Contents. List of fi gures List of tables

Transcription

1 Contents List of fi gures List of tables Preface About the contributors xi xxi xxv xxvii 1 Implementation of light-scattering instrumentation: innovation, design and development 1 Roger White, Nikolai Zhelev and David Bradley Glossary Introduction Application and need Innovation Do the right thing Funding The prototype How to keep ahead of the competition design in saleability! The evolutionary history of the NS4910 protein aggregation monitor (PAM) Conclusions Notes Acknowledgements References 41 vii

2 Mechatronics and manufacturing engineering 2 Planar micromanipulation on microconveyor platforms: recent developments 47 Panos Lazarou and Nikos A. Aspragathos 2.1 Introduction Microconveyor platforms for micromanipulation Manipulation of parts on microconveyor platforms: an integrated approach for programmable force fi eld design and platform programming Future research directions and conclusions References 91 3 Single-axis arm designed with an ultrasonic motor: basic active/passive joint torque control 99 Fusaomi Nagata, Keisuke Ogiwara and Keigo Watanabe 3.1 Introduction Single-axis arm designed with an ultrasonic motor Control system Example of application Conclusions References Signal processing for tool condition monitoring: from wavelet analysis to sparse decomposition 115 Zhu Kunpeng, Wong Yoke San and Hong Geok Soon 4.1 Overview of tool condition monitoring and signal processing issues Signal space, linear system and Fourier transform Wavelet analysis Sparse coding Applications Conclusions References 153 viii

3 Contents 5 ANN modelling of fractal dimension in machining 159 Prasanta Sahoo and Tapan Kr. Barman 5.1 Introduction Basic considerations CNC end milling CNC turning Cylindrical grinding Electrical discharge machining Conclusion References Predicting forces and damage in drilling of polymer composites: soft computing techniques 227 Inderdeep Singh, Pawan Kumar Rakesh and Jagannath Malik 6.1 Drilling of polymer composites Soft computing techniques References Minimising burr size in drilling: integrating response surface methodology with particle swarm optimisation 259 V.N. Gaitonde, S.R. Karnik and J. Paulo Davim 7.1 Introduction Response surface methodology Particle swarm optimisation Experimental details Results and discussion Conclusions References 289 ix

4 Mechatronics and manufacturing engineering 8 Single point incremental forming of polymers 293 Maria Beatriz Silva, Tânia Marques and Paolo A.F. Martins 8.1 Introduction Theoretical framework Experimental background Results and discussion Conclusions Acknowledgement References 328 Index 333 x

5 List of figures 1.1 The basis structure of a light-scattering system Theoretical Zimm plot showing the double extrapolation of M w as the circled point Simplified system configuration for a light-scattering instrument The innovation process Rothwell s innovation model Closed and open innovation Cost allocation and expenditure in product development Cost of error remediation in product development The management of risk The product development process and tools to support that process (Wodehouse and Bradley, 2006) User-centred design flow Simplified V-model for design management Functional matrix project management structure Hierarchical project management structure Profiles of technology adoption and market penetration Light-scattering evolution showing the traditional market leader (bottom), original AggreKem with built-in PC (top), and NS4910 PAM (front) 38 xi

6 Mechatronics and manufacturing engineering 2.1 Group of actuators and one motion pixel cell of the cilia platform (Suh et al., 1997) A work cell of the planar cilia platform (Ataka et al., 2010; [2010] IEEE) Schematic of actuation principle based on a four V-groove joint. By heating the joint a horizontal displacement Δx is obtained due to greater thermal expansion of the polyimide at the top of the V-groove than at the bottom (adapted from Ebefors, 2000) Schematic of an ECT actuator (adapted from Guckel et al., 1992) Schematic of an SMA microrapper actuator in open and close position (adapted from Gill et al., 2001) Side view schematic of a 1-DOF frictional conveyor showing inverted foot motions, executing one step of the plate to the right (adapted from Shay et al., 2008) Travelling field inductive surface drive motor (adapted from Egawa and Higuchi, 1990) Configurations of (a) the straight module, (b) the turning module and (c) the separation module (Dao et al., 2008; [2008] IEEE) Actuation principle of the scratch drive actuator (adapted from Akiyama and Shono, 1993a) Actuation principle based on EWOD, (adapted from Moon and Kim, 2006) Operation principle of the electromagnetic actuator (adapted from Moon and Kim, 2006) Schematic of the linear piezoelectric ultrasonic actuator (adapted from Friend et al., 2008) Bending modes of the wobble motor type actuators (adapted from Watson et al., 2009) 71 xii

7 List of figures 2.14 Principle of airflow manipulation (adapted from Chapuis et al., 2005) Conveyance of a silicon chip using periodic compressed air. The blowing direction is represented by an arrow on the object (Zeggari et al., 2006) Phases of an assembly procedure: (a) initial positions and orientations of two parts, (b) centred parts with radial fields, (c) application of curl fields, (d) desired part orientations after rotation, (e) push field applied to one part, (f) assembled parts (adapted from Luo and Kavraki, 2000) Final desirable pose of an N-polygon, bounding lines and an indicative field of one of them Stable equilibrium pose of a square micropart, corresponding half-planes and the final force field Top: Use of a trapezoid-like micropart for the programming of an 8x8 array; Bottom: region 5 motion pixel actuation rates (Lazarou and Aspragathos, 2009) Final desired pose and corresponding force field (Lazarou and Aspragathos, 2009) Part s position and orientation over time (Lazarou and Aspragathos, 2009) Single-axis arm designed with an ultrasonic motor Hardware block diagram of the experimental system Relation between joint driving torque and rotational speed in steady state 103 xiii

8 Mechatronics and manufacturing engineering 3.4 Step responses obtained by using Equation 3.1, in which 500 pulses mean π rad Joint driving voltage calculated by using Equation Step responses obtained by using Equation Joint torque control result by using Equation Stiffness control result by using Equation Compliance control result by using Equation Impedance control result by using Equation Block diagram of an application called the assist device for assisting a damaged or weakened joint Experimental scene assumed to be the assist device Joint torque manually controlled by an operator, in which the force is given by the operator s fingers TCM as a pattern recognition system Cutting forces, Fourier transform and spectrogram Haar wavelet, Morlet wavelet and Daubechies wavelet Morlet wavelet transform at different scales and locations Time-frequency resolution of Fourier transform and wavelet transform Geometry of MRA MRA analysis of cutting force and their frequency bands Sparse representation of the signal vector Signal reconstructed below Nyquist frequency The force s sparse representation in STFT domain 145 xiv

9 List of figures 4.11 Illustrative of the statistics of noise: a) noise signal, b) noise distribution compared to Gaussian distribution, c) in frequency domain, d) the autocorrelation coefficients The sensor output and their corresponding power spectrum Cutting forces reconstructed Residue of wavelet de-noised force Geometry of wavelet singular detection HE value of typical signal Modulus maxima for slight wear tool and severe wear tool Fishbone diagram showing parameters affecting surface roughness (Benardos and Vosniakos, 2003) Display of surface texture Component parts of a typical stylus surface-measuring instrument Formation of Koch curve Qualitative description of statistical self-affinity for a surface profile Face-centred central composite design with three factors Architecture of the neural network Performance of ANN model using regression analysis for training pattern (CNC milling) Performance of ANN model using regression analysis for testing pattern (CNC milling) Comparative study of experimental D with ANN model predicted D in CNC turning Performance of ANN model using regression analysis in CNC turning Performance of ANN model using regression analysis for training pattern in grinding 213 xv

10 Mechatronics and manufacturing engineering 5.13 Performance of ANN model using regression analysis for testing pattern in grinding Comparative study of experimental D and ANN predicted D for testing pattern using L-M algorithm in grinding Comparative study of experimental D with ANN model predicted D in EDM Performance of ANN model using regression analysis in EDM Number of papers published in the field of drilling of PMCs in last two decades Summary of focus areas in the field of drilling of PMCs Elements of the drilling system in context of PMCs Different types of drill geometry Thrust force for different drill point geometries Drilling-induced damage in unidirectional GFRP laminates Research directions in the field of drilling of PMCs Drilling process with input and output variables Topology of a feed-forward neural network Structure of a single neuron Outline of genetic algorithm (a) Experimental and predicted output for different models on test data; (b) Histogram plot of prediction accuracy for AGA-ANN Plot of ANN-PSO output (normalised) against testing data Modification of a searching point concept by PSO in a two-dimensional space 265 xvi

11 List of fi gures 7.2 Experimental and predicted values of burr height for the experimental data Experimental and predicted values of burr thickness for the experimental data Interaction effect of drill diameter and cutting speed on burr size (f = 0.08 mm/rev and θ = 126 degrees) Interaction effect of drill diameter and feed on burr size (v = 12m/min and θ = 126 degrees) Interaction effect of drill diameter and point angle on burr size (v = 12m/min and f = 0.08mm/rev) Fitness mapping of burr height and burr thickness PSO convergence for a drill diameter of 20mm Optimal burr size obtained by PSO simulation for different values of drill diameter Relationship between drill diameter and optimal feed Relationship between drill diameter and optimal point angle Single-point incremental forming: (a) schematic representation of the process; (b) tool set-up that was utilised in the experiments with polymer sheets Failure modes that are experimentally observed in the SPIF of polymers: (a) Failure mode 1 (PC); (b) Failure mode 2 (PET); and (c) Failure mode 3 (PVC) Essentials for the theoretical framework based on membrane analysis: (a) Schematic representation of the local contact area between the tool and sheet placed immediately ahead; (b) Approximation of the local contact xvii

12 Mechatronics and manufacturing engineering area by a shell element; (c) Cross-section view showing the acting stresses in meridional, circumferential and thickness directions Schematic representation of the stress field in a cross-section view of the SPIF process by a meridional plane; the detail of the instantaneous plastically deforming region BC illustrates thinning at the corner radius Fracture forming lines (FFL) of PC, PVC, PA and PET, inset shows pictures of tensile and bulge tests, and equations of approximation to the FFLs; schematic representation of the major and minor axis of the ellipses that result from the plastic deformation of the grids of circles Experimental strains in truncated conical and pyramidal SPIF parts with 3mm thickness using an initial drawing angle ψ 0 = 30º: (a) PC, (b) PVC, (c) PA and (d) PET Experimental strains obtained in the SPIF of truncated conical parts with 3mm thickness using an initial drawing angle ψ 0 = 30º and tool radius r tool = 4, 5 and 6 mm: (a) PC, (b) PVC Triaxiality ratio σ m /σ Y as a function of sheet thickness t calculated from the theoretical framework; the strength differential effect β = 0 for facilitating representation Experimental strains obtained in the SPIF of truncated conical parts with 2 and 3mm thickness using an initial drawing angle ψ 0 = 30º and a tool radius r tool = 4 mm. (a) PC, (b) PVC 324 xviii

13 List of figures 8.10 Experimental strains obtained in the SPIF of truncated conical parts with 2mm of thickness, made from PET, with a tool radius of 4mm and initial drawing angles ψ 0 of 30º, 45º and 60º Variation in density as a function of the drawing angle ψ along the conical wall of SPIF parts made from PA, PC, PET and PVC (r tool = 8 mm, ψ 0 = 30º, t 0 = 2 mm); inset shows a photograph of an SPIF part made from PVC 326 xix

14 List of tables 1.1 Closed and open innovation characteristics and principles Comparison of the most indicative implementations of actuators and actuator platforms for microconveyance Variable levels used in CNC milling Specification of CNC end milling machine Composition and mechanical properties of work-piece material Experimental results for CNC milling considering full factorial design Performance comparison of different models in CNC milling Comparative study of experimental and ANN predicted fractal dimension, D for testing set (CNC milling) Process parameter levels used in CNC turning Design matrix of the rotatable CCD design in CNC turning Experimental results for CNC turning MSE data for different architecture in CNC turning Process variables and their levels in grinding Specification of the cylindrical grinding machine used 205 xxi

15 Mechatronics and manufacturing engineering 5.13 Design matrix of process variables and the experimental results in grinding Performance of different networks in grinding Comparison of network performances based on different training algorithms in grinding Variable levels used in EDM Design matrix of the FCC design in EDM Specification of the EDM equipment Electrode material properties Experimental results in EDM MSE data for different architecture in EDM Process parameters and their levels Box-Behnken design (BBD) matrix and measured values of burr size Chemical composition and mechanical properties of AISI 316L stainless steel work material Analysis of variance (ANOVA) for burr size models Comparison of experimental and RSM-based predicted values of burr size for the validation data Technical and economic aspects of polymer processing State of stress and strain in the small localised plastic zone of the rotational symmetric SPIF of metals and polymers Representative summary of the physical and mechanical properties of the polymers utilised in the investigation with photographs of the specimens utilised in tensile and fracture toughness tests 313 xxii

16 List of tables 8.4 Plan of experiments and geometrical details of the formability tests performed on truncated conical and pyramidal shapes with initial drawing angle ψ 0 and increasing drawing angle ψ(h) with depth Experimental maximum drawing angle ψ max that sheet blanks made of steel, aluminum and polymers can undertake when forming a truncated conical shape by means of SPIF 325 xxiii