The development of a manufacturability analysis system for micro-milling

Abdul Shukor, Syaimak (2010) The development of a manufacturability analysis system for micro-milling. PhD thesis, University of Nottingham.

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Manufacturability analysis systems (MASs) have been developed to enable the evaluation of manufacturability aspects during the design stage. MASs have been shown to be useful for macro-manufacturing processes but less attention or effort has been put for their development in the scope of micro-manufacturing. This thesis describes the development of a MAS for a micro-machining domain (MicroMAS) with a custom-made 4-axis Miniature Machine Tool (MMT) being the scope of implementation.

There are three important components in this study which are; MAS, Uncertainty Evaluation Model (UEM) and micro-milling experiments. The integration between the results from the UEM analysis and micro-machining experiments were being incorporated into the MicroMAS to provide the system with the real condition of the MMT.

In MicroMAS, Primitive Feature Analysis (PFA) is introduced as a new technique in gathering information from a CAD model and analysing its manufacturability. The results from the manufacturability assessment in MicroMAS are successfully achieved through the manufacturability index which indicates the relative ease of machining the CAD model and list of related suggestions.

UEM is developed to analyse the influence of the errors stemmed from the MMT construction on the geometrical accuracy of the machined micro-parts. The model has allowed a methodology for the errors in a custom-made machine tool to be predicted and to further understand the origin of the errors on the machined micro-part (either from the machine or the process itself). The abilities of the MMT are evaluated through various types of experiments where the surface quality and geometrical accuracy can be concluded to be at an acceptable range.

From the experience gained from the research, the development of MicroMAS for micro-milling has been found to be practical in assisting a user to generate micro-parts using the MMT.

Item Type: Thesis (University of Nottingham only) (PhD)
Supervisors: Axinte, D.
Pashby, I.R.
Keywords: Manufacturability analysis systems, Uncertainty evaluation model, Micro-milling experiments, Micro-manufacturing, Design of micro-products
Subjects: T Technology > TS Manufactures
Faculties/Schools: UK Campuses > Faculty of Engineering > Department of Mechanical, Materials and Manufacturing Engineering
Item ID: 11835
Depositing User: EP, Services
Date Deposited: 25 Feb 2011 10:46
Last Modified: 25 Sep 2016 20:37

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