Development of Micro-Factory Based on Leading Design

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We propose a new concept of machining ＆ handling system using robot arm, which can reduce microfactory size and increase its versatility. Feasibility study is carried out through micro machining/assembling examinations and prototyping of micro gripper.Micro machining examination is carried out using high-speed air spindle of 132,000[rpm] and WC end mill of outer diameter 0.3, to get cutting force of aluminum, brass and stainless steel. It turns out that the dynamic load of 1,300[mN] for each cutting edge and the static load of 350[mN] as time averaged value arise at minimized feeding rate. Micro assembling examination is carried out to get friction load by 0.5〜5.0 diameter hole ＆ shaft insertion test. It turns out that the required axial force is about 1,000[mN]. So, the required static stiffness of micro robot arm is 350[mN/μm], and the required gripping rigidity of micro gripper is 1300[mN].The optimum design of micro gripper configuration based on characteristic data of "Two Shape Memory Alloy" (TSMA) is carried out. Micro gripper prototyping and performance evaluation results in the gripper/work size ratio of 5.6, and the gripper bear out bending moment load of 4[mm]×1,300[mN] on the gripping work. Moreover, the real micro parts machining is demonstrated using combined system of micro gripper and flexible cantilever, which simulates the dynamics of micro robot arm.