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This paper presents an integrated roller embossing process named Continuous Injection Direct Rolling (CIDR) process. The CIDR process is similar to Continue Casting Direct Rolling (CCDR) process for metal material. The process consists of Plastic Injection Module, Injection Nozzle, Precision Rolling Module, and Automatic Coiling Module. In the proposed CIDR process, the plastic plate with microstructured pattern is produced by the integrated injection and rolling process, which is different from the current rolling or plastic injection process. Some key technologies including injection nozzle design, roller design, roller coupling, and ultra-precision machining of rollers, are presented. An on-machine measurement method is also proposed and presented to avoid the incontinence and errors caused by disassembling the roller workpiece for off-line measurement. The results of the pilot study are also discussed. The research work provides an enabling solution for precision manufacturing plastic plate and film with microstructured patterns.

IRN (injection-rolling nozzle) is the key component of the new Polymer CIDR (Continue Injection Direct Rolling) process, and it has higher requirements than the metal roll-casting nozzle. In order to achieve uniform exit velocity, a new type of structure of the flow channel which is called IRN flow channel structure is designed by combining with the two traditional flow channel characteristics, i.e. the fishtail and coat-hanger flow channel. Then numerical simulation was used to calculate the fluid field in IRN flow channel and analyze 3D flow phenomenon and characteristics. The simulation results show that it has a uniform exit velocity of the IRN flow channel with the value of about 0.06m/s.

Thermal microimprint is a promising technology for polymer microstructure, so it is used to form V-groove on the surface of optical devices. However, it is difficult to control the size accuracy of V-groove because of the elastic recovery of polymer. In order to solve the problem, the influencing factors on the polymer elastic recovery were firstly analyzed in this article. Then, it was proposed that the embossment height of mold should be modified according to the depth of V-groove and the modifier formulas should be constructed based on the theory of polymer viscoelasticity. In the end, the optimal technological parameters of thermal microimprint were obtained through the thermal imprint experiments, and the embossment height of the mold after modification was calculated according to the experimental data, and thus a new mold was produced as to verify the accuracy of the modifier formulas. The results showed that the approach of modification could not only ensure dimension accuracy of V-groove, by keeping the error within 1μm, but also shorten the imprint time, consequently the efficiency of thermal microimprint would be improved.

Rolling Imprint Lithography is an Enabling Technique for the Mass Production of Ultra-Precision Micro-Structured Surfaces which are Widely Used in High Value Added Optical Products such as Backlight Guides for Display Devices. the Accuracy of the Produced Micro-Structured Surfaces Relies Heavily on the Master Roller of which Quality is Difficult to be Controlled by Traditional Off-Line Measurement Process due to the Large Dimension and Heavy Weight of the Workpiece. this Paper Presents a CCD Based Non-Contact Measurement System to Perform the on-Machine Measurement of the Structure Pattern on Machined Rollers. Instead of Measuring each Single Structure on the Roller, the System is more Focused on the Characterization of the Conformance of the Structure Pattern with the Designer’s Requirement. Low Angle Monochromatic Light is Used to Extract the Structure Pattern on the Machined Roller Using a High Magnification Objective Lens with a High Resolution CCD Sensor. the Image Processing Techniques are then Employed to Characterize the Captured Image Based on the Designed Pattern Structure. the Developed System has been Mounted on a Single-Point Diamond Turning Machine to Measure the Machined Structured Roller, and the Results Indicate that the Developed Measurement System is Able to Perform the on-Machine Measurement and Characterization of the Structure Pattern of the Machined Roller with Sub-Micrometre Accuracy.

The abnormal periodic noise from the slider-crank massager was complained by many consumers when it was under unilateral massage. By anglicizing the worm non-working surface stained with marking compound, the reason of the abnormal periodic noise which stemming from repeated mating of non-normal mating surfaces of the worm gear mechanism is founded. In order to solve the problem the overrunning clutch is used as it’s beyond separation functions. When the force is loaded to passive wheel, the clutch is linked; while the load becomes kinetic energy, the power will be separated immediately. The characteristic determines that the overrunning clutch is one of the best choices to separate the load on the slider-crank massager. And the results of the experiment indicate that the method has a significant effect to reduce noise. It also has a practical significance to the common problems of the mechanism and to the related scientific problems.

It is necessary to study the dynamic characteristics of the structure of processing shaft cascade in high speed and high precision PCB drilling machine because of its great impact on the drilling precision. As a basic part, the dynamic characteristics of the structure of cascade depend on the dynamic characteristics of the Z-axis floor. Based on it, firstly, the free mode test is conducted on the Z-axis floor, the same as the modes that it is just set up on the guide rail, the cascade is added and the motor spindle has been added on the Z-axis floor. From the four situations, the modal pa-rameters are gained in the tests. Then the ODS test is carried out and the vibration is analyzed in the real situation. The vibration tests of the cascade comprehensively acquire dynamic characteristics from the Z-axis floor before being assembled to the Z-axis floor which is entirely cascaded on the Z axis. Acknowledge of the impact that the vibrations bring to the drilling precision of the drilling machine provides the direction of improving the structure.

With the development of high density, multi-functions, miniaturization and multi-layer on printed circuit board (PCB) design, great challenges have been presented to the miniaturization of drilling on PCB. In order to meet the hole precision, quality and improve the performance, efficiency of mechanical drilling, further research should be done on the cutting state. Kistler high-precision micro-force platform was used in this paper to test and analyze the cutting force, investigate the general laws of micro drilling, and optimize the parameters for HANS PCB drilling machine. Thereby, to improve the efficiency and precision of the drilling, range of processing, and increasing market competitiveness.

In order to carry out automatic transformation to the two-roll reversible hot-rolling mill of a aluminum plate production factory, firstly a series of mathematical models of aluminum plate hot-rolling parameters are established, then a new optimization algorithm which is suitable for aluminum plate rolling production combined with the various constraints in the rolling process is proposed, and rolling schedule optimization software system is developed. Finally, by measuring the process parameters in rolling production site and applying the optimized rolling schedule to the rolling production, many test data are obtained. The analysis of test results and evaluation of the practical production show that the mathematical models established have high accuracy compared with the old rolling schedule. The optimization schedule can not only ensure the production quality, but also has higher efficiency and less energy consumption.

In order to investigate the impact factor of hot rolled aluminum alloy, a experiment was finished in a factory, to determine the effects of hot-rolled aluminum alloy plate with the system deformation resistance coefficient of the various factors and to mark the influence about the temperature to the hot rolling deformation resistance; Then, established the mathematical models of 1100,3003,5052 series hot rolled aluminum alloy plate's deformation resistance; The data calculated by the theoretical mathematical models is in good agreement the measured data. So this mathematical have the importance actual significance to actual production.

The mechanical properties of the extruded profiles depend on the final microstructure distribution in the extrusion process. To investigate the effect of the stain-rate and temperature on the microstructure distribution of the aluminum profiles, the aluminum profile with different wall thickness was studied by metallographic experiment and numerical simulation. The result showed that the distribution of fine equiaxed grain developed by the complete process of primary recrystallization and coarse grain developed by secondary recrystallization was consist with the distribution of temperature and strain-rate. The variation gradient of the strain-rate was the key factor which determines the distribution of microstructure in thick wall section. Compared with thick section, the higher strain-rate is the key factor that leads to secondary recrystallization, but lower temperature prevents complete process of recrystallization. in thin wall section.

A new method, namely Metal Powder Extrusion & Stacking Modeling is proposed in this paper based on RP and Metal Injection Molding (MIM) principle. Stainless steel powder and thermoplastic paraffin wax-based binder are used in our experiment. Firstly, feedstock is generated by mixing power and binder in a rotor internal mixer. Then the granular feedstock is put into screw-extruder devices to extruded filament, and accumulating green part at atmospheric status. Finally, green part is thermal defatted and sintered in hydrogen atmosphere to product the sintered parts. The testing results are as follows. The density of our RP product is 73.75%. The average shrinkage rate is 7.51%, 18.00%, and 29.31%, for diameter, thickness and volume respectively. Brinell hardness is HB77.52, while bending strength is 457MPa and tensile strength is 163Mpa. The experimental results verify that our proposed method is promising.