ULTRA-PRECISION DIRECT DIAMOND SHAPING OF FREEFORM MICROSTRUCTURES

Ph.DDOCTOR OF PHILOSOPHY (CDE-ENG

Design guidelines development of successive forming tooling for tailor-formed blanks fabrication

As the demands of manufacturing become more tailored to suit the needs of customers, there has been a great interest to develop highly efficient and cheaper alternatives to produce customized parts without the hassle of outsourcing due to machine restrictions. Successive Forming (SF) is a Combined Stamping Forging (CSF) method capable of producing metal plates with different cross sectional thicknesses by progressively forging upon the plate to produce the desired profile. The manufactured profile, also known as a Tailor-Formed Blanks (TFB), can then be further processed to produce parts with various capabilities. An experimental study to identify the inherent problems on SF was conducted to understand the forming process window of the technique. This was accompanied by series of numerical studies which were conducted to identify the optimal die features and their geometrical windows. The results show that the features of the die should be as short and stubby as possible with sufficient interaction between the forming zones, which can be achieved by limiting the range of the spreading angle, β, from β = 7ᵒ and β = 21ᵒ. Other topographies such as steps or forward-facing facets should also be avoided. The guidelines developed from this study would allow SF process designers select the appropriate die geometry and process parameters to produce these TFB’s. These guidelines are accompanied by an optimised die design developed using the data gathered.Bachelor of Engineering (Mechanical Engineering

A Review on the Design and Application of Compliant Mechanism-Based Fast-Tool Servos for Ultraprecision Machining

The compliant mechanism (CM)-based fast-tool servo (FTS) is used in ultraprecision machining contexts to produce high value products for technically advanced applications. Far too often, the FTS’ machined products are expected to be geometrically complex with minimal form tolerance and surface roughness. Since the FTS’ enclosing CM is responsible for guiding the cutting motion, its design is of utmost importance in determining the quality of the machined product. The objective of this paper is therefore to review specifically the design and structural related aspects of CM-based FTS that affects its ultraprecision machining performance. After a brief introduction, the fundamentals for designing ultraprecision capable CMs such as flexure hinge modelling, actuator selection and isolation and CM designing are comprehensively explained. In the subsequent section, the various configurations of CM-based FTSs that exist so far and their functionalities are listed. The critical factors which impact the CM-based FTS’ ultraprecision machining performance are identified and mitigating measures are provided wherever possible. Before concluding, the research questions that should be investigated for raising the state of the art of CM-based FTSs are presented as food for thought. With this review article, not only can practitioners have a clearer picture of how better to design their CMs for their FTSs, but they can also improve upon existing FTS designs from leading researchers so that products of higher quality than before can be made for the future

Generating Direct Diamond Shaping tool paths using special-purpose Computer-Aided-Machining post-processor

10.1080/0951192X.2022.2027522International Journal of Computer Integrated Manufacturing3591010-102

Design and fabrication of composite polygonal Fresnel lenses

10.1364/oe.436290Optics Express292236516-3653

Review on laser directed energy deposited aluminum alloys

Lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing (AM) to process high-value Al parts. As a mainstream AM technique, laser-directed energy deposition (LDED) shows good scalability to meet the requirements for large-format component manufacturing and repair. However, LDED Al alloys are highly challenging due to their inherent poor printability (e.g. low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, element evaporation and resultant inferior mechanical properties (worse than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. Future opportunities and perspectives in LDED high-performance Al alloys are also outlined

Paediatric COVID-19 mortality: a database analysis of the impact of health resource disparity

Background The impact of the COVID-19 pandemic on paediatric populations varied between high-income countries (HICs) versus low-income to middle-income countries (LMICs). We sought to investigate differences in paediatric clinical outcomes and identify factors contributing to disparity between countries.Methods The International Severe Acute Respiratory and Emerging Infections Consortium (ISARIC) COVID-19 database was queried to include children under 19 years of age admitted to hospital from January 2020 to April 2021 with suspected or confirmed COVID-19 diagnosis. Univariate and multivariable analysis of contributing factors for mortality were assessed by country group (HICs vs LMICs) as defined by the World Bank criteria.Results A total of 12 860 children (3819 from 21 HICs and 9041 from 15 LMICs) participated in this study. Of these, 8961 were laboratory-confirmed and 3899 suspected COVID-19 cases. About 52% of LMICs children were black, and more than 40% were infants and adolescent. Overall in-hospital mortality rate (95% CI) was 3.3% [=(3.0% to 3.6%), higher in LMICs than HICs (4.0% (3.6% to 4.4%) and 1.7% (1.3% to 2.1%), respectively). There were significant differences between country income groups in intervention profile, with higher use of antibiotics, antivirals, corticosteroids, prone positioning, high flow nasal cannula, non-invasive and invasive mechanical ventilation in HICs. Out of the 439 mechanically ventilated children, mortality occurred in 106 (24.1%) subjects, which was higher in LMICs than HICs (89 (43.6%) vs 17 (7.2%) respectively). Pre-existing infectious comorbidities (tuberculosis and HIV) and some complications (bacterial pneumonia, acute respiratory distress syndrome and myocarditis) were significantly higher in LMICs compared with HICs. On multivariable analysis, LMIC as country income group was associated with increased risk of mortality (adjusted HR 4.73 (3.16 to 7.10)).Conclusion Mortality and morbidities were higher in LMICs than HICs, and it may be attributable to differences in patient demographics, complications and access to supportive and treatment modalities

Association of Country Income Level With the Characteristics and Outcomes of Critically Ill Patients Hospitalized With Acute Kidney Injury and COVID-19

Introduction: Acute kidney injury (AKI) has been identified as one of the most common and significant problems in hospitalized patients with COVID-19. However, studies examining the relationship between COVID-19 and AKI in low- and low-middle income countries (LLMIC) are lacking. Given that AKI is known to carry a higher mortality rate in these countries, it is important to understand differences in this population. Methods: This prospective, observational study examines the AKI incidence and characteristics of 32,210 patients with COVID-19 from 49 countries across all income levels who were admitted to an intensive care unit during their hospital stay. Results: Among patients with COVID-19 admitted to the intensive care unit, AKI incidence was highest in patients in LLMIC, followed by patients in upper-middle income countries (UMIC) and high-income countries (HIC) (53%, 38%, and 30%, respectively), whereas dialysis rates were lowest among patients with AKI from LLMIC and highest among those from HIC (27% vs. 45%). Patients with AKI in LLMIC had the largest proportion of community-acquired AKI (CA-AKI) and highest rate of in-hospital death (79% vs. 54% in HIC and 66% in UMIC). The association between AKI, being from LLMIC and in-hospital death persisted even after adjusting for disease severity. Conclusions: AKI is a particularly devastating complication of COVID-19 among patients from poorer nations where the gaps in accessibility and quality of healthcare delivery have a major impact on patient outcomes

The value of open-source clinical science in pandemic response: lessons from ISARIC

International audienc