Investigation of feeding devices and development of design considerations for a new feeder for micro-sheet forming

Recent review in micro-forming research and technological development suggested that the trend of the development is more focused on the manufacturing processes, machines and tooling, and efforts on the methods and systems for integrated precision material handling are insufficient. Most of the developed micro-forming machines were based on standalone concepts which do not support efficient integration to make them fully automated and integrated. At present, material feeding in micro-forming is not of sufficient precision and reliability for high throughput manufacturing applications. Precise feeding is necessary to ensure that micro-parts can be produced with sufficient accuracy, especially in multi-stage forming, while high-speed feeding is a must to meet the production-rate requirements. Therefore, design of a new high-precision and high-speed feeder for micro-forming is proposed. Several possible approaches are examined with a view to establishing feasible concepts. Based on the investigation, several concepts for thin sheet-metal feeding for micro-forming are generated, they being argued and assessed with applicable loads and forces analysis. These form a basis of designing a new feeder

Design and construction of a novel reconfigurable micro manufacturing cell

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Demands for producing small components are increasing. Such components are usually produced using large-size conventional machining tools. This results in the inadequate usage of resources, including energy, space and time. In the 1990s, the concept of a microfactory was introduced in order to achieve better usage of these resources by scaling down the size of the machine tool itself. Several industries can benefit from implementing such a concept, such as the medical, automotive and electronics industries. A novel architecture for a reconfigurable micro-manufacturing cell (RMC) is presented in this research, aiming at delivering certain manufacturing strategies such as point of use (POU) and cellular manufacturing (CM) as well as several capabilities, including modularity, reconfigurability, mobility and upgradability. Unlike conventional machine tools, the proposed design is capable of providing several machining processes within a small footprint (500 mm2), yet processing parts within a volume up to 100 mm3. In addition, it delivers a rapid structure and process reconfiguration while achieving a micromachining level of accuracy. The approach followed in developing the system is highly iterative with several feedback loops. It was deemed necessary to adopt such an approach to ensure that not only was the design relevant, but also that it progresses the state-of-the-art and takes into account the many considerations in machine design. Following this approach, several design iterations have been developed before reaching a final design that is capable of delivering the required manufacturing qualities and operational performance. A prototype has been built based on the specifications of the selected design iteration, followed by providing a detailed material and components selection process and assembly method before running a performance assessment analysis of the prototype. At this stage, a correlation between the Finite Element Analysis (FEA) model and prototype has been considered, aiming at studying the level of performance of the RMC when optimising the design in the future. Then, based on the data collected during each stage of the design process, an optimisation process was suggested to improve the overall performance of the system, using computer aided design and modelling (CAD/CAM) tools to generate, analyse and optimise the design

Technology for the Future: In-Space Technology Experiments Program, part 2

The purpose of the Office of Aeronautics and Space Technology (OAST) In-Space Technology Experiments Program In-STEP 1988 Workshop was to identify and prioritize technologies that are critical for future national space programs and require validation in the space environment, and review current NASA (In-Reach) and industry/ university (Out-Reach) experiments. A prioritized list of the critical technology needs was developed for the following eight disciplines: structures; environmental effects; power systems and thermal management; fluid management and propulsion systems; automation and robotics; sensors and information systems; in-space systems; and humans in space. This is part two of two parts and contains the critical technology presentations for the eight theme elements and a summary listing of critical space technology needs for each theme

NASA SBIR abstracts of 1991 phase 1 projects

The objectives of 301 projects placed under contract by the Small Business Innovation Research (SBIR) program of the National Aeronautics and Space Administration (NASA) are described. These projects were selected competitively from among proposals submitted to NASA in response to the 1991 SBIR Program Solicitation. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 301, in order of its appearance in the body of the report. Appendixes to provide additional information about the SBIR program and permit cross-reference of the 1991 Phase 1 projects by company name, location by state, principal investigator, NASA Field Center responsible for management of each project, and NASA contract number are included

Hybrid micro-machining processes : a review

Micro-machining has attracted great attention as micro-components/products such as micro-displays, micro-sensors, micro-batteries, etc. are becoming established in all major areas of our daily life and can already been found across the broad spectrum of application areas especially in sectors such as automotive, aerospace, photonics, renewable energy and medical instruments. These micro-components/products are usually made of multi-materials (may include hard-to-machine materials) and possess complex shaped micro-structures but demand sub-micron machining accuracy. A number of micro-machining processes is therefore, needed to deliver such components/products. The paper reviews recent development of hybrid micro-machining processes which involve integration of various micro-machining processes with the purpose of improving machinability, geometrical accuracy, tool life, surface integrity, machining rate and reducing the process forces. Hybrid micro-machining processes are classified in two major categories namely, assisted and combined hybrid micro-machining techniques. The machining capability, advantages and disadvantages of the state-of-the-art hybrid micro-machining processes are characterized and assessed. Some case studies on integration of hybrid micro-machining with other micro-machining and assisted techniques are also introduced. Possible future efforts and developments in the field of hybrid micro-machining processes are also discussed

Proceeding Of Mechanical Engineering Research Day 2016 (MERD’16)

This Open Access e-Proceeding contains a compilation of 105 selected papers from the Mechanical Engineering Research Day 2016 (MERD’16) event, which is held in Kampus Teknologi, Universiti Teknikal Malaysia Melaka (UTeM) - Melaka, Malaysia, on 31 March 2016. The theme chosen for this event is ‘IDEA. INSPIRE. INNOVATE’. It was gratifying to all of us when the response for MERD’16 is overwhelming as the technical committees received more than 200 submissions from various areas of mechanical engineering. After a peer-review process, the editors have accepted 105 papers for the e-proceeding that cover 7 main themes. This open access e-Proceeding can be viewed or downloaded at www3.utem.edu.my/care/proceedings. We hope that these proceeding will serve as a valuable reference for researchers. With the large number of submissions from the researchers in other faculties, the event has achieved its main objective which is to bring together educators, researchers and practitioners to share their findings and perhaps sustaining the research culture in the university. The topics of MERD’16 are based on a combination of fundamental researches, advanced research methodologies and application technologies. As the editor-in-chief, we would like to express our gratitude to the editorial board and fellow review members for their tireless effort in compiling and reviewing the selected papers for this proceeding. We would also like to extend our great appreciation to the members of the Publication Committee and Secretariat for their excellent cooperation in preparing the proceeding of MERD’16

NASA SBIR abstracts of 1990 phase 1 projects

The research objectives of the 280 projects placed under contract in the National Aeronautics and Space Administration (NASA) 1990 Small Business Innovation Research (SBIR) Phase 1 program are described. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses in response to NASA's 1990 SBIR Phase 1 Program Solicitation. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 280, in order of its appearance in the body of the report. The document also includes Appendixes to provide additional information about the SBIR program and permit cross-reference in the 1990 Phase 1 projects by company name, location by state, principal investigator, NASA field center responsible for management of each project, and NASA contract number

Wire and arc additive manufacturing: equipment development and parts characterization

Wire and arc additive manufacturing (WAAM) is finding applications in different industrial sectors where it shows to be competitive compared to laser based additive manufacturing technologies. Two major advantages are associated to WAAM: it is a low capital investment technology with reduced running and maintenance costs and allows to manufacture parts with insipient or no porosities. This study aimed at testing and validating a three-axis positioning system designed and manufactured at Mechanical Technology Group of Mechanical and Industrial Engineering Department at Nova University. The major characteristics of the developed system are the following: 4.5 m3 working space, a maximum travel speed of 59 mm/s for the X and Y axes and of 2 mm/s for the Z axis. A maximum positional deviation of 0.02 mm, a minimal travel speed deviation of 0.24 mm/s and a displacement of 0.2 mm of the welding torch due to vibrations during a unidirectional movement. The equipment was validated by manufacturing thin walls by deposition of a high strength low alloy (HSLA) steel wire with Gas Metal Arc Welding (GMAW), monitoring the thermal cycles by infrared thermography to evaluate them in different layers. Geometrical, microstructural and mechanical characterization of parts was performed. Manufactured parts exhibited good surface finishing measured by the surface waviness that was around 300 μm and no internal defects were observed. Parts were isotropic as far as microstructural features and mechanical performance are concerned. The microstructure was mainly constituted by acicular ferrite and perlite with hardness below 320 HV. Energy dispersive spectrometry was performed, and no element loss was identified. Ultimate tensile strength varied between 700 and 809 MPa, depending on the process parameters. Resistance to impact was assessed by Charpy V impact tests with reduced size specimens and the absorbed energy registered was of 15 and 18 J, in longitudinal (Y) and normal (Z) directions, respectively. A ductile fracture surface was observed which is also a relevant indicator of mechanical performance of parts produced by WAAM in a HSLA steel