Hot Embossing of Micro Grating and Its Replication Accuracy

The Hot Embossing (HE) process was applied in the fabrication of micro grating. High-density polyethene (HDPE) was used as a specimen material for producing microstructure components and parts. In this research, a series of experiments were conducted using an HDPE specimen and embossed the polymer under different parameters such as temperature, embossing time, and embossing force as factors. The experimental setup was based on a response surface method (RSM) that employed a face composite design. The constructed RSM quadratic models assisted in analysing the response parameters, namely accuracy and surface roughness, to determine the relevant linkages between the input variables and the replies. The results defined that hot embossing temperature and hot embossing force will enhance the accuracy and surface quality of the micro grating. Based on RSM, the results revealed that the optimal parameters were as follows: hot embossing temperature is 1650c, embossing force is 10kN/s, and embossing holding time is 150 seconds. Under this condition, the actual deviation of accuracy and surface roughness is 5,75% and -1.32% respectively compared to the actual size of the micro grating mould. Hence, it is highly agreed with the model prediction value. In conclusion, optimization of process parameters on the hot embossing system that was developed is promising to fabricate the HDPE micro grating substrate with optimum dimensional accuracy and surface quality

Investigation of optimum milling parameters in micro dimples machining

This research used a carbide ball nose end mill cutting tool to fabricate a micro dimple on the aluminium block. The problem is that the micro dimple should be fabricated with a better surface finish which is related to surface integrity and form accuracy of the dimple. The objective is to study the optimum CNC milling parameters for the micro dimple fabrication and analyse the surface integrity and form accuracy of the dimple. Based on three different parameters which is depth of cut, feed rate, and spindle speed, the better surface roughness and the diameter, depth of micro dimple are experimented using the carbide cutting tools to fabricate micro dimple and analyse the data using 3D confocal microscope. The better surface roughness, high form accuracy and surface integrity of micro dimple structure were achieved with the optimum CNC milling parameters. The high spindle speed, low depth of cut and low feed rate showed the best results for the surface roughness and form accuracy. The proposed parameters were high spindle speed of 3600 RPM, low depth of cut 0.25mm and low feed rate of 50mm/min

Investigation of optimum EDM die sinking parameters in micro dimple machining

Micro dimple is a standard surface structure that is commonly used in micro-moulds, micro/nano-fluid devices, micromechanical systems, and bionic functional surfaces. These microstructure surfaces can be used for optical communication systems, micro sensors, flat panel display, light emitting diode applications and others. Many researchers have performed investigations on the parameters that help in manufacturing the micro dimple. However, there is still limited research on the certain parameters that will affect the micro dimple using EDM die sinking machine. EDM die sinking process involved a tool and workpiece material which immersed in a dielectric fluid medium and use the electrical spark discharges from electric pulse generation to remove the workpiece material. The actual performance of the surface integrity and form accuracy in micro dimple by EDM die sinking machine remains unclear. Therefore, this research attempts to investigate the effect of the dimple measurement such as diameter, depth and surface roughness (Ra) to the parameters which is surface roughness (Rz), sparking gap and type of electrode. By utilising the parameters, the lab experiment was conducted, and their surface integrity, effects in micro dimple behaviour were investigated. It was discovered that the higher surface roughness (Rz), the higher current produced thus erodes the material and caused the measurement of the dimple (diameter, depth and surface roughness (Ra)) differed from the expected size. Also the findings that the surface integrity was ununiformed due to the tool worn out occurred during the electric spark process causing high material rate removal. Other than that, the material electrode which has the high thermal conductivity and melting point resulted the best form accuracy of micro dimple

Study on die shoulder patterning method (DSPM) to minimise springback of U-bending

U-bending is increasingly used in the sheet metal industry such as car door pillars. However, springback phenomenon always tends to occur after removing sheet metal from the fixtures and resulting in changing product effectiveness, wasting material as well as increasing manufacturing costs. Thus, minimizing springback in the bending of sheet metal is vital to maintain close geometric tolerances in the deformed part. Many researchers have done investigated and predicted the springback occurrence by experiments and simulations. Neverthessly, there is no actual study on the die shoulder patterning method (DSPM) to reduce springback of hat-shaped parts. In this paper, the hat-shaped part is deformed using the new developed forming method and have been experimented with as well as validated using three-way Anova and graphical analysis. As expected, DSPM dominates the springback sensitivity, with higher contact area reducing the springback of hat-shaped parts. For AISI 1030 of pattern 2, springback is dramatically reduced as the sliding stress between the die shoulder and surface of the blank is optimized

Experimental study on die shoulder patterning method (DSPM) to reduce springback of U-bending hat-shape part (in Press)

In the sheet metal industry, such as car door pillars, U-bending is becoming more common. However, when extracting sheet metal from fixtures, the springback phenomenon often occurs, resulting in a change in product efficacy, waste of material, and an increase in production costs. As a result, minimising springback in sheet metal bending is critical for maintaining tight geometric tolerances in the deformed component. Experiments and simulations have been used by several researchers to investigate and predict the occurrence of springback. Regardless, no studies on the application of die shoulder patterning to reduce springback in hat-shaped parts have been conducted. The hat-shaped component is deformed in this paper using a new develop forming process, which has been tested and validated using new finite element prediction. As predicted, die shoulder patterning dominates springback sensitivity, with hat-shaped parts having a lower springback due to a larger contact region. Springback is greatly reduced in AISI 1030 due to the optimised sliding tension between the die shoulder and the blank board

Familiarity and Overcoming of Uncanny Valley towards Computer-Generated Imagery Characters in Malaysian Film

Recently, the idea of the uncanny valley has drawn interest in robotics and other scientific circles and popular culture. Several scholars have discussed its implications and reactions towards human-like robots. However, only several previous studies examined overcoming the uncanny valley for realistic looking computer-generated actors in films and animation. This seeks to examine the familiarity of participants with the use of digital characters as actors. This paper explains how computer-generated imagery (CGI) was used to create actors in Malaysian films, the uncanny valley characteristics that may affect the audience’s attention. The researcher has chosen visual stimuli consisting of 1 genuine human character and 1 less humanlike subject. A self-administered survey (n = 127) with sample film footage and photos were delivered online via email and social networks to responders. Surprisingly, based on the data, the human resemblance of the humanlike characters was substantially higher than expected. This research concluded that the artificial CGI characters had higher perceived eeriness if the character was highly familiar to the audience. As a result, the digital actor’s replacement an impression of eeriness and disbelief, which confirms the uncanny valley theory

Team Learning in Motion Capture Operations and Independent Rigging Processes

This article discusses team learning activities among motion captures operators and how such occasions contribute to the producing successful on recording human movement. This paper specifically monitors between each team behaviors reacts, communicate members in performing successful optical motion capture tasks. Among task's component discussed in this article were team members ability to operate the equipment, calibrate, and most significantly, the social interaction between team in avoiding numerous of errors in motion capture operations. The tests were influenced of the reason of high requirement by animation industry in Malaysia, where most graduates are required highly skilled in multiple software platform. This study aim to obtain practice-based factors among team learning , which can be implement to the simulated start-ups environments, which can be applied and simulate beyond current education systems. Method-The motion capture test activities were advertised among undergraduate students, with unrestricted level of undergraduate and postgraduate students. Two tasks given, team-based task, and individual-based tasks. All participants were required to attend the tests which in 5 days duration. The required background of all participants skills in Motion Capture operations were not required, only with minimal multimedia knowledge background. Most of demographics were mixture gender participants with 11 animation students of (8 freshmen) and (3 sophomore) and divided into 3 teams. All task was based on test-time learning to all participants. Each team learning activities also observed with repeated Motion Capture operations and include individual tests. Results-The time-based team result showed all team successfully calibrated all process setup in Motion Capture accordingly, where the outcome indicated each team member communicate effectively in perform all operations tasks. In opposite of independent tasks, the findings indicated individual tasks took longer duration as compared team-based task. As a result, team of learners positively contributed to efficient productivity than individual learners. As conclusion, the study discovered the importance of practice-based learning in teams for staging production work and found new elements by acknowledging the differences and similarities in each team members work cultures and environments

Physical Rigging Procedures Based on Character Type and Design in 3D Animation

In 3D (Three-Dimensional) animation pipeline, the term rigging is commonly used to describe the process of creating skeleton system inside the finishing 3D character geometry and assigning animation controllers for animators to animate the 3D character. In order to establish a fluidity movement on the character, the proper setting must be planned and the flexibility of the controller must be setup properly. However, the discussion and understanding about rigging setup for specific 3D characters from previous researcher is very limited. Hence, the process of rigging will take longer time to complete especially for novice rigger artist. This study will explore the fundamental process of character rigging system and identify the method and techniques for rigging characters based on their anatomy designs. The analysis of this study will look on the conceptual design of the character; how to implement proper techniques and workflow based on the primary and secondary data provided in this study. The findings in this paper indicate common techniques for human rig object in 3D characters is using Biped, CAT or auto rigs. From our experiment, we found biped or CAT rigging is the best setting for the animals and realism characters. Custom rig is suitable for cartoony characters. Rigging system for anthropomorphism character is a bit different from the human rigs system. Anthropomorphism character requires several modifications on their physical appearances in which adding or subtracting the limb that physically taken from specific animal or any objects. For this type of character, we suggested to use biped rigging system. However, for complex anthropomorphism characters with many form structures, the study of movement, exaggeration and bone limitation must be analyzed before deciding the proper technique for rigging. Hence, the chain rig system is the best option for this type of anthropomorphism character. Therefore, rigging in animation is the process assembling the skeleton system into the character. The use of proper rigging style will determine how the character move and pose in final animation

Laser-assisted thermal imprinting of glass guided mode resonant (GMR) optical filter

Laser-assisted thermal imprinting of glass nanostructures is demonstrated. Compare to the existing thermal imprinting, this method significantly reduced the contact imprinting time. The quality of the replicated glass nanostructures revealed by field emission scanning electron microscope ( SEM) and atomic force microscope ( AFM) exhibited a very smooth surface finish that closely matched the profile of the silicon mold. As proof-of-concept, the utility of laser-assisted, imprinted glass nanostructures as guided-mode resonant (GMR ) optical filter was evaluated. The peak spectral values obtained were satisfactory; which yielded an average FWHM and PWV of 4.6 nm and 691.39 nm respectively

Rapid Direct Continuous Method for Hot Embossing of Glass Microlens Array Combined with CO2 Laser Irradiation and External Preheating/Cooling

Hot embossing of glass micro structures requires long thermal cycle, generally takes no less than 15 min due to the isothermal heating, pressing and cooling performed inside a closed vacuum chamber. In this paper, a new hot embossing procedure was presented. First, the glass was preheated slightly below its glass transition temperature at the heating station. Then, a thin layer of the glass surface was further raised to high temperature temporarily through CO2 laser irradiation. The glass was then quickly transferred to the embossing station for pattern transfer, demolding and followed by external cooling. This method accelerated the filling of glass material into the microlens array mold cavities and outperforms the conventional method in terms of overall cycle time reduction, lower mold working temperature and embossing pressure. Microlens array with diameter of 135 µm, sag height of 18.5 µm and pitch of 200 µm were faithfully embossed onto the K-PG375 optical glass time in a time scale of about ~3 s. Optical evaluation of the glass MLA was also performed using charge couple device (CCD) camera which showed uniform spot intensity