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An Integrated Setup for Sequential Hybrid Laser Beam Micromachining (LBMM) and Micro-EDM for Machining Micro-hole Arrays with Automated Tool Localization

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International Journal of Precision Engineering and Manufacturing 2025年 1-18页

作者： Azhar, Wan Ahmad Bin Wan Saleh, Tanveer Autonomous Systems and Robotics Research Unit Department of Mechatronics Engineering International Islamic University Malaysia Jalan Gombak Kuala Lumpur53100 Malaysia

Micro holes array has significant applications in the field of aerospace and turbo machinery, industrial filtration, microfluidic devices, biomedical engineering, and so on. There are various ways to manufacture micro holes arrays. In order to have a cost-effective, yet precise and efficient process for the fabrication of micro holes array, an integrated setup has been introduced in this paper to combine Laser Beam Micro Machining (LBMM) and micro-EDM (μEDM). This approach uses LBMM for quick material removal and µEDM for precise finishing. However, one of the main challenges in hybrid LBMM-µEDM is the localization of LBMM micro holes for accurate positioning of μEDM electrode. In this present study, an integrated setup with automated hole localization has been presented to improve the hybrid LBMM-μEDM process in terms of alignment accuracy and machining rate. The microscope camera that is mounted on the μEDM stage scans and captures images of LBMM holes. Then, the images were stitched and processed using image processing techniques to get the center coordinate of the LBMM micro holes. Finally, the operator validated the coordinates and G-code was automatically generated for the µEDM process to perform the fine finishing. The result indicated that the alignment accuracy is within 15 μm. Furthermore, the newly developed automation strategies for the hybrid LBMM-μEDM process show significant improvement in machining time with 5 × faster than the pure μEDM process, and better performances in overcut, taper angle, and electrode wear. Furthermore, the hybrid process was found to be 1.6 × more energy efficient as compared to the pure µEDM process. Overall, the newly developed integrated system was found to be highly effective for producing micro holes array. © The Author(s), under exclusive licence to Korean Society for Precision Engineering 2025.

关键词： Precision engineering

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Laser-MicroEDM Based Hybrid Micromachining 1

Laser-MicroEDM Based Hybrid Micromachining

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丛书名： SpringerBriefs in Applied Sciences and Technology

1000年

作者： Tanveer Saleh Mir Akmam Noor Rashid Wan Ahmad Bin Wan Azhar Wazed Ibne Noor

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Development of an Active Fixture for Ultrasonically Assisted Micro Electro-Discharge Machining

Development of an Active Fixture for Ultrasonically Assisted...

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International Conference on Mechatronics (ICOM)

作者： Md Shohag Mollik Wazed Ibne Noor Tanveer Saleh Mohammed Gamal Abdulhameed Bazarah Autonomous Systems and Robotics Research Unit International Islamic University Malaysia Kuala Lumpur Malaysia

ISBN: (纸本)9781728129723

Micromachining technologies have enjoyed a recent resurgence due to massive demands in many engineering, production and manufacturing sectors. Micro Electric Discharge Machining (μ-EDM) is one of the most popular techniques available to produce microscopic features and components for various industries. This technique can ensure better machining performance in terms of reduced Heat Affected Zones and surface finishing. It also comes with inherent disadvantages such as high machining time, low material removal rate (MRR) and unstable machining. To overcome these factors vigorous flushing of dielectric fluid is performed. The flushing is achieved through imparting ultrasonic vibration on either of the tool, dielectric fluid or workpiece. The vibration aids in carrying away the debris accumulated in the spark-gap region. In this paper, a novel design of an ultrasonic vibration fixture has been proposed. This fixture will facilitate vibration of the workpiece that is required to improve machining performance. Further enhancement of the design leads to better machining performance. System Identification helps to determine the nature of the system and model the input-output response. The oscillation of the system can be easily characterized and validated using System Identification. Machining results are compared to gain some more insight about the nature of ultrasonic vibration assisted μ-EDM.

关键词： Micromachining μ-EDM Vibration MRR Modeling Microtechnology Fixtures machining Modeling Ultrasonic vibration Ultrasonic Waves material removal rate oscillatory system workpiece Surface finish

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Development and Performance Evaluation of Modular RC-based Power Supply for Micro-EDM

Development and Performance Evaluation of Modular RC-based P...

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International Conference on Mechatronics (ICOM)

作者： Wan Ahmad Bin Wan Azhar Tanveer Saleh Autonomous Systems and Robotics Research Unit International Islamic University Malaysia Kuala Lumpur Malaysia

ISBN: (纸本)9781728129723

One of the demanding manufacturing processes nowadays is Micro-EDM. Micro-EDM stands for Micro Electrical Discharge Machining. A low discharge energy per pulse is important to achieve micro-level machining by controlling parameters such as gap voltage and type of power supply. Furthermore, developing a Micro-EDM machine is time-consuming and complex. Generally, the power supply unit is built along with the development of the EDM machine and it is not sold separately in the market. Therefore, the purpose of this research is to develop and evaluate a modular power supply unit that is compatible with any EDM or CNC machine for micro machining. The power supply unit is based on Resistor-Capacitor (RC) power supply with the options to vary the output voltage and the capacitance value. In addition, the current is monitored using micro-controller ATmega328p to provide options for short circuit current detection levels. A prototype of a Micro-EDM machine is built for the evaluation of the power supply. Performance evaluations of the power supply are conducted with through-holes drilling by studying the machining time, MRR, diametrical overcut and taper angle with a different variation of gap voltage, RC's capacitance, and short circuit current detection level. The evaluation results show that the power supply is capable to perform Micro-EDM machining. The power supply can deliver power up to 360 W. During the discharging, the peak current is recorded to spike up to 7A. The discharge energy per pulse can easily be controlled by changing the output voltage and the RC's capacitance. It is found that at lower discharge energy per pulse, the peak current is lower resulting improvement in MRR, diametrical overcut and taper angle at cost of longer machining time. Furthermore, short circuit current detection level results indicate that machining time is reduced by approximately 5 minutes for every 20 percent increase of the detection level.

关键词： Micro Electrical discharge machining EDM Discharge gap model Modular RC Power supply Electric Power Source power unit ELECTRIC DISCHARGE MACHINES Modularity discharge energy Ritchey-Chretien telescope micro-edm wire cutting taper angle micro output voltage Performance Evaluation Machine time peak current

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COURAGEOUS: Test Methods for Counter-UAS systems 10

COURAGEOUS: Test Methods for Counter-UAS Systems

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Target and Background Signatures X: Traditional Methods and Artificial Intelligence 2024

作者： Borghgraef, Alexander Vandewal, Marijke De Cubber, Geert Royal Military Academy Dept. CISS Research Unit Laser and Optronics Renaissancelaan 30 Brussels1000 Belgium Royal Military Academy Dept. MECA Robotics and Autonomous Systems Renaissancelaan 30 Brussels1000 Belgium

ISBN: (纸本)9781510681064

The proliferation of Unmanned Aerial systems (UAS), both commercial-off-the-shelf and homebuilt, is increasingly posing a challenge to the authorities. Law enforcement agencies are confronted with the new task of policing the lower airspace, requiring them to be equipped with effective and appropriate counter-UAS systems for detecting, tracking, identifying (DTI) the offending drone. A number of technologies exists on the market today, using radar, EO/IR, acoustic and RF sensors. Evaluating the performance of these systems is not a trivial task, as different nations and entities often have different approaches. The COURAGEOUS project seeks to develop evaluation methodologies for counter-UAS systems, leading to a CENELEC pre-standard. We organized one of three validation trials for this project, implementing a maritime border protection scenario. We invited manufacturers to test their systems against a range of UAS, comparing their DTI data to the flightpath ground truth. These evaluations were not ranked to determine the best technology, but rather used to evaluate the usefulness of the evaluation methods developed by the project, allowing us to progress towards developing an EU-wide standard for evaluating DTI technologies. © 2024 SPIE ·

关键词： Commercial off-the-shelf

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Modelling of Machining Time and its Uncertainty in Micro Electrical Discharge Machining Process Using RSM

Modelling of Machining Time and its Uncertainty in Micro Ele...

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International Conference on Mechatronics (ICOM)

作者： Mohammad Mainul Hasan Tanveer Saleh Ali Sophian Autonomous Systems and Robotics Research Unit (ASSRU) Department of Mechatronics Engineering International Islamic University Malaysia Kuala Lumpur Malaysia

ISBN: (数字)9798350349788

ISBN: (纸本)9798350349795

In modern manufacturing processes, precision and efficiency are paramount, particularly in a stochastic method such as Micro Electrical Discharge Machining (μEDM). With its ability to fabricate intricate geometries in hard and difficult-to-machine materials, μEDM has become indispensable in various industries. However, optimising machining time while ensuring reliability and accuracy remains a significant challenge that often relies on the intuition and experience of machinists. In response, this paper presents a comprehensive study on the modelling of machining time (MT) and also its associated uncertainty characterised by the standard deviation (SD) in the μEDM process using Response Surface Methodology (RSM). The study utilises experimental data generated through the I -optimal design of experiment technique (DOE) to develop quadratic equations for the MT Mean and SD MT models. The input factors for the models include capacitance, voltage, feed rate, tool speed, tool diameter, workpiece thickness, and workpiece materials defined by thermal conductivity, melting point, and electrical resistivity. The adequacy of both models was assessed based on ANOV A and fit statistics, demonstrating their effectiveness. Additionally, the mean percentage accuracies of the MT Mean and SD MT models are evaluated as 74.5% and 58% for the train set and 86.8% and 82.1 % for the test set, respectively. By leveraging RSM techniques, this research aims to provide insights into the complex relationships between machining parameters and the resulting machining time and uncertainty, facilitating enhanced process μEDM control and performance optimisatio n.

关键词： Training Adaptation models Uncertainty Accuracy Estimation Machining Predictive models

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Conceptualization of a Hybrid Machine Combining Laser Beam Micro Machining (LBMM) and Micro Electrical Discharge Machining (Micro-EDM) in a Single Setup

Conceptualization of a Hybrid Machine Combining Laser Beam M...

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International Conference on Mechatronics (ICOM)

作者： Wan Ahmad Bin Wan Azhar Tanveer Saleh Autonomous Systems and Robotics Research Unit Department of Mechatronics Engineering International Islamic University Malaysia Jalan Gombak Kuala Lumpur Malaysia

ISBN: (数字)9798350349788

ISBN: (纸本)9798350349795

The utilization of hybrid laser beam micro machining (LBMM) in conjunction with micro electrical discharge machining $(\mu\text{EDM})$ has gained widespread popularity due to its ability to improve material removal rates and enhance surface quality. Typically, these processes occur on separate machines, resulting in drawbacks such as time loss during workpiece transfer, potential misalignment issues, and increased risks of sample damage during the transfer. This research provides a system and method for a two-step sequential machining process of LBMM and $\mu\text{EDM}$ that allows the workpiece to remain at the same location for both processes. A LBMM process is used for drilling a rough blind hole, followed by $\mu\text{EDM}$ for the finishing process. The workpiece is fixed and positioned in the $\mu\text{EDM}$ workstation. A microscopic camera, which is mounted on the $\mu\text{EDM}$ machine, is used to provide common coordinate position data for the laser and $\mu\text{EDM}$ machine. This coordinate is used by the $\mu\text{EDM}$ machine to position the electrode perfectly on top of LBMM hole before machining. The results suggest that LBMM- $\mu\text{EDM}$ machining can reduce machining time while achieving good hole quality and repeatability. The hybrid sequential process significantly reduces drilling time, being about 1.55 times faster than the pure $\mu\text{EDM}$ [method. However, the findings also indicate that it is not necessary to use LBMM- $\mu\text{pEDM}$ for low aspect ratio holes. This concept enables the workpiece to stay in one position throughout both processes, eliminating any time loss and damage during transfer, as well as avoiding misalignment issues.

关键词： Drilling Mechatronics Surface discharges Microscopy Surface emitting lasers Machining Micromachining

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Correction to: Dual-stage artificial neural network (ANN) model for sequential LBMM-μEDM-based micro-drilling

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The International Journal of Advanced Manufacturing Technology 2021年第11期117卷 3367-3367页

作者： Noor, Wazed Ibne Saleh, Tanveer Rashid, Mir Akmam Noor Ibrahim, Azhar Mohd Ali, Mohamed Sultan Mohamed Autonomous Systems and Robotics Research Unit (ASRRU) Department of Mechatronics Engineering International Islamic University Malaysia Kuala Lumpur Malaysia Department of Mechatronics Engineering International Islamic University Malaysia Kuala Lumpur Malaysia School of Electrical Engineering Universiti Teknologi Malaysia UTM Johor Bahru Malaysia

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TRIDENT – Technology based impact assessment tool foR sustaInable, transparent Deep sEa miNing exploraTion and exploitation: A project overview

TRIDENT – Technology based impact assessment tool foR susta...

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OCEANS

作者： E. Silva D. Viegas A. Martins J. Almeida C. Almeida B. Neves P. Madureira A.J. Wheeler G. Salavasidis A. Phillips A. Schaap B. Murton A. Berry A. Weir G. Dooly E. Omerdic D. Toal P.C. Collins M. Miranda C. Petrioli C. Barrera Rodríguez D. Demoor C. Drouet G.El Serafy S.M. Jesus J. Dañobeitia V. Tegas S. Cusi L. Lopes B. Bodo L. Beguery S. VanDam J. Dumortier L. Neves V. Srivastava T.G. Dahlgren J. Thomassen Hestetun R. Eiras R. Caldeira C. Rossi J. Spearman L. Somoza F.J. González R. Bartolomé P. Bahurel INESC TEC Porto Portugal Instituto Superior Engenharia do Porto ISEP Portugal Portuguese Task Group for the Extension of the Continental Shelf EMEPC Portugal Department of Geosciences and Institute of Earth Sciences University of Évora Portugal SFI Centre for Research in Applied Geosciences School of Biological Earth & Environmental Sciences University College Cork Ireland Marine Autonomous and Robotic Systems National Oceanography Centre NOC United Kingdom Ocean Technology and Engineering NOC United Kingdom Ocean BioGeosciences NOC United Kingdom Marine Institute Ireland University of Limerick Centre for Robotics & Intelligent Systems CRIS Ireland School of Biological Science Queen’s University Belfast Northern Ireland Instituto Português do Mar e Atmosfera IPMA Portugal WSENSE Italy Head of Vehicle Base VIMAS Consortium for the Design Equipping and Exploitation of the Oceanic Platform of the Canary Islands Spain GREENOV-ITES France Unit of Coastal and Sea Systems Stichting Deltares& TU Delft The Netherlands LARSys University of Algarve Portugal EMSO-ERIC Italy Marine Technology Unit UTM-CSIC Spain La Palma Research Centre Spain Alseamar France Agora Partners Malha Technology Israel Timelex Belgium Gesi Belgium NORCE Norwegian Research Centre Norway Forum Oceano UPTEC POLO DO MAR Portugal ARDITI Portugal Center for Automation and Robotics UPM-CSIC Universidad Politécnica de Madrid Spain HRWallingford United Kingdom Geological Survey of Spain Marine Geology Resources and Extreme Environments IGME-CSIC Spain Institute for Marine Science ICM-CSIC Spain Mercator Ocean France

By creating a dependable, transparent, and cost-effective system for forecasting and ongoing environmental impact monitoring of exploration and exploitation activities in the deep sea, TRIDENT seeks to contribute to the sustainable exploitation of seabed mineral resources. In order to operate autonomously in remote locations under harsh conditions and send real-time data to authorities in charge of granting licenses and providing oversight, this system will create and integrate new technology and innovative solutions. The efficient monitoring and inspection system that will be created will abide by national and international legal frameworks. At the sea surface, mid-water, and the bottom, TRIDENT will identify all pertinent physical, chemical, geological, and biological characteristics that must be monitored. It will also look for data gaps and suggest procedures for addressing them. These are crucial actions to take in order to produce accurate indicators of excellent environmental status, statistically robust environmental baselines, and thresholds for significant impact, allowing for the standardization of methods and tools. In order to monitor environmental parameters on mining and reference areas at representative spatial and temporal scales, the project consortium will thereafter develop and test an integrated system of stationary and mobile observatory platforms outfitted with the most recent automatic sensors and samplers. The system will incorporate high-capacity data processing pipelines able to gather, transmit, process, and display monitoring data in close to real-time to facilitate prompt actions for preventing major harm to the environment. Last but not least, it will offer systemic and technological solutions for predicting probable impacts of applying the developed monitoring and mitigation techniques.

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