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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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Design and realization of a 6 degree of freedom robotic extrusion platform 27

Design and realization of a 6 degree of freedom robotic extr...

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27th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2016

作者： Kubalak, Joseph R. Mansfield, Craig D. Pesek, Taylor H. Snow, Zachary K. Cottiss, Edward B. Ebeling-Koning, Oliver D. Price, Matthew G. Traverso, Mark H. Tichnell, L. David Williams, Christopher B. Wicks, Alfred L. Design Research and Education for Additive Manufacturing Systems Laboratory Mechatronics and Autonomous Vehicles Laboratory Terrestrial Robotics Engineering and Controls Laboratory Department of Mechanical Engineering Polymer Processing Laboratory Department of Chemical Engineering Virginia Tech United States

The layer-wise deposition of Additive Manufacturing (AM) processes allows for significant freedom in the design of product geometry;however, the use of 3-axis deposition tools results in layer interfaces that reduce material properties in the build direction. Adding additional degrees-of-freedom (DOF) to the AM tool could remove this limitation by enabling out of plane material deposition. For example, multi-DOF tool paths could align material extrusion with a part's stress contours to circumvent inter-layer delamination. As a step towards this goal, the authors designed, fabricated, and tested an AM extrusion system that leverages a 6-DOF robotic arm. In this paper, the authors detail the realization of this system including the design of a high-temperature filament extruder, kinematics and tool path generation, and user interface. The performance of the system is evaluated through layered deposition of ABS thermoplastic. © 2016 The department of Energy’s Kansas City National Security Campus is operated and managed by Honeywell Federal Manufacturing Technologies, LLC under contract number DE-NA0002839.

关键词： 3D printers

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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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Metaheuristic optimization approach to mobile robot path planning

Metaheuristic optimization approach to mobile robot path pla...

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International Conference on engineering and Technology (ICET)

作者： Ahmed Hussein Heba Mostafa Mohamed Badrel-din Osama Sultan Alaa Khamis Robotics and Autonomous Systems (RAS) Research Group Department of Mechatronics Engineering German University in Cairo Egypt

This paper presents a metaheuristic optimization-based approach to mobile robot path planning problem. A comparative study between trajectory-based metaheuristic optimization and population-based metaheuristic optimization is conducted. Breadth-first deterministic search is used to find the optimal solution (ground truth) that is compared to the paths generated by tabu search, simulated annealing and genetic algorithm. The experimental study shows that simulated annealing outperforms the other algorithms in terms of computational time while tabu search gives the shortest path.

关键词： Path planning Genetic algorithms Mobile robots Simulated annealing Algorithm design and analysis

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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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Novel Design of a Soft Lightweight Pneumatic Continuum Robot Arm with Decoupled Variable Stiffness and Positioning

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Soft robotics 2018年第1期5卷 54-70页

作者： Giannaccini, Maria Elena Xiang, Chaoqun Atyabi, Adham Theodoridis, Theo Nefti-Meziani, Samia Davis, Steve Centre for Autonomous Systems and Advanced Robotics School of Computing Science and Engineering University of Salford Stoke Gifford BristolBS16 1QY United Kingdom School of Mechanical Engineering and Automation Institute of Mechatronics Engineering Northeastern University Shenyang China Department of Pediatrics University of Washington SeattleWA United States Seattle Children's Research Institute SeattleWA United States

Soft robot arms possess unique capabilities when it comes to adaptability, flexibility, and dexterity. In addition, soft systems that are pneumatically actuated can claim high power-to-weight ratio. One of the main drawbacks of pneumatically actuated soft arms is that their stiffness cannot be varied independently from their end-effector position in space. The novel robot arm physical design presented in this article successfully decouples its end-effector positioning from its stiffness. An experimental characterization of this ability is coupled with a mathematical analysis. The arm combines the light weight, high payload to weight ratio and robustness of pneumatic actuation with the adaptability and versatility of variable stiffness. Light weight is a vital component of the inherent safety approach to physical human-robot interaction. To characterize the arm, a neural network analysis of the curvature of the arm for different input pressures is performed. The curvature-pressure relationship is also characterized experimentally. © Copyright 2018, Mary Ann Liebert, Inc. 2018.

关键词： Stiffness

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Team-theoretic approach to cooperative multirobot systems: Humanitarian demining as a case study

Team-theoretic approach to cooperative multirobot systems: H...

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International Conference on engineering and Technology (ICET)

作者： Asser ElGindy Alaa Khamis Robotics and Autonomous Systems (RAS) Research Group Mechatronics Engineering Department German University in Cairo New Cairo Egypt

This article presents an approach to implement a cooperative multirobot system capable of solving complex problems. In this cooperative multirobot system, individual actions of the robots are controlled by the Belief-Desire-Intention model to endow the robots with the know-how needed to execute these actions deliberately. The cooperative behaviors between the heterogeneous robots are governed by the Team-Log theory to endow all the robots in the team with the know-how-to-cooperate and determine the team member's commitments to each other despite their different types, properties and goals. The proposed approach is tested for validity with the real life problem of humanitarian demining, as it requires cooperation between different robots to scan and clear a minefield from all the landmines.

关键词： Robot sensing systems Robot kinematics Multirobot systems Landmine detection Sensitivity

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Estimating reflectance parameters, light direction, and shape from a single multispectral image

Estimating reflectance parameters, light direction, and shap...

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作者： Rahman, Sejuti Robles-Kelly, Antonio Centre for Autonomous Systems University of Technology Sydney SydneyNSW2007 Australia Department of Robotics and Mechatronics University of Dhaka Dhaka1000 Bangladesh at Their Canberra City Site Research School of Engineering Australian National University CanberraACT0200 Australia

This paper presents a novel approach for estimating the light direction, shape, and reflectance parameters from a single multispectral image. We start from a general formulation that hinges in the notion that the light reflected from an object can be deemed to be a linear combination of specular and diffuse reflections. This permits the recovery of the reflection parameters through an iterative optimization scheme, which we render well posed by adopting a novel reparameterization that reduces the number of degrees of freedom in the cost function. With the estimated specular reflectance parameters, we recover the single point light source position from specular highlights by applying two novel constraints, coplanarity and Kullback-Leibler divergence. Then, by integrating the knowledge of light source and diffuse reflectance parameters, we recover shape of the scene from the diffuse component. Our approach is quite general in nature and can be applied to a family of reflectance models that are based on the Fresnel reflection theory. We demonstrate the utility of our method on synthetic and real world imagery. We also compare our results to several alternatives in the literature. © 2015 IEEE.

关键词： Reflection

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Distributed backstepping control for synchronization of networked class of underactuated systems: A passivity approach

Distributed backstepping control for synchronization of netw...

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Mediterranean Conference on Control and Automation

作者： Ghommam, Jawhar Bouterra, Yassine Mnif, Faiçal Poisson, Gérard National School of Engineering of Sfax Research Unit on Mechatronics and Autonomous Systems BPW 3038 Sfax Tunisia Department of Electrical and Computer Engineering College of Engineering Sultan Qaboos University P.O. Box 33 Muscat 123 Oman Institut Prisme Université d'Orléans BP 6749 45067 Orléans cedex 2 France

ISBN: (纸本)9781457701252

This paper considers the cooperative control problem of networked class of underactuated systems. We propose a new set up for synchronization of this type of systems based on the use of passivity as a design tool to solve the problem in hand. First the underactuated system is transformed to a class of nonlinear system with chain structure using a suitable non-linear static feedback. The cooperative control is designed using a combination of the standard backstepping procedure and the passivity theory by which a synchronizing outputs are constructed recursively then shared within the group. The proposed design technique is based on strongly connected digraph communication structures. Numerical simulations are carried out to illustrate the effectiveness of the proposed approach. © 2011 IEEE.

关键词： Synchronization

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