumakura Ryo, Arai Takashi, Uchishiba Eishiro, Murakami Makoto, Sagara Takahisa, Kakinuma Yasuhiro

International Journal of Automation Technology 8 ( 6 ) 827 - 836 2014.11

Research paper (scientific journal), ISSN 1881-7629

<p>In current practice, the buffing process required to finish the surface of mechanical parts is performed manually by a technical expert as it requires a delicate adjustment of the buffing force. The automation of this process is desirable in an effort to shorten the process time and reduce labor cost. To automate the buffing process, a beneficial process monitoring technique that supervises the buffing tool conditions in real time must be developed. From a practical perspective, an observer technique that does not require additional sensors would be most suitable for monitoring the tool operating condition. The authors propose a technique that estimates the buffing tool stiffness based on a disturbance observer. The validity of the proposed method as a buffing tool condition monitoring technique is verified through numerical simulations and experiments.</p>

Sensorless tool stiffness monitoring in buffing

Ryo Koike; Ryo Kumakura; Takashi Arai; Eishiro Uchishiba; Makoto Murakami; Takahisa Sagara; Yasuhiro Kakinuma

International Journal of Automation Technology 8 ( 6 ) 827 - 836 2014

Research paper (scientific journal)

Active chatter suppression in turning by band-limited force control

Kakinuma, Yasuhiro, Enomoto, Kazuto, Hirano, Takayuki, Ohnishi, Kouhei

CIRP ANNALS-MANUFACTURING TECHNOLOGY (ELSEVIER SCIENCE BV) 63 ( 1 ) 365 - 368 2014

Research paper (scientific journal), ISSN 0007-8506

The suppression of chatter vibration is required to enhance the machined surface quality and to increase tool life. In this study, a new, conceptually active approach for chatter suppression in machining is proposed. The hybrid control method developed by applying sensorless force control with a disturbance observer enables the simultaneous and independent control of the position trajectory and band-limited forces. The proposed method is introduced to the carriage of a prototype desktop-sized turning machine, and the ability to suppress chatter is evaluated by end-face cutting tests. The results demonstrate that actively controlling a band-limited force leads to the avoidance of chatter. (C) 2014 CIRP.

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Basic study on high efficiency ultra-precision grinding of the optical glass lens

Rei Sekiguchi; Shun Yoshikawa; Yasuhiro Kakinuma; Katsutoshi Tanaka; Masahiko Fukuta

Advanced Materials Research (Trans Tech Publications Ltd) 1017 21 - 26 2014

Research paper (scientific journal), ISSN 1662-8985

The demand for large aperture lenses with high surface quality and form accuracy used for single-lens reflex cameras has been increasing. Generally, large aperture glass lenses are produced by ultra-precision grinding. Considering the increasing global competition, the grinding process has to be improved. However, highly efficient grinding causes worse surface quality, which leads to much polishing and ultimately results in lower form accuracy. Thus in this study, aiming at the realization of highly efficient and precise grinding of glass lenses, cross grinding of optical glass BK7 is carried out. As a first step of the study, the influence of grinding conditions on the surface quality is investigated experimentally.

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Drill fracture detection by integrating disturbance observer and rotational digital filter

R. Koike; Y. Kakinuma; T. Aoyama

CIRP Journal of Manufacturing Science and Technology (Elsevier BV) 7 ( 3 ) 177 - 184 2014

Research paper (scientific journal), ISSN 1755-5817

Tool fracture detection is important to avoid tool breakage and ensure cutting accuracy. However, conventional tool condition monitoring methods use additional sensors that are expensive, increase the failure rate, and reduce the machine-tool stiffness. This study proposes a novel in-process method to detect tool fracture based on disturbance observer theory. It uses only servo information in a ballscrew-driven stage control system. Furthermore, a rotational digital filter is developed and applied to drilling tests to enhance the detection accuracy. Tool fracture is successfully detected without any external sensors by the proposed method. © 2014 CIRP.

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Monitoring of tool collision in drilling by disturbance observer

S. Tönissen; R. Koike; Y. Kakinuma; T. Aoyama; F. Klocke

CIRP Journal of Manufacturing Science and Technology (Elsevier Ltd) 7 ( 3 ) 274 - 282 2014

Research paper (scientific journal), ISSN 1755-5817

Disturbance observation is a sensorless process monitoring technique that has not yet been applied to the monitoring of tool collision in the use of machine tools. This paper presents a monitoring algorithm that detects collisions that involve the breakage of drills through observation of the disturbance force change rate. A comprehensive experimental study of diverse operator-induced collisions was conducted to analyze the collision detection potential of the disturbance observer. It was found that collision monitoring by the disturbance observer is more sensitive and responsive than that using a sensorless jerk observer. © 2014 CIRP.

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Sensorless cutting force estimation in ball-screw-driven system using triple-inertia model

Yuki Yamada; Yasuhiro Kakinuma; Takamichi Ito; Jun Fujita; Makoto Sawazaki; Makoto Sagara

Advanced Materials Research (Trans Tech Publications Ltd) 1017 619 - 623 2014

Research paper (scientific journal), ISSN 1662-8985

In this paper, we propose cutting-force-estimation method for a ball-screw-driven system using triple inertia model. In many cases, dual-inertia model is applied to describe the dynamic behavior of the ball-screw-driven system. In this paper, triple-inertia model is applied and cutting force was estimated without additional sensors, such as dynamometer. The cutting force observer is designed, regarding the ball-screw-driven system as two input and three output system. Simulation results indicate that the proposed method enables accurate estimation around the resonance frequencies. Experimental results showed that the proposed method could monitor external force without being interrupted by the inertia forces.

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Temperature and shear rate characteristics of electrorheological gel applied to a clutch

K. Koyanagi; Y. Takata; Y. Kakinuma; H. Anzai; K. Sakurai; T. Motoyoshi; T. Oshima

Journal of Physics: Conference Series (IOP PUBLISHING LTD) 412 ( 1 ) 827 - 836 2013

Research paper (scientific journal), ISSN 1742-6588

This investigation reports the physical characteristics of electrorheological (ER) gels, which are a type of functional material having controlled surface friction. We previously developed slip clutches using ER gels sandwiched between electrodes, and verified their responses and controllability. We newly report the temperature and shear rate characteristics of ER gel in this study because the input and output electrodes of the clutch continuously slip past each other. While the temperature of ER gels increased when energized, the shear stress hardly changed. Instead, wearing and adaptation to the electrode affect the property. The shear rate hardly affected the shear stress in the high-shear-rate region. Conversely, the shear stress depended on the shear rate in the lower region.

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Development of 5-axis polishing machine capable of simultaneous trajectory, posture, and force control

Kakinuma, Yasuhiro, Igarashi, Keisuke, Katsura, Seiichiro, Aoyama, Tojiro

CIRP ANNALS-MANUFACTURING TECHNOLOGY (ELSEVIER SCIENCE BV) 62 ( 1 ) 379 - 382 2013

Research paper (scientific journal), ISSN 0007-8506

The buffing process for finishing an automobile's body is still done manually, and the final surface quality of the body depends on the skill and technique of the worker. To automate buffing, not only tool path control but also precise and fast force control is required. In this study, a novel methodology based on the sensor-less force control technique and the quarry matrix capable of the mode decoupling is proposed for a parallel mechanism polishing machine to control x-y trajectory, tool posture, and polishing force in z-direction, and its validity for automated buffing is verified. (C) 2013 CIRP.

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Ultra-precision cryogenic machining of viscoelastic polymers

Y. Kakinuma, S. Kidani, T. Aoyama

CIRP Annals-Manufacturing Technology (ELSEVIER SCIENCE BV) 61 ( 1 ) 79-82 - 82 2012.08

Research paper (scientific journal), Joint Work, Accepted, ISSN 0007-8506

Microfluidic chips with micro- or nanoscale channels are currently in great demand. PDMS (polydimethylsiloxane), a viscoelastic polymer, has high transparency and good chemical stability, making it a suitable substrate material for such chips. However, it is difficult to machine PDMS by conventional cutting processes because of its high elasticity and adhesion. We proposed the cryogenic micromachining of PDMS completely immersed in liquid nitrogen as a direct process to fabricate customized 3D nano/microfluidic chips precisely. In this study, the feasibility of ultra-precision cryogenic machining is studied as an extended nanofabrication process. (C) 2012 CIRP.

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センサレス研磨圧制御法を用いた低弾性樹脂材のバフ研磨特性解析

五十嵐恵介, 柿沼康弘

砥粒加工学会誌 56 ( 12 ) 835-840 2012

Research paper (scientific journal), Joint Work, Accepted

Three-dimensional measurement of gas dissolution process in gas–liquid microchannel ﬂow

M. Ichiyanagi, I. Tsutsui, Y. Kakinuma, Y. Sato, K. Hishida

International Journal of Heat and Mass Transfer (PERGAMON-ELSEVIER SCIENCE LTD) 55 ( 11-12 ) 2872-2878 - 2878 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 0017-9310

The three-dimensional CO2 dissolution process through a gas-liquid interface in microfluidic devices was investigated experimentally, for the precise control of CO2 dissolution. The gas dissolution was evaluated by using confocal micron-resolution particle image velocimetry (micro-Ply) combined with laser induced fluorescence (LIF), which has the ability to measure the velocity and dissolved CO2 concentration distribution in a liquid flow field. The measurement system is based on the confocal microscope, which has excellent depth resolution and enables visualization of the three-dimensional distributions of velocity and dissolved CO2 concentration by rendering two-dimensional data. The device is comprised of a polydimethylsiloxane chip, whose microchannels were fabricated by using a cryogenic micromachining system. The width and depth of the liquid flow channel are larger than those of the gas flow channel. This is due to the need for decreasing the width of the gas-liquid interface and increasing the hydraulic diameter of the liquid channel, whose conditions generate a static gas-liquid interface. The experiments were performed for three different liquid flow conditions corresponding to Reynolds numbers of 1.0 x 10(-2), 1.2 x 10(-2) and 1.7 x 10(-2), and the gas flow rate was set to be constant at 150 mu L/min. The LIF measurements indicate that an increase in the Reynolds number yields a decrease in dissolved gas in the spanwise directions. Furthermore, molar fluxes by convection and diffusion were evaluated from the experimental data. The molar fluxes in the streamwise direction were at least 20 times as large as those in the spanwise and depthwise directions. This reveals that an increase in momentum transport in the spanwise and depthwise directions is an important factor for enhancing mass transfer in the gas-liquid microchannel flow. (C) 2012 Elsevier Ltd. All rights reserved.

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Evaluation methodology of gas permeable characterization in a polymer-based microfluidic device by confocal fluorescence imaging

M. Ichiyanagi, K. Sakai, S. Kidani, Y. Kakinuma, Y. Sato, K. Hishida

Journal of Micromechanics and Microengineering (IOP PUBLISHING LTD) 22 ( 6 ) 065023 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 0960-1317

The evaluation technique of gas permeable characterization has been developed for an increased efficiency of gas-liquid chemical reactions and high accuracy of environmental diagnosis. This technique enables us to measure spatial distributions of velocity and dissolved gas concentration by utilizing confocal micron-resolution particle image velocimetry combined with a laser-induced fluorescence technique. Microfluidic devices with gas permeability through polymer membranes are composed of a cover glass and a polydimethylsiloxane (PDMS) chip with the ability to permeate various gases, since PDMS is an elastomeric material. In the chip, microchannels are manufactured using a cryogenic micromachining system. The gas permeation is dominated by several factors, such as the gas and liquid flow rates, the membrane thickness between the gas and liquid flow, and the surface area of the membranes. The advantage of the present device is to realize the control of gas permeability by changing the surface roughness of PDMS, because the cryogenic micromachining enables us to control the surface roughness of microchannels and an increase in roughness yields an increase in the surface area of membranes. The experiments were performed under several conditions with a change in the gas flow rate, the PDMS membrane thickness and the surface roughness, which affect the gas permeation phenomena. The spatial distributions of velocity and dissolved gas concentration were measured in the liquid flow fields. The results indicate that the velocity-vector distributions have similar patterns under all experimental conditions, while the dissolved gas concentration distributions have different patterns. It was observed that the gas permeability through PDMS membranes increased with an increase in gas flow rates and surface roughness and with a decrease in membrane thicknesses, which is in qualitative agreement with membrane theory. The important conclusion is that the proposed technique is suggested to have the possibility of evaluating the characterization of gas permeable microfluidic device through membranes.

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Basic Performance Evaluation of Electro-adhesive Film with Micro Mesh Sheet

T. Kubo, Y. Kakinuma

Key Engineering Materials (TRANS TECH PUBLICATIONS LTD) 516 222-227 - 227 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 1013-9826

Smart materials have been developed in many leading technologies. Smart material is a material that gives a specific reaction to the change and stimulus of the external environment such as light, heat and electromagnetic fields. Electro-rheological Gel (ERG) is one smart material. ERG changes its surface adhesive properties rapidly according to the intensity of the applied electrical field. This unique property is named Electro-adhesive effect (EA effect). In this research, as a novel electro-adhesive film which is replaced with ERG, Electro-adhesive film with micro mesh sheets is developed and named EAMS. Furthermore, it is proved that the developed film using the mesh sheet produces the EA effect and that the performance of EAMS is enhanced according to the increase of the open space and the number of layers.

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Real-Time Cutting Force/Torque Prediction During Turning

K. Enomoto, M. Takei, Y. Kakinuma

International Journal of Automation Technology (Fuji Technology Press) 6 ( 5 ) 669-674 - 674 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 1883-8022

The automation of machining processes requireshighly accurate process monitoring. However, the use of additional sensors leads to a significant increase in the cost and reduces the stiffness and reliability of mechanical systems. Hence, we propose a system called the cutting force observer, which uses a sensor-less and real-time cutting force estimation methodology based on the disturbance observer theory. Monitoring methods using the cutting force observer may enhance the productivity during turning. One of the parameters that significantly affect the cutting process is the shear angle. The determination of the shear angle is very important as it can be used for identifying the machining conditions. In this study, an external sensor-less monitoring system of the shear angle during turning is developed, and its performance is evaluated.

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Development of an intelligent stage with sensor-less cutting force and torque monitoring function

T. Kamigochi, Y. Kakinuma

International Journal of Automation Technology (Fuji Technology Press) 6 ( 6 ) 736-741 - 741 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 1883-8022

Intelligent machine tool is required to implement highprecision process monitoring for judging the abnormal tool conditions. Various techniques have been widely researched and studied to maintain machine tool in good condition and to detect tool wear. The occurrence of tool wear can be detected by monitoring the cutting torque, which is basic information for machining. The purpose of this study was to propose a sensor-less cutting force and torque monitoring method and to develop an intelligent stage using this method.

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Sensor-less Tool Fracture Detection Applying Disturbance Observer Theory

R. Koike, Y. Kakinuma, T.Aoyama

Key Engineering Materials (TRANSACTION PUBLISHERS) 523 439-444 - 444 2012

Research paper (scientific journal), Joint Work, Accepted, ISSN 1013-9826

Detection of a tool fracture is necessary to ensure cutting accuracy and to avoid a tool breakage because tool fracture is one of the significant prediction signals of the tool breakage. For monitoring the tool condition, generally additional sensors are used. However using these sensors causes high cost and increase of failure rate. In this paper, a novel sensor-less detection method of tool fracture in drilling process is proposed on the basis of a disturbance observer theory. It is applied to the x-y stage of the machine tool. The proposed method requires no external sensor because it uses only the servo information of the spindle control system. Since structures of normal drills with two floats are symmetrical with respect to a point, theoretically the cutting force in the x and y directions does not work. When the drill is fractured, its structure becomes asymmetry so that unbalanced forces would exert in the x and y directions at intervals of the spindle speed. Therefore, it is possible to detect a tool fracture by the frequency analysis of estimated disturbance force with a wavelet transform. The experimental results show that the proposed method is available for detection of the small tool fracture effectively.

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低弾性樹脂材料の研磨表面評価

久保貴生，柿沼康弘

砥粒加工学会誌 55 ( 9 ) 546-551 2011

Research paper (scientific journal), Joint Work, Accepted

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