Frontiers in Ultra-Precision Machining

Ultra-precision machining is a multi-disciplinary research area that is an important branch of manufacturing technology. It targets achieving ultra-precision form or surface roughness accuracy, forming the backbone and support of today’s innovative technology industries in aerospace, semiconductors, optics, telecommunications, energy, etc. The increasing demand for components with ultra-precision accuracy has stimulated the development of ultra-precision machining technology in recent decades. Accordingly, this Special Issue includes reviews and regular research papers on the frontiers of ultra-precision machining and will serve as a platform for the communication of the latest development and innovations of ultra-precision machining technologies

VIABILITY OF A CONTROLLABLE CHAOTIC MICROMIXER THROUGH THE USE OF TITANIUM-NICKEL SHAPE MEMORY ALLOY

Microfluidic devices have found applications in a number of areas, such as medical analysis, chemical synthesis, biological study, and drug delivery. Because of the small channel dimensions used in these systems, most microchannels exhibit laminar flow due to their low Reynold’s number, making mixing of fluids very challenging. Mixing at this size scale is diffusion-limited, so inducing chaotic flow patterns can increase the interface surface area between two fluids, thereby decreasing overall mixing time. One method to create a chaotic flow within the channel is through the introduction of internal protrusions into the channel. In such an application protrusions that create a rotational flow within the channel are preferred due to their effectiveness in folding the two fluids over one another. The novel mixer outlined in this paper uses a Ti-Ni shape memory alloy for the creation of protrusions that can be turned controlled through material temperature. Controllability of the alloy allows users to turn the chaotic flow created by the protrusions off and on by varying the temperature of the mixer. This ability contributes to the idea of a continuous microfluidic system that can be turned on only when necessary as well as recycle unmixed fluids while turned off

Stabilization and Imaging of Cohesionless Soil Specimens

abstract: This dissertation describes development of a procedure for obtaining high quality, optical grade sand coupons from frozen sand specimens of Ottawa 20/30 sand for image processing and analysis to quantify soil structure along with a methodology for quantifying the microstructure from the images. A technique for thawing and stabilizing frozen core samples was developed using optical grade Buehler® Epo-Tek® epoxy resin, a modified triaxial cell, a vacuum/reservoir chamber, a desiccator, and a moisture gauge. The uniform epoxy resin impregnation required proper drying of the soil specimen, application of appropriate confining pressure and vacuum levels, and epoxy mixing, de-airing and curing. The resulting stabilized sand specimen was sectioned into 10 mm thick coupons that were planed, ground, and polished with progressively finer diamond abrasive grit levels using the modified Allied HTP Inc. polishing method so that the soil structure could be accurately quantified using images obtained with the use of an optical microscopy technique. Illumination via Bright Field Microscopy was used to capture the images for subsequent image processing and sand microstructure analysis. The quality of resulting images and the validity of the subsequent image morphology analysis hinged largely on employment of a polishing and grinding technique that resulted in a flat, scratch free, reflective coupon surface characterized by minimal microstructure relief and good contrast between the sand particles and the surrounding epoxy resin. Subsequent image processing involved conversion of the color images first to gray scale images and then to binary images with the use of contrast and image adjustments, removal of noise and image artifacts, image filtering, and image segmentation. Mathematical morphology algorithms were used on the resulting binary images to further enhance image quality. The binary images were then used to calculate soil structure parameters that included particle roundness and sphericity, particle orientation variability represented by rose diagrams, statistics on the local void ratio variability as a function of the sample size, and the local void ratio distribution histograms using Oda's method and Voronoi tessellation method, including the skewness, kurtosis, and entropy of a gamma cumulative probability distribution fit to the local void ratio distribution.Dissertation/ThesisM.S. Civil Engineering 201

An Accurate Kinematics Model of the Sanding-Belt-Wheel Driving System of a CNC Grinding Machine and its Application

CNC Sanding-belt grinding machines are widely used in the manufacturing industry. These machine tools are featured with multiple linear and rotary axes, complex driving system of the sanding belt wheel, and very high investment. The advantages of these machine tools include making complex parts with high accuracy and being productive without manual operation. A kernel technique of these machine tools is to align the sanding belt well match the part geometry so that the sanding belt can accurately grind complex parts. However, the driving system of the sanding belt wheel is complicated, and the kinetics model of the driving system has not been established. Currently, the motion of the sanding belt wheel is simplified as vertical ups and downs. The drawback of the current kinetics of the sanding belt wheel costs the sanding belt location and the part accuracy. The objective of this research is to establish the accurate kinetics model of the driving system and apply this model to calculate the sanding belt wheel location. In this thesis, first, the mechanism of the driving system is investigated. based on geometric principles of the pressure drive system, a mathematical model is built to predict the position of the sanding belt wheel under different grinding pressure. Then a novel kinematics chain considering the sanding belt wheel position is developed to generate various NC programs for different grinding pressure. This kinematics chain is novel, and no one has done relevant research before. The experimental results showed that the NC program after compensation enhanced the machining quality significantly

The Application of Zeeko Polishing Technology to Freeform Femoral Knee Replacement Component Manufacture

The purpose of this study was to develop an advanced 7-axis Computer Numerical Controlled (CNC) Polishing Machine from its successful original application of industrial optics manufacture into a process for the manufacture of femoral knee components to improve wear characteristics and prolong component lifetimes. It was indentified that the successful manufacture of optical components using a corrective polishing procedure to enhance their performance could be applied to femoral knee implant components. Current femoral knee implants mimic the natural shape of the joint and are freeform (no axis of symmetry) in nature hence an advanced CNC polishing machine that can follow the contours associated with such shapes could improve surface finish and conformity of replacement femoral knee bearing surfaces, leading to improved performance. The process involved generating machine parameters that would optimize the polishing procedure to minimize wear of materials used in femoral knee implant manufacture. Secondly a design of a Non-Uniform Refind B-Spline (NURBS) model for control of the Polishing Machine over the freeform contours of the femoral component. Completing the process involved development of a corrective polishing process that would improve form control of the components. Such developments would improve surface finish and conformity which are well documented contributors to wear and hence the lifeline of orthopaedic implants. By the means of comparison of this technique to that of a conventional finishing technique using pin-on-plate disc testing it was concluded that performance of the CNC polished components was an improvement on that of the conventional technique. In the case of form control their were slight indications through small decreases in peak to valley (PV) error that the process helped reduce form error and could increase the lifetime of femoral knee replacement components. The overall study provided results that indicate the the Zeeko process could be used in the application of polishing of hard-on-hard material combinations to improve form control without compromising surface finish hence improving lifetimes of the implant. The results have their limitations in the fact that the wear test performance was only carried out on orthopaedic implant materials using a pin-on-plate wear test rig. Due to the time limitations on the thesis it can be said that further analysis of correcting form without compromising surface finish on entire implant systems under full joint simulator testing which would provide mre realistic contitions would a more definitive answer be achieved