A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines

Advances in Micro and Nano Manufacturing: Process Modeling and Applications

Micro- and nanomanufacturing technologies have been researched and developed in the industrial environment with the goal of supporting product miniaturization and the integration of new functionalities. The technological development of new materials and processing methods needs to be supported by predictive models which can simulate the interactions between materials, process states, and product properties. In comparison with the conventional manufacturing scale, micro- and nanoscale technologies require the study of different mechanical, thermal, and fluid dynamics, phenomena which need to be assessed and modeled.This Special Issue is dedicated to advances in the modeling of micro- and nanomanufacturing processes. The development of new models, validation of state-of-the-art modeling strategies, and approaches to material model calibration are presented. The goal is to provide state-of-the-art examples of the use of modeling and simulation in micro- and nanomanufacturing processes, promoting the diffusion and development of these technologies

Integration of Bulk Piezoelectric Materials into Microsystems.

Bulk piezoelectric ceramics, compared to deposited piezoelectric thin-films, provide greater electromechanical coupling and charge capacity, which are highly desirable in many MEMS applications. In this thesis, a technology platform is developed for wafer-level integration of bulk piezoelectric substrates on silicon, with a final film thickness of 5-100μm. The characterized processes include reliable low-temperature (200˚C) AuIn diffusion bonding and parylene bonding of bulk-PZT on silicon, wafer-level lapping of bulk-PZT with high-uniformity (±0.5μm), and low-damage micro-machining of PZT films via dicing-saw patterning, laser ablation, and wet-etching. Preservation of ferroelectric and piezoelectric properties is confirmed with hysteresis and piezo-response measurements. The introduced technology offers higher material quality and unique advantages in fabrication flexibility over existing piezoelectric film deposition methods. In order to confirm the preserved bulk properties in the final film, diaphragm and cantilever beam actuators operating in the transverse-mode are designed, fabricated and tested. The diaphragm structure and electrode shapes/sizes are optimized for maximum deflection through finite-element simulations. During tests of fabricated devices, greater than 12μmPP displacement is obtained by actuation of a 1mm2 diaphragm at 111kHz with <7mW power consumption. The close match between test data and simulation results suggests that the piezoelectric properties of bulk-PZT5A are mostly preserved without any necessity of repolarization. Three generations of resonant vibration energy harvesters are designed, simulated and fabricated to demonstrate the competitive performance of the new fabrication process over traditional piezoelectric deposition systems. An unpackaged PZT/Si unimorph harvester with 27mm3 active device volume produces up to 205μW at 1.5g/154Hz. The prototypes have achieved the highest figure-of-merits (normalized-power-density × bandwidth) amongst previously reported inertial energy harvesters. The fabricated energy harvester is utilized to create an autonomous energy generation platform in 0.3cm3 by system-level integration of a 50-80% efficient power management IC, which incorporates a supply-independent bias circuitry, an active diode for low-dropout rectification, a bias-flip system for higher efficiency, and a trickle battery charger. The overall system does not require a pre-charged battery, and has power consumption of <1μW in active-mode (measured) and <5pA in sleep-mode (simulated). Under 1g vibration at 155Hz, a 70mF ultra-capacitor is charged from 0V to 1.85V in 50 minutes.Ph.D.Electrical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/91479/1/aktakka_3.pdfhttp://deepblue.lib.umich.edu/bitstream/2027.42/91479/2/aktakka_2.pdfhttp://deepblue.lib.umich.edu/bitstream/2027.42/91479/3/aktakka_1.pd

Design, Simulation, Manufacturing: The Innovation Exchange

The content of this book is based on the 3rd International Conference on Design, Simulation, Manufacturing: The Innovation Exchange (DSMIE-2020), held on June 9-12, 2020, in Kharkiv, Ukraine. This book reports on topics at the interface between manufacturing, materials, mechanical, and chemical engineering, with a special emphasis on design, simulation, and manufacturing issues. Specifically, it covers the development of computer-aided technologies for product design, the implementation of smart manufacturing systems and Industry 4.0 strategies, topics in technological assurance, numerical simulation, and experimental studies of cutting, milling, grinding, pressing, and profiling processes, as well as the development and implementation of advanced materials. It covers recent developments in the mechanics of solids and structures, numerical simulation of coupled problems, including wearing, compression, detonation, and collision, chemical process technology, including ultrasonic technology, capillary rising process, pneumatic classification, membrane electrolysis, and absorption process. Further, it reports on developments in the field of heat and mass transfer, energyefficient technologies, and industrial ecology. The book provides academics and professionals with extensive information on trends, technologies, challenges, and practice-oriented experience in the areas mentioned above

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., "LAMMPS Molecular Dynamics Simulator," or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help

Vibration assisted machining: Modelling, simulation, optimization, control and applications

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University, 30/11/2010.Increasing demand for precision components made of hard and brittle materials such as glasses, steel alloys and advanced ceramics, is such that conventional grinding and polishing techniques can no longer meet the requirements of today's precision manufacturing engineering. Particularly, in order to undertake micro-milling of optical glasses or other hard-machining materials, vibration assisted machining techniques have been adopted. However, it is essential and much needed to undertake such processes based on a scientific approach, i.e. the process to be quantitatively controlled and optimized rather than carried out with a trial-and-error manner. In this research, theoretical modelling and instrumental implementation issues for vibration assisted micro-milling are presented and explored in depth. The modelling is focused on establishing the scientific relationship between the process variables such as vibration frequency, vibration amplitude, feedrate and spindle speed while taking into account machine dynamics effect and the outcomes such as surface roughness generated, tool wear and material removal rate in the process. The machine dynamics has been investigated including a static analysis, machine tool-loop stiffness, modal analysis, frequency response function, etc, carried out for both the machine structure and the piezo-actuator device. The instrumentation implementation mainly includes the design of the desktop vibration assisted machining system and its control system. The machining system consists of a piezo-driven XY stage, air bearing spindle, jig, workpiece holder, PI slideway, manual slideway and solid metal table to improve the system stability. The control system is developed using LabVIEW 7.1 programming. The control algorithms are developed based on theoretical models developed by the author. The process optimisation of vibration assisted micro-milling has been studied by using design and analysis of experiment (DOE) approach. Regression analysis, analysis of variance (ANOVA), Taguchi method and Response Surface Methodology (RSM) have been chosen to perform this study. The effects of cutting parameters are evaluated and the optimal cutting conditions are determined. The interaction of cutting parameters is established to illustrate the intrinsic relationship between cutting parameters and surface roughness, tool wear and material removal rate. The predicted results are confirmed by validation experimental cutting trials. This research project has led to the following contribution to knowledge: (1) Development of a prototype desktop vibration assisted micro-milling machine. (2) Development of theoretical models that can predict the surface finish, tool wear and material removal rate quantitatively. (3) Establishing in depth knowledge on the use of vibration assisted machining principles. (4) Optimisation of cutting process parameters and conditions through simulations and machining trials for through investigation of vibration assisted machining.Financial support was obtained from Brunel University

Dinamica degli organi rotanti: analisi, identificazione e controllo

Gli organi rotanti di macchinari moderni sono soggetti a velocità sempre più elevate e limiti vibratori sempre più ristretti. Gli strumenti per ridurre tali vibrazioni sono l’analisi e l’identificazione dei sistemi per un opportuno dimensionamento delle parti rotanti, e l’utilizzo di appropriati smorzatori. Elementi importanti nella dinamica dei rotori ma di difficile caratterizzazione sono i supporti. Il metodo identificativo delle funzioni modulanti è stato applicato all’identificazione dei coefficienti dinamici di cuscinetti idrodinamici. Sono stati ottenuti risultati incoraggianti sia dalle analisi numeriche che sperimentali. Inoltre è presentato il progetto di uno smorzatore magnetoreologico a “squeeze-film”. Sono stati condotti sia una analisi numerica che una campagna sperimentale. Poichè il coefficiente smorzante del cuscinetto può essere variato con continuità è stato possibile impostare le condizioni di funzionamento ottimo per ogni condizione operativa. Un controllore automatico è stato progettato con l’uso di logica Fuzzy e algoritmi genetici. Infine sono state studiate le vibrazioni di dischi sottili rotanti in presenza di attrito secco, problema molto complesso e molto sentito in vari ambiti industriali. Sono quindi presentati e discussi i risultati di un’indagine sperimentale condotta sia su un macchinario commerciale di una cartiera che su una attrezzatura sperimentale. È stata mostrata l’influeza di alcuni parametri sull’insorgere delle vibrazioni