Proceedings of the 35th International MATADOR Conference: Formerly The International Machine Tool Design and Research Conference

390 Pages·2007·38.749 MB·English

by  C. Y. Liu, N. K. Chang, Y. T. Chang, J. H. Hsu, S. H. Chang (auth.), Srichand Hinduja PhD, Kuang-Chao Fan PhD (eds.)

Proceedings of the 35th International MATADOR Conference
Srichand Hinduja • Kuang-Chao Fan
Editors
Proceedings of the 35th International
MATADOR Conference
Formerly The International Machine Tool Design
and Research Conference
123
Srichand Hinduja, PhD Kuang-Chao Fan, PhD
School of Mechanical, Aerospace and Civil Engineering Department of Mechanical Engineering
The University of Manchester National Taiwan University
Sackville Street 1, Sec. 4, Roosevelt Rd.
Manchester Taipei 10627
M60 1QD Taiwan
UK ROC

British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library

Library of Congress Control Number: 2007929078

ISBN-13: 978-1-84628-987-3 e-ISBN-13: 978-1-84628-988-0

Printed on acid-free paper.

© Springer-Verlag London Limited 2007
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Proceedings of The
Thirty-Fifth International
MATADOR
Conference
Organising Committee
Professor S. Hinduja (Co-Chairman)
Professor K.-C. Fan (Co-Chairman)
Professor Z. Q. Lin (Co-Chairman)
Professor L. Li
Professor C. L. Liu
Professor Y. S. Liao
Professor Y. Y. Tsai
Professor L. F. Xi
Dr J. Atkinson
Dr P. Mativenga
Dr S. Mekid
Dr M. A. Sheikh
Dr R. Heinemann
Organising Secretaries
Mrs C. Collins
Ms J. Chen
The University of Manchester,
National Taiwan University
and
Shanghai Jiao Tong University
Foreword by the Conference Chairmen
It gives us pleasure to introduce the Proceedings for the 35th internal MATADOR conference. The Proceedings include 88
refereed papers from several countries on different continents, thus making this Conference truly international.
Since its inception in 1959, the MATADOR conferences have been held at various locations within the United Kingdom
and this is the first time that it is being held in Taiwan. This reflects the increasingly important role played by the East
Asian countries in manufacturing.
When the MATADOR Conference was established, it dealt with metal working fundamentals in cutting, grinding and
forming and the design of metal working machines for this purpose. Since those early days, new areas of research in
manufacturing have emerged which therefore have become part of the conference’s scope as well. Some of the emerging
areas that have been addressed in this conference include:
• Micro- and nano-manufacture;
• Laser materials processing;
• Advanced coatings technology;
• Globalisation of manufacture and its implications;
• Fuel Cell technology;
• Rapid Manufacture, and
• Inspection technology for micro parts.
We would like to express our gratitude to all the members of the organising committee and the companies and
organisations that have made this conference possible. Our special thanks go to Ms Christine Collins and Dr Robert
Heinemann for their extra effort in organising this conference and in the preparation of these proceedings.
We hope you find the papers interesting and stimulating.
Professors Srichand Hinduja and Kung-Chao Fan
Manchester, UK and Taipei, Taiwan
2007
Contents
1 Bio- and Nano-technologies
1–1 Preheated Carbon Source for Carbon Nanotube Synthesis
C.Y. Liu, N.K. Chang, Y.T. Chang, J.H. Hsu and S.H. Chang..................................................................................................3
1–2 Nano Manufacturing of a Small-tipped Stylus for Measurement of Micro-Machine Elements with Concave Surfaces
S. Kurokawa and S. Imamura..................................................................................................................................................7
1–3 Surface Plasmon Resonance Instrument to Detect Biomolecular Interactions
C.L. Chiang, H.C. Shih, T.K. Chou and C.T. Yang................................................................................................................11
2 Coating Technology
2–1 Plasma-Ion Enhanced Optical Multilayer Thin-film Coating for Consumer Electronics Products
G.L. Chen, C.C. Chang, S.C. Chien, T.S. Tung, H.H. Lee, W.C. Ling and H.L. Lee.............................................................17
2–2 The Structure and Properties of Electroless Ni-P and Ni-Mo-P Deposits
Y. H. Chou, C. Y. Bai, M. D. Ger, C. L. Chao, S. J. Lee, C. Y. Lee........................................................................................21
2–3 The Mechanism of Amorphous Silicon Thin Films Using XeF Excimer Laser Crystallization
C. C. Kuo, W.C. Yeh, C.P. Hsiao and J.Y. Jeng.....................................................................................................................25
2–4 Surface Properties of Polypropylene Treated Using Atmospheric Pressure Plasma Jet
C.H. Su, T.H. Chen, S.H. Yang, C.H. Liu, S. Lin, J.T. Teng and H. Chen.............................................................................29
3 Computer-Aided Engineering
3–1 Development of STEP-NC Compliant Machine Tool Data Model
W.Z. Yang, X. Xu and S.Q. Xie...............................................................................................................................................35
3–2 Geometric Modelling and NC Machining of Scroll Profiles Using Circular Biarcs Fitting
J.N. Lee and R.S. Lee.............................................................................................................................................................41
3–3 Establishing Parametric Design Management to Facilitate Activity-based Costing
C.L. Liu and R. Holland.........................................................................................................................................................45
3–4 An Enhanced Graph and Artificial Intelligence-based Approach for Assembly Sequence Planning
Y.Y. Hsu, W.C. Chen, P.H. Tai and M.D. Tsai.......................................................................................................................49
3–5 The Development of an Agent-based Distributed Surface Machining System
Y.C. Kao, M.S. Chen and J.S. Lia..........................................................................................................................................53
x Contents
4 Design of Optical Components
4–1 The Improvement of Plastic Aspheric Lens for the Application of Compact Camera Module
S.C. Yen, Y.C. Chien and K.M. Chang...................................................................................................................................59
4–2 Design of O-ring-driven Liquid-filled Lens
D. Shaw and C.W. Lin............................................................................................................................................................63
4–3 Surface Modification for Advanced Light Guide Plate for TFTLCD Display
G.-L. Chen, and T.-C. Yu.......................................................................................................................................................67
4–4 Optical Design for Three Mega Pixel Mobile Phone Camera
G.-L. Chen, C.-Y. Lee, A. Yuan and P. Chang.......................................................................................................................71
5 Electro-physical and chemical Processes
5–1 Micro-Electric Discharge Machining in Standard Setup
S. Chatterjee and S. Das........................................................................................................................................................77
5–2 Development of in situ Monitoring and Control of Micro-EDM Process
S.H. Yeo, W. Kurnia, P.C. Tan, M. Mushan...........................................................................................................................81
5–3 Improvement of Roundness of Cylindrical Parts Using Hybrid Electrochemical Smoothing and Roller Burnishing
Process
T.A. El-Taweel, and S.J. Ebeid..............................................................................................................................................85
5–4 Workpiece Surface Hardness as an Indicator of Process Regime in Peripheral Electrochemical Grinding
J. Atkinson..............................................................................................................................................................................89
5–5 Design of Compound Processes of Electrochemical Finishing and Rolling–Levelling following Turning
P.S. Pa...................................................................................................................................................................................95
6 Forming
6–1 Investigation of Micro Sheet Metal Forming of Ball Retainer Using Finite Element Analysis
R.S. Lee, C.H. Chen and Y.F. Sung......................................................................................................................................101
6–2 Design of Titanium Alloy Superplastic Blow-forming in Ellip-cylindrical Die Using Taguchi Method
D.-C. Chen, J.-Y. Lin, M.-W. Jheng and J.-M. Chen...........................................................................................................105
6–3 The Cold Orbital Forging Die and Process Design of a Hollow-ring Gear Part
J.J. Sheu and C.H. Yu..........................................................................................................................................................111
6–4 Semisolid Extrusion of Wrought Magnesium Alloy AZ61 and Its Mechanical Properties
S. Sugiyama, J.L. Kuo, S.H. Hsiang and J. Yanagimoto......................................................................................................115
6–5 Improving the Productivity and the Quality of a Manufacturing Robotized Cell for MIG/MAG Welding
A. Barcellona, M. Bruccoleri, C. D’Onofrio, D. Palmeri and R. Riccobono.......................................................................119
6–6 Surface Finish of the Injection Molding Tool Steel PX4 Using Ball-burnishing, Nickel-plating, and Ball-polishing
Processes
F.J. Shiou and C.M. Cheng..................................................................................................................................................123
7 Fuel Cell Technology
7–1 The Performance Analysis of a Portable Charger System Using Direct Methanol Fuel Cells
Y.D. Kuan, S.R. Lee, S.M. Lee, M.F. Sung and H.S. Chiou................................................................................................129
Contents xi
7–2 A Novel Integration Approach for Combining the Porous Silicon on a Micro Fuel Cell
C.Y. Lee, S.J. Lee, C.W. Chuang and R.D. Huang...............................................................................................................133
8 Laser Processing
8–1 High-performance Laser Technological Processing Systems for Scientific and Industrial Applications
Y.V. Chugui, V.P. Kiryanov and A.G. Verkhogliad..............................................................................................................139
8–2 Evaluation of Minimum Distance for Split Rectangular Beam for Glass Cutting
S. Nisar, S. Safdar, M.A. Sheikh and L. Li...........................................................................................................................143
8–3 Nonlinear Penetrating Behavior in High Energy Beam Drilling
J.E. Ho and H.T. Young.......................................................................................................................................................147
8–4 Analysis of Enhanced Thermal Conductivity Approach for Predicting Melt Pool Geometry and Temperature
Distribution for Laser Melting Processes
S. Safdar, F. Qureshi, L. Li and M.A. Sheikh.......................................................................................................................151
9 Manufacturing
9–1 Towards Collaborative Manufacturing in Small and Medium Manufacturing Enterprises
H.W. Lin, S. Nagalingam and G. Lin...................................................................................................................................157
9–2 Application of Virtual CIM in Small and Medium Manufacturing Enterprises
N. Zhou, S. Nagaligam and G. Lin.......................................................................................................................................161
9–3 Effectiveness Measurement of Facilities Layout
D. Raman, S.V. Nagalingam, B.W. Gurd and G.C.I. Lin.....................................................................................................165
9–4 High-level Business Processes for Agile B2B Collaboration
K. Mous, K.L. Ko, S.G. Lee, P.S. Tan and E.W. Lee............................................................................................................169
9–5 Configuring an Optimal Supply Chain of New Products Using Analytical Target Cascading
T. Qu, G.Q. Huang, S. Bin and H.P. Chen...........................................................................................................................173
9–6 An Agent-based Inference System for FMS Dispatching
C.L. Kuo, C.C. Ku and J.P. Tsai..........................................................................................................................................177
9–7 Investigation of Machines Sequencing Flexibility in Traditional and Flexible Manufacturing Systems (FMS) Using
Genetic Algorithms (GA).
S.Noor, M.K. Khan, I.Hussain.............................................................................................................................................181
10 Metal Cutting
10–1 Effect of Tool Coatings on the Performance of Small-diameter Drills in Drilling Deep Holes with Higher Cutting
Speed
R. Heinemann and S. Hinduja..............................................................................................................................................187
10–2 Comparison of Cutting Strategies for High Productive End Milling
M.S. Uddin, A. Matsubara, S. Ibaraki and T.Yasuda...........................................................................................................191
10–3 Experimental Investigation of Brittle Material Milling Using Rotary Ultrasonic Machining
K. L. Kuo..............................................................................................................................................................................195
10–4 Effect of Edge Bevelling on Burr Formation in Face Milling
P.P. Saha, D. Das, and S. Das.............................................................................................................................................199
xii Contents
10–5 The Effect of AlCrTiN Coatings on Product Quality in Micro-milling of 45 HRC Hardened H13 Die Steel
A. Aramcharoen, P.T. Mativenga and S. Yang....................................................................................................................203
10–6 Theoretical Investigation for the Material Removal Rate of Metal Polishing Process
Y.R. Jeng, P.Y. Huang and H.J. Tsai...................................................................................................................................207
10–7 Dummy Heat Source Technique for Estimating the Machining Error Caused by Thermal Behavior in Fine Boring
Y.L. Tang, H. Sasahara, K. Nishimura and T. Watanabe....................................................................................................211
10–8 An Investigation of the Tool–Chip Interface Temperature and Heat Partition in High-speed Machining of AISI/SAE
4140 Steel with TiN-coated Tool
F. Akbar, P.T. Mativenga and M.A. Sheikh.........................................................................................................................215
11 Metrology
11–1 The Study of Using X-Ray Laminography on Printed-Circuit Board Inspection
H.C. Chen and S.C. Lin........................................................................................................................................................221
11–2 Realization of Defect Automatic Inspection System for Flexible Printed Circuit (FPC)
C.-H. Chen, C.-C. Wang, C.-Y. Lin, Y.-S. Shih and C.-F. Tu...............................................................................................225
11–3 Investigation of Auto-focus Technology for Panel Inspection in the Flat-panel Display Industry
C.Y. Chung, C.M. Tseng, Y.C. Lu and K.M. Yeh..................................................................................................................229
11–4 Automatic Optical Inspection on Mura Defect of TFT-LCD
S.L. Chen and J.W. Jhou......................................................................................................................................................233
11–5 Development of Simultaneous Confocal Full-field Surface Profilometry for Automatic Optical Inspection (AOI)
L.C. Chen and Y.W. Chang..................................................................................................................................................237
11–6 Aspheric Lens Decenter Measurement
J. Chang, B.-H. Hu, W. Tsai, L. Li and P. Chang................................................................................................................241
11–7 A High-speed Inspection System of Large Area Component
C.Y. Hung, C.L. Chang, S.C. Lu, J.J. Jeng, and W.Y. Chen.................................................................................................245
11–8 An Air-bearing Displacement Sensor with a Micro-ball Stylus for Profile Measurement of 3D Micro-structured
Surfaces
Y. Yoshikawa, A. Shibuya and W. Gao.................................................................................................................................249
11–9 In-plane Displacement Measurement with Subnanometer Resolution for Precision Manufacture Platform
C.C. Wu, C.C. Hsu, J.Y. Lee, H.Y. Chen and H.F. Weng.....................................................................................................253
11–10 Width Measurement of Metal Surface Cracks Based on Image Analysis Technique
Li M., Wang Z.-y., Shuai M..................................................................................................................................................257
11–11 A Multifunctional Scanning White-Light Interferometer (SWLI): Construction of 2-D and 3-D Measurements
J.-L. Chen, K. Kuo, C.-H. Tung and C.C. Chang.................................................................................................................261
11–12 The Error Analysis of Cross-section Curve with Contact Mode Atomic Force Microscopy Simulation Measurement
by Using Trapezoidal Cantilever Based on Molecular Mechanics
Z.C. Lin, J.C. Huang and C.H. Yeh......................................................................................................................................265
11–13 Molecular Dynamics Simulation of AFM/FFM Surface Observation: Influence of Probe Tip Shape
J. Shimizu, L. Zhou and H. Eda...........................................................................................................................................271
11–14 Measurement of Mechanical Properties of Boron Nanowire Using Nano-manipulation System
C.H. Lin, M. Chang, X. Li and J.R. Deka............................................................................................................................275
Contents xiii
12 Precision Machine Design
12–1 Modelling and Simulation Considerations of a Micro-chuck Mechanism
Y.M. Chen, T.Y. Wu, S.H. Tu and C.P. Chiang....................................................................................................................281
12–2 Prediction of Machining Accuracy of 5-Axis Machine Tools with Kinematic Errors
M. Sharif Uddin, S. Ibaraki, A. Matsubara, and T. Matsushita...........................................................................................285
12–3 Active Aerostatic Bearings for Ultraprecision Applications
H. Mizumoto, S. Arii, Y. Yabuta, Y. Kami and Y. Tazoe.......................................................................................................289
12–4 Jacobian Inversion Analysis and Extraction of Dexterous Workspace in PKMs
A. Khalid and S. Mekid........................................................................................................................................................293
12–5 The Structure Design of a Micro-precision CMM with Abbé Principle
K.C. Fan, C.L. Liu, P. T. Wu, Y.C. Chen and W.L. Wang....................................................................................................297
12–6 Evaluation of Size Effect on Micro-machine-tools Design for Microfactory
M. Yamanaka, S. Hirotomi and K. Inoue.............................................................................................................................301
13 Process and Machine Tool Control
13–1 Closed-loop Sensor System for Automated Manufacturing Machines
A.A. Shaik, G. Bright and W.L. Xu.......................................................................................................................................307
13–2 Friction Compensator for Feed Drive Systems Consisting of Ball Screw and Linear Ball Guide
R. Sato and M. Tsutsumi......................................................................................................................................................311
13–3 Radial Basis Function Sliding-mode Control for the Laser Alloying Process
H.-Y. Chen and S.-J. Huang.................................................................................................................................................315
13–4 Real-Time Tracking and Stereo Vision-Based Control of a Goldfish-Catching System
C.C. Ho and C.L. Shih.........................................................................................................................................................319
13–5 Nano-positioning Drive with Piezoelectric Actuator Integrated into Support Bearing Unit of Ball Screw
A. Matsubara, T. Fujita, D. Kono, N.Tanaka and Y.Watanabe...........................................................................................323
13–6 Real-time Monitoring of a Pulsed Power for Reactive Magnetron Sputtering Using a LabVIEW System
F.L. Wen, C.H. Wen, I. Hsu, H.S. Wu and H.J. Wen............................................................................................................327
13–7 Windows CE-based Intelligent Remote Monitoring System
S.-L. Chen and T.-H. Lin......................................................................................................................................................331
14 Rapid Prototyping
14–1 Digital Additive Manufacturing: From Rapid Prototyping to Rapid Manufacturing
K.K.B. Hon...........................................................................................................................................................................337
14–2 Effects of Mold Pattern with Anti-adhesive Treatment in Nanoimprint Lithography
T.L. Chang, F.Y. Chang, H.Y. Lin, W.L. Lai, J.H. Tsai, and S.H. Chang............................................................................341
14–3 Component Repair Using Laser Direct Metal Deposition
W. Wang, A.J. Pinkerton, L.M. Wee and L. Li.....................................................................................................................345
14–4 Selective Laser Sintering of High-density Alumina Ceramic Parts
Z.H. Liu, J.J. Nolte, J.I. Packard, G. Hilmas, F. Dogan and M.C. Leu................................................................................351