Design of ultraprecision machine tools with application to manufacturing of miniature and micro components

Currently the underlying necessities for predictability, producibility and productivity remain big issues in ultraprecision machining of miniature/microproducts. The demand on rapid and economic fabrication of miniature/microproducts with complex shapes has also made new challenges for ultraprecision machine tool design. In this paper the design for an ultraprecision machine tool is introduced by describing its key machine elements and machine tool design procedures. The focus is on the review and assessment of the state-of-the-art ultraprecision machining tools. It also illustrates the application promise of miniature/microproducts. The trends on machine tool development, tooling, workpiece material and machining processes are pointed out

Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 1: Holistic design approach, design considerations and specifications

High-accuracy three-dimensional miniature components and microstructures are increasingly in demand in the sector of electro-optics, automotive, biotechnology, aerospace and information-technology industries. A rational approach to mechanical micro machining is to develop ultra-precision machines with small footprints. In part 1 of this two-part paper, the-state-of-the-art of ultra-precision machines with micro-machining capability is critically reviewed. The design considerations and specifications of a five-axis ultra-precision micro-milling machine—UltraMill—are discussed. Three prioritised design issues: motion accuracy, dynamic stiffness and thermal stability, formulate the holistic design approach for UltraMill. This approach has been applied to the development of key machine components and their integration so as to achieve high accuracy and nanometer surface finish

An investigation into miniature hydraulic actuation techniques for needle control on industrial knitting and sewing machines

The thesis is presented in four main parts: (1) the design and development of a hydraulic circular weft knitting machine; (2) the construction and testing of a hydraulic lockstitch sewing machine; (3) a detailed design study and analysis of pulse-generating rotary valves; (4) the design of a multi-feeder hydraulic circular weft knitting machine. Part 1 deals with the knitting machine aspect of the project consisting of verifying that a multi-actuator rotary valve system would operate with the desired time displacement profile, and in the correct sequence. This was then used as the basis for developing a ninety-six-needle, single feeder hydraulic circular weft knitting machine. This prototype machine was tested to obtain an assessment as to the advantages offered by hydraulic knitting techniques. Part 2 involved replacing the needle and thread take-up mechanisms of a lockstitch sewing machine, by two miniature hydraulic actuators, controlled by a rotary valve. The purpose of this machine was to prove that stitches could be formed successfully, thus demonstrating any beneficial features offered by hydraulic sewing devices. Part 3 deals with the detailed design study for pulse-generating rotary valves resulting from the previous applications. This valve was a new concept in valve technology and having established its definite potential, warranted the formation of a design procedure. The study outlines a method of optimising the torque required to rotate the bobbin by the construction of a mathematical model. Part 4 was concerned with designing a multi-feeder hydraulic circular weft knitting machine. This machine, controlled by an integrated actuator rotary collar valve to generate pulses, demonstrated how a series of twelve knitting time-displacement profiles could be created by ninety-six actuators positioned in a circular configuration. Thus, the research programme has been aimed at demonstrating how high speed motions, normally obtained by mechanical devices (cams, linkages) can be produced by miniature hydraulic actuation techniques. The feasibility of using these techniques has been verified by the building and testing of probably the first ever hydraulic knitting and sewing machines

Conceptual Study of Rotary-Wing Microrobotics

This thesis presents a novel rotary-wing micro-electro-mechanical systems (MEMS) robot design. Two MEMS wing designs were designed, fabricated and tested including one that possesses features conducive to insect level aerodynamics. Two methods for fabricating an angled wing were also attempted with photoresist and CrystalBond™ to create an angle of attack. One particular design consisted of the wing designs mounted on a gear which are driven by MEMS actuators. MEMS comb drive actuators were analyzed, simulated and tested as a feasible drive system. The comb drive resonators were also designed orthogonally which successfully rotated a gear without wings. With wings attached to the gear, orthogonal MEMS thermal actuators demonstrated wing rotation with limited success. Multi-disciplinary theoretical expressions were formulated to account for necessary mechanical force, allowable mass for lift, and electrical power requirements. The robot design did not achieve flight, but the small pieces presented in this research with minor modifications are promising for a potential complete robot design under 1 cm2 wingspan. The complete robot design would work best in a symmetrical quad-rotor configuration for simpler maneuverability and control. The military’s method to gather surveillance, reconnaissance and intelligence could be transformed given a MEMS rotary-wing robot’s diminutive size and multi-role capabilities

Design of a simulated cruise scene visual attachment. Volume 1 - Design report

Television-type, out-window visual simulation image generator design and specifications for aircraft or spacecraft manned flight simulatio

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 Development of Miniature Mechanisms for Small Spacecraft

With the continued push for smaller, faster, and cheaper spacecraft comes a new era in mechanism design. The desire to develop “Micro Satellites”, along with advances in the processing and selection of materials, have created an abundance of opportunities to miniaturize mechanisms. Simple designs with direct applications of developing technologies are ideal for these miniature mechanisms. This paper will focus on the design and development of a miniature satellite “tool kit”. Six mechanisms were developed by Starsys Research and the Applied Physics Laboratory (APL) at John Hopkins University (JHU) under a NASA Advanced Technology Development (ATD) Program. The mechanisms developed included a Micro and Mini Separation Nut, a Mini Rotary Actuator, a Micro Burn Wire Release, a SMA Linear Actuator, and a SMA Redundant Release Mechanism. The paper will discuss the concepts evaluated, designs chosen for fabrications, problems encountered during development, achieved performance characteristics, and recommendations for future development

Miniaturized modular manipulator design for high precision assembly and manipulation tasks

In this paper, design and control issues for the development of miniaturized manipulators which are aimed to be used in high precision assembly and manipulation tasks are presented. The developed manipulators are size adapted devices, miniaturized versions of conventional robots based on well-known kinematic structures. 3 degrees of freedom (DOF) delta robot and a 2 DOF pantograph mechanism enhanced with a rotational axis at the tip and a Z axis actuating the whole mechanism are given as examples of study. These parallel mechanisms are designed and developed to be used in modular assembly systems for the realization of high precision assembly and manipulation tasks. In that sense, modularity is addressed as an important design consideration. The design procedures are given in details in order to provide solutions for miniaturization and experimental results are given to show the achieved performances

Performance Comparisons and Down Selection of Small Motors for Two-Blade Heliogyro Solar Sail 6U CubeSat

This report compiles a review of 130 commercial small scale motors (piezoelectric and electric motors) and almost 20 researched-type small scale piezoelectricmotors for potential use in a 2 blades Heliogyro Solar Sail 6U CubeSat. In this application, a motor and gearhead (drive system) will deploy a roll of solar sailthin film (2 um thick)accommodated in a 2U CubeSat (100 x 200 x 100 mm) housing. The application requirements are: space rated, output torque at fulldeployment of 0.8 Nm, reel speed of 3 rpm, drive system weight limited to 150 grams, diameter limited to 50 mm, and the length not to exceed 40 mm. The 50mm diameter limit was imposed as motors with larger diameters would likely weigh too much and use more space on the satellite wall. This would limit theamount of the payload. The motors performance are compared between small scale, volume within 3x102 cm3 (3x105 mm3), commercial electric DC motors,commercial piezoelectric motors, and researched-type (non-commercial) piezoelectric motors extracted from scientific and product literature. The comparisonssuggest that piezoelectric motors without a gearhead exhibit larger output torque with respect to their volume and weight and require less input power toproduce high torque. A commercially available electric motor plus a gearhead was chosen through a proposed selection process to meet the applications designrequirements

A miniature short stroke linear actuator - Design and analysis

We report a newly developed miniature short stroke tubular linear permanent-magnet actuator for robotic applications. Compared to a rotary-to-linear mechanism, the linear actuator has the advantages of efficiency, thrust control, and compact size in generating linear motion. We optimized the electromagnetic force of the actuator analytically by selecting appropriate dimensions and then predicted the force produced by the winding currents by the finite-element method under the brushless dc excitation scheme. We analyzed the actuation performance by dynamic modeling of the actuator. We constructed and tested a prototype on a specially designed test bench to verify the design. Finally, we analyzed and measured the end effect on the magnetic force due to the limited length of the stator core and translator.Compared with the rotary-to-linear mechanism, linear actuators show advantages in terms of efficiency, thrust control, and system volume when linear motion is required. This paper presents the design and analysis of a newly developed miniature short stroke tubular linear permanent-magnet actuator for robotic applications. The electromagnetic force of the actuator was optimized analytically by selecting appropriate dimensions. The force produced by the winding currents was then predicted by the finite-element method under the brushless dc excitation scheme. The actuation performance was also analyzed through the dynamic modeling of the actuator. A prototype was constructed and tested on a specially designed test bench to verify the design. Moreover, the end effect on the magnetic force due to the limited length of the stator core and translator was analyzed and measured. © 2006 IEEE