Freeform Fabrication of Ionomeric Polymer-Metal Composite Actuators

Ionomeric polymer-metal composite (IPMC) actuators are a type of soft electromechanically active material which offers large displacement, rapid motion with only ~1V stimulus. IPMC’s are entering commercial applications in toys (Ashley 2003) and biomedical devices (Soltanpour 2001; Shahinpoor 2002; Shahinpoor, Shahinpoor et al. 2003; Soltanpour and Shahinpoor 2003; Soltanpour and Shahinpoor 2004), but unfortunately they can only actuate by bending, limiting their utility. Freeform fabrication offers a possible means of producing IPMC with novel geometry and/or tightly integrated with mechanisms which can yield linear or more complex motion. We have developed materials and processes which allow us to freeform fabricate complete IPMC actuators and their fabrication substrate which will allow integration within other freeform fabricated devices. We have produced simple IPMC’s using our multiple material freeform fabrication system, and have demonstrated operation in air for more than 40 minutes and 256 bidirectional actuation cycles. The output stress scaled to input power is two orders of magnitude inferior to that of the best reported performance for devices produced in the traditional manner, but only slightly inferior to devices produced in a more similar manner. Possible explanations and paths to improvement are presented. Freeform fabrication of complete electroactive polymer actuators in unusual geometries, with tailored actuation behavior, and integrated with other freeform fabricated active components, will enable advances in biomedical device engineering, biologically inspired robotics, and other fields. This work constitutes the first demonstration of complete, functional, IPMC actuators produced entirely by freeform fabrication.Mechanical Engineerin

Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

Implementation of a Functionally Gradient Material Modeling and Design System

New advancements in Solid Freeform Fabrication (SFF) processes promise the capability to produce Functionally Gradient Material (FGM) parts, in which the material compositions vary spatially. To realize this potential there is a need for CAD methods and design software to model, design, represent and exchange material information and instructions to the manufacturing process. However, currently available commercial CAD systems are limited to representing and storing only geometric information, which is not adequate for material design purposes. This work presents an extension of a theoretical approach based on Volumetric MultiTexturing (VMT) and hypertexturing schemes to make the material design process intuitive and user controllable. Inverse distance weighted interpolation is used in conjunction with procedural material functions to accomplish axial or linear material gradient directions from surface to surface across a solid. This offers the capability of specifying fixed material composition values to the faces in the solid and blending them across the interior of the solid. The extension of the proposed approach to the modeling of discrete material domains is also discussed. These material regions can be combined using special sets of operators depending on the form of the material functions. Finally, a design environment has been developed, which allows users to systematically apply material information to geometry and captures design intent.Mechanical Engineerin

Cyber Physical Manufacturing Metrology

The Cyber Physical Manufacturing Metrology (CP2M) is based on integration of the Cyber Physical Manufacturing (CPM) and connection between Internet of Things (IoT) and Cloud technology (CT). These are high-level methodologies for development of new generation manufacturing metrology systems, which are more intelligent, flexible and self-adaptable. CP2M generates Big Data, horizontally by integration (network of machines/CMMs, processes and sensors) and vertically by control (usually defined over five levels) which should be analytically processed and managed by the CP2M. In this paper was given, a detailed analysis of the current framework of development the CP2M. A brief overview of the concept CP2M research, particularly in Serbia is given as well

Cyber Physical Manufacturing Metrology

The Cyber Physical Manufacturing Metrology (CP2M) is based on integration of the Cyber Physical Manufacturing (CPM) and connection between Internet of Things (IoT) and Cloud technology (CT). These are high-level methodologies for development of new generation manufacturing metrology systems, which are more intelligent, flexible and self-adaptable. CP2M generates Big Data, horizontally by integration (network of machines/CMMs, processes and sensors) and vertically by control (usually defined over five levels) which should be analytically processed and managed by the CP2M. In this paper was given, a detailed analysis of the current framework of development the CP2M. A brief overview of the concept CP2M research, particularly in Serbia is given as well

Exploring Model-Based Engineering Concepts for Additive Manufacturing

Robust geometry and tolerance representations are needed in additive manufacturing for precise part specification and interoperability with downstream activities such as manufacturing, inspection, and long-term archiving. A disconnection exists between process-independent part geometry and tolerances, and process-dependent information requirements for additive manufacturing. Existing and emerging standards for part geometry (ASTM AMF, 3MF, ISO 10303 STEP) and tolerances (ASME Y14) contain information related to the additive manufacturing process. Details of the standards will be discussed, how their use and improvement can benefit the additive manufacturing process, and their integration into the model-based engineering paradigm.Mechanical Engineerin

Freeform construction application research

The level of automation technology and processes control, within the construction sector, faces unique challenges if it is to catch up with automotive and aerospace applications. The construction industry has problems relating to health and safety, environmental legislation and traditional methods of procurement. These are compounded by diminishing skills in the labour force. One way to address these issues is by increased automation and integration of design, modelling and process control. Digital Fabrication has demonstrated the feasibility of the integration of design and component production on a large scale. Freeform Construction builds on Digital Fabrication by integrating the control of final material deposition. This paper reports on recent meetings held with industrialists to gauge their perceptions of the technology and encourage discourse to identify both applications and opportunities for the wider research community. Examples of digital fabrication in construction are discussed. Freeform Construction is defined and potential applications are presented. An example of physical model generation from construction CAD software is described

Mini-Workshop: Analytical and Numerical Methods in Image and Surface Processing

The workshop successfully brought together researchers from mathematical analysis, numerical mathematics, computer graphics and image processing. The focus was on variational methods in image and surface processing such as active contour models, Mumford-Shah type functionals, image and surface denoising based on geometric evolution problems in image and surface fairing, physical modeling of surfaces, the restoration of images and surfaces using higher order variational formulations

Integration of sketch-based ideation and 3D modeling with CAD systems

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.This thesis is concerned with the study of how sketch-based systems can be improved to enhance idea generation process in conceptual design stage. It is also concerned with achieving a kind of integration between sketch-based systems and CAD systems to complete the digitization of the design process as sketching phase is still not integrated with other phases due to the different nature of it and the incomplete digitization of sketching phase itself. Previous studies identified three main related issues: sketching process, sketch-based modeling, and the integration between the digitized design phases. Here, the thesis is motivated from the desire to improve sketch-based modeling to support idea generation process but unlike previous studies that only focused on the technical or drawing part of sketching, this thesis attempts to concentrate more on the mental part of the sketching process which play a key role in developing ideas in design. Another motivation of this thesis is to produce a kind of integration between sketch-based systems and CAD systems to enable 3D models produced by sketching to be edited in detailed design stage. As such, there are two main contributions have been addressed in this thesis. The first contribution is the presenting of a new approach in designing sketch-based systems that enable more support for idea generation by separating thinking and developing ideas from the 3D modeling process. This kind of separation allows designers to think freely and concentrate more on their ideas rather than 3D modeling. the second contribution is achieving a kind of integration between gesture-based systems and CAD systems by using an IGES file in exchanging data between systems and a new method to organize data within the file in an order that make it more understood by feature recognition embedded in commercial CAD systems.This study is funded by the Ministry of Higher Education of Egypt