The "Next Generation TATARA Project," part of the Cabinet Office's Regional University and Industry Revitalization Grant Program (Selected for the Expansion Category during FY2023–FY2027), is being promoted at the Next Generation Tatara Co-Creation Center (NEXTA). This initiative aims to establish Shimane as a hub for advanced metallic materials through two industry-academia collaborative research projects.

One of the themes within the next-generation aircraft and energy project is the Advanced Machining Project, led by Assistant Professor Asuka Kutsukake. In collaboration with Visiting Professor Yoshinori Yoshida, a theory called the Process State Sphere was developed and used to create a machining state monitoring system in partnership with local companies.

Machining special steels is challenging and often relies on tacit knowledge and intuition from skilled workers. To digitally inherit these skills and improve quality and efficiency by detecting signs of defects early, the MACE system (Measurement system on ACE) was developed. ACE stands for Automatic Cutting Experiment System.

This project is a rare example of theory developed by researchers being validated through the skills of local companies. After much trial and error and heated discussions, a patent was filed. In late May, MACE was introduced to actual machining equipment at Hata Seiko Co., Ltd. (Yasugi City) and MAKATA Co., Ltd. (Matsue City), members of the SUSANOO group aiming for the aircraft industry.

Future Plans
Continuous data collection will be conducted, and improvements will be made based on company needs. The goal is to build a system that uses machine learning to explore optimal cutting conditions.
                  
Installation in progress　　　　　　　　　　　　　　　　　　　MACE（Holder)

 

Company Comments
Hada Seiko Co., Ltd. – President Tomohiro Hada
We process difficult-to-cut materials like super heat-resistant alloys daily. These materials are expensive, so we pay close attention to tool wear and chipping. With the growing demand for aircraft energy, machining such materials will increase. However, it's difficult to train skilled workers over long periods due to hiring challenges. Tools like this monitoring system will become increasingly necessary to support less experienced operators.

MAKATA Industry Inc. – President Kazuo Matsuo
This was our first industry-academia collaboration, and we were unsure how to engage with the university at the beginning. Our main work involves turning heat-resistant alloy raw materials, which causes frequent tool damage. Visualizing the cutting process was a major achievement. If the intuition of veteran machinists can be standardized through data, it could be useful for training.

Kiguchi Technics Inc. – Executive Director Hiroyuki Takehisa
Selecting sensors to detect cutting forces at the chip edge was challenging, but we succeeded in independently measuring the three components of cutting force using strain gauges. This allows real-time visualization and numerical understanding of cutting conditions, which were previously judged by experience. Looking ahead, we hope to enable threshold settings for wear detection and implement automatic stop functions to enhance safety and efficiency. Furthermore, we anticipate that this system will support optimal chip selection and cutting condition adjustments, particularly in the machining of difficult-to-cut materials.

NEXTA Researchers' Comments
Visiting Professor Yoshinori Yoshida
Developing anomaly detection technology for cutting chip tips took time and effort, but we finally completed a robust system based on scientific methods. It enables stable evaluation of highly variable cutting phenomena and real-time monitoring from a physical perspective. We aim to reach TRL9 (Technology Readiness Level) and eventually develop remote manufacturing and autonomous machining systems.

Assistant Professor Asuka Kutsukake
Cutting involves high-speed, large deformation processes, making stable data acquisition difficult. Signal levels differ between lab experiments and real-world implementation. By testing in actual environments, we developed a more practical system. We built custom measurement devices to differentiate from competitors, which took time to refine. We plan to improve measurement accuracy and data analysis methods and collaborate with participating companies to update the system and deepen understanding through simulations.

Contact Information for MACE Inquiries:
 Shimane University, Regional Revitalization Promotion Division, NEXTA Project Promotion Office