A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines

Ultraprecision machines with small footprints or micro-machines are highly desirable for micro-manufacturing high-precision micro-mechanical components. However, the development of the machines is still at the nascent stage by working on an individual machine basis and hence lacks generic scientific approach and design guidelines. Using computer models to predict the dynamic performance of ultraprecision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machines. Furthermore, the machine dynamic performance depends not only upon the mechanical structure and components but also the control system and electronic drives. This paper proposed a holistic integrated dynamic design and modelling approach, which supports analysis and optimization of the overall machine dynamic performance at the early design stage. Based on the proposed approach the modelling and simulation process on a novel 5-axis bench-top ultraprecision micro-milling machine tool – UltraMill – is presented. The modelling and simulation cover the dynamics of the machine structure, moving components, control system and the machining process, and are used to predict the overall machine performance of two typical configurations. Preliminary machining trials have been carried out and provided the evidence of the approach being helpful to assure the machine performing right at the first setup

Magnetically directed self-assembled arrays of the gold nanoparticle stabilised Pickering ferrofluid emulsion for enhanced infrared absorption.

Gold strip gratings enhance the molecular vibration signals, due to grating resonances and local electric field hot spots. Such enhancement is also observed in colloidal gold island films; however, the random geometrical features of these films tend to provide nonlinear relation of enhancement with morphological features, leading to limit on tunability. Fabrication of well-defined metal patterns using a top-down approach such as nanolithography provides a tuneable antenna to enhance the absorption, although this technique is costlier and complex. To simplify the process, a magnetic and spin coating-directed self-assembly (MSCDS) was used to prepare optically-sensitive ordered arrays of the gold nanoparticle Pickering ferrofluid emulsion chains in polyvinyl alcohol (PVA) on glass substrate. Unlike gold strips, the chains in arrays were discontinuous, contained iron oxide nanoparticles (NP) and contributed to nonlinear enhancement. Despite these shortcomings, the chain-like ordered arrays have shown to increase local field to enhance the infrared absorption corresponding to asymmetric vibration of -CH2 (2920cm-1) bond present in PVA by 40% at 45 degrees grazing angle, as chain thickness (CT) increased by 178%. This scalable and simple method has potential to generate patterns for absorbing antennas

Performance improvement of the LM device and its application to precise measurement of motion trajectories within a small range with a machining centre

In order to apply the LM device previously developed to precisely measuring small motion trajectories located on the different motion planes, three major improvements are successfully performed under the condition of completely maintaining the advantages of the device. These improvements include 1) development of a novel connection mechanism to smoothly attach the device to the spindle of a machining centre; 2) employment of a new data sampling method to achieve a high sampling frequency independent of the operating system of the control computer; and 3) proposal of a set-up method to conveniently install the device on the test machining centre with respect to different motion planes. Practical measurement experiment results with the improved device on a machining centre sufficiently demonstrate the effectiveness of the improvements and confirm several features including a very good response to small displacement close to the resolution of the device, high precision, repeatability and reliance. Moreover, based on the measurement results for a number of trajectories for a wide range of motion conditions, the error characteristics of small size motions are systematically discussed and the effect of the movement size and feed rate on the motion accuracy is verified for the machining centre tested

Enhancement of infrared absorption through a patterned thin film of magnetic field and spin-coating directed self-assembly of gold nanoparticle stabilised ferrofluid emulsion.

Molecular vibration signals were amplified by the gold strip gratings as a result of grating resonances and nearby electric field hotspots. Colloidal gold island films exhibit similar enhancement; however, the uneven geometrical characteristics of these films restrict the tunability of the vibrational enhancement. Infrared absorption is enhanced by regular metallic patterns such as arrays of strips fabricated using a top-down approach such as nanolithography, although this technology is expensive and difficult. The significant infrared absorption may serve as tuneable antenna sensitization to improve the sensor performance. In this article, we present a simple one-step process for fabricating optically sensitive ordered arrays of a gold nanoparticle ferrofluid emulsion in polyvinyl alcohol (PVA), using a magnetic field-directed and spin-coating self-assembly (MDSCSA) process. Techniques such as UV-visible absorption, scanning electron microscopy, and grazing-angle infrared spectroscopy were used to evaluate various parameters associated with the nanostructures. Unlike the gold strips, the chain-like features in the iron oxide nanoparticle arrays were discontinuous. The fabricated chain-like ordered arrays have been shown to increase the local field to enhance the infrared absorption corresponding to the symmetric vibration of the –CH2 (2918 cm−1) group present in PVA by ~667% at a 45° grazing angle, as the chain thickness (CT) increased by 178%. This scalable and simple method can potentially generate low-cost patterns for antenna sensitisation

Experimental investigation on micromachining of epoxy/graphene nano platelet nanocomposites

This paper investigates the effect of graphene nano platelet (GNP) content (%weight fraction) on the machinability of epoxy/GNP nanocomposites. The machinability of nanocomposites with varying loadings of GNP content was evaluated experimentally through the characterisation of cutting forces, surface morphology, chip morphology and tool wear. The minimum chip thickness phenomena of epoxy/GNP occurred at feed per tooth (FPT) between 0.2 and 0.4 μm. In order to achieve to better surface quality, the FPT should be over 0.4 μm. Epoxy/GNP with 1.0 wt% nanocomposite has produced the highest cutting force of a feed rate of ~ 3 N at 12 μm/rev. Epoxy/GNP nanocomposites exhibit the different cracking tendencies compared with plain epoxy, and the tool wear for GNP/epoxy nanocomposites is very small compared with metal nanocomposites. There is no significant difference in slot width accuracy between different types of tools, such as uncoated tool, diamond-like carbon-coated and diamond-coated tools

Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: Integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations

Novel method of healing the fibre reinforced thermoplastic composite: a potential model for offshore applications.

Continuous fibre reinforced thermoplastic composites are increasingly finding their use as engineering materials in many industries due to the excellent fire, smoke and toxicity performance. However, the composite component produced using automated continuous fibre reinforced thermoplastic tapes laying machine are susceptible to sudden failure emanating from microscale cracks. This study demonstrates the healing potential of a layered Glass Fibre Reinforced Polymer (GFRP) composite consisting of alternative layers of GFRP and a magnetic polyamide-6 (PA-6) nanocomposite (PNC) film. The self-healing process is presented in three steps, viz. (i) polymer nanocomposite synthesis, (ii) preparation of the layered GFRP layered composite sample and (iii) self-healing and testing of GFRP layered composite sample. Firstly, the multilayer dog bone sample consisting of a magnetic polymer nanocomposite (PNC) film sandwiched between thermoplastic unidirectional GFRP tapes are prepared. Healing is triggered by exposing the damaged multilayer sample to microwave causing selective heating of nanocomposite film and its subsequent melting. The healing process completes when liquid polymer fills the micro-crack in the multilayer tape through capillary action and solidifies upon cooling. The healing yields 84% of the undamaged tensile strength recovery. Results demonstrate the potential application of an autonomous self-healing method for thermoplastic composite used in the offshore environment

Evaluation of a Novel Controlled Cutting Fluid Impinging Supply System When Machining Titanium Alloys

Following a comprehensive review on titanium machining and methods of cutting fluid application, this paper presents a new Controlled cutting fluid impinging supply system (Cut‐list) developed to deliver an accurate amount of cutting fluid into the machining zone via wellpositioned coherent nozzles based on the calculation of the heat generated. The performance of the new system was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti‐6Al‐4V using vegetable oil‐based cutting fluid. The comparison was performed at different cutting speeds and feed rates. Comparison measures/indicators were cutting force, workpiece temperature, tool flank wear, burr formation and average surface roughness (Ra). The new system provided significant reductions in cutting fluid consumption of up to 42%. Additionally, reductions in cutting force, tool flank wear and burr height of 16.41%, 46.77%, and 31.70% were recorded, respectively. Smaller Ra values were also found with the use of the new system