This study proposes a novel microprobing system for the surface detection of the side wall of micrometric scale workpieces based on the detection of the local surface interaction force. A spherical tip-shaped glass capillary tube with a micrometric scale diameter was employed as a micro-stylus. To obtain a low measuring force, the local attractive interaction force on the surface of the workpieces was detected by the vibrating micro-stylus and used as the probing trigger signal. The vibration in the main axis direction of the stylus allowed detection of the local surface interaction force in all directions around the stylus shaft. In this paper, the principle and configuration of the developed microprobe are mentioned. Probing detections around the stylus shaft were verified by the surface detection of a pin gauge. Repeatability of the probing by the developed microprobing system was evaluated.

Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce costs and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and residual stress are always a challenge for WAAM because they can affect the component’s geometric accuracy and drastically degrade the mechanical properties of the components. In this paper, wire-based and wire arc technology processes for 3D metal printing, including their advantages and limitations are reviewed. The optimization parametric study and modification of WAAM to reduce both residual stress and distortion are tabulated, summarized, and discussed.

Mechatronic structures deform under static and dynamic loads. These deformations lead to deviations at the tool center point (TCP), affecting the reachable accuracy and/or productivity of the machines. The scope of this work is the comparison of calculations and measurements of different static and dynamic errors on a dynamic test bench. A reduced-order modelling approach is applied for the test bench modelling. It uses a combination of modal condensation and moment-matching methods with Krylov subspaces. The different modelling steps and requirements are presented. The same model is used for all static and dynamic evaluations presented within this paper. Static deformations, leading to roll and pitch deviations at the TCP of the test bench structure, are simulated using the described modelling methodology and validated by inclination measurements. The modal behavior of the system is investigated by calculation and compared to the measurements at a single axes position. The spatial change of the frequency response functions of the modelled system is investigated further, by calculation and measurement of the velocity open-loop FRFs of one axis for different machine configurations. In addition, a transient trajectory simulation is performed and compared to the Heidenhain KGM and encoder measurements. The large variety of comparisons shows the efficient applicability of the modelling environment MORe.

This paper presents the development and implementation of a pneumatic muscle actuator based on an idea proposed by a research group at the University of Warsaw. The muscle comprises a silicone rubber tube with plugs at the ends. The tube wall contains high-rigidity wires arranged parallel to the tube axis. Circular rings are present on the exterior of the tube. When air is introduced into the tube, the actuator becomes bulky and contracts. In order to establish a prediction model of muscle behavior, a finite element model was developed, and in this model, the Mooney-Rivlin formulation was implemented with two coefficients for rubber simulation and truss elements for the wires. Several prototypes were developed, and a test bench for the experimental characterization of muscle performance was set up. The results of comparison between prototype behavior and model prediction are presented. The finite element model can be used to design the actuator with different dimensions; hence, it was used to conduct a simulated test campaign to develop a quick actuator sizing procedure. Using dimensional analysis, few project parameters were identified on which the performance of the actuator depends. Through a complete simulation campaign using the finite element model, an abacus was constructed. It allows sizing the actuator as required based on the desired performances according to an established procedure.

A novel abrasive-free planarization method named catalyst-referred etching (CARE) was developed. A polishing pad is coated with a catalytic material to promote chemical etching of the work substrate. During processing, the topmost areas of the work substrate, which are in contact with the catalyst surface, are selectively etched off. Atomically highly ordered surfaces are obtained for many types of work substrates. In this paper, the removal characteristics and mechanism of CARE for single crystalline 4H-SiC are reviewed.

A fourth industrial revolution is occurring in global manufacturing. It is based on the introduction ofInternet of thingsandservitizationconcepts into manufacturing companies, leading to vertically and horizontally integrated production systems. The resultingsmart factoriesare able to fulfill dynamic customer demands with high variability in small lot sizes while integrating human ingenuity and automation. To support the manufacturing industry in this conversion process and enhance global competitiveness, policy makers in several countries have established research and technology transfer schemes. Most prominently, Germany has enacted itsIndustrie 4.0program, which is increasingly affecting European policy, while the United States focuses onsmart manufacturing. Other industrial nations have established their own programs on smart manufacturing, notably Japan and Korea. This shows that manufacturing intelligence has become a crucial topic for researchers and industries worldwide. The main object of these activities are the so-called cyber-physical systems (CPS): physical entities (e.g., machines, vehicles, and work pieces), which are equipped with technologies such as RFIDs, sensors, microprocessors, telematics or complete embedded systems. They are characterized by being able to collect data of themselves and their environment, process and evaluate these data, connect and communicate with other systems, and initiate actions. In addition, CPS enabled new services that can replace traditional business models based solely on product sales. The objective of this paper is to provide an overview of the Industrie 4.0 and smart manufacturing programs, analyze the application potential of CPS starting from product design through production and logistics up to maintenance and exploitation (e.g., recycling), and identify current and future research issues. Besides the technological perspective, the paper also takes into account the economic side considering the new business strategies and models available.

The European Commission outlined the energy-related products (ErPs) meant to be labelled and regulated in order to achieve the goals to reduce the European amount of CO2-emissions by 20% by 2020 compared to projections. Machine tools (MTs) fulfill all mandatory criteria to be categorized as ErP, namely: significant sales volume, significant environmental impact and significant improvement potential. However, the energy consumption and energy efficiency of MTs strongly depend on their utilization. A generic evaluation approach for quantifying a MT’s energy efficiency is still under development by the working group ISO/TC 39/WG 12, which drives forward the ISO 14955 series for environmental evaluation of MTs.This work presents an approach for a generic energy efficiency evaluation of MTs. Component-specific behavior is investigated and aggregated in order to entirely describe the power consumption of a MT for any utilization by power mapping. Power maps contain all possible operational scenarios under the condition of the component boundaries. The approach allows a generic MT evaluation independent on the utilization and forms the base for future MT energy efficiency labelling. The presented approach is applied and validated in a practical case study.

A mosquito’s proboscis, which is used for sucking blood, consists of seven complicated parts. For example, the labrum has a hollow structure, and the maxillae have micrometer-sized tooth like projections on its tip. In this study, microneedles imitating one labium and two maxillae were fabricated using a precision three-dimensional laser lithography system “Nanoscribe.” The maximum length of the fabricated microneedle was 2.0 mm, the minimum length required to reach human capillary blood vessel underneath the epidermis.

Patterns made from conventional wax materials in the Investment Casting (IC) process can easily be distorted, damaged, or broken in transportation or routine handling or due to exposure to heat. Alternatively, the strength and toughness of most Rapid Prototyping (RP) materials virtually eliminates this drawback due to their resistance to heat, humidity, and post curing. The current study is conducted to investigate the feasibility of using RP processes such as FDM and MJM to fabricate IC patterns from Acrylonitrile Butadine Styrene (ABS) and acrylate based materials respectively to be used directly in IC process. Evaluation of the effects of different internal pattern designs of the RP parts are conducted based on the thermal analysis approach and burnout properties of the RP patterns. Ceramic shell molds are fabricated on both RP patterns and subsequently placed in an oven which is gradually heated to 1000°C. The decomposition temperature and the residual ash of the RP pattern materials is determined and analyzed. Results show that the acrylate pattern ofMJMdecomposes rapidly compared to the ABS pattern from the FDM process. It is also observed that quasi and square hollow internal structures show better collapsibility or burnout properties, with no cracks, compared to cross pattern and cross hatch designs.

Dynamic motion errors of machine tools consist of errors in the mechanical system and the servo system. In this study, a simple method to estimate the dynamic mechanical error is proposed to evaluate machine tool structures. The dynamic mechanical error in the low frequency range is estimated from the static deformation due to the driving force, the counter force, and the inertial force. The error in a high-precision machine tool is estimated for comparison with measurements. Two calculation tools, finite element analysis and rigid multi-body simulation, are used for the estimation. Measured dynamic mechanical errors can be correctly estimated by the proposed method using finite element analysis. The tilt of driven bodies is the major reason for dynamic mechanical errors. When the reduction factor representing the structural deformation is properly determined, the rigid multi-body simulation is also an effective tool. Use of the proposed method for modification planning is demonstrated. Stiffness enhancement of the saddle was an effective modification candidate to reduce the dynamic mechanical error. If the error should be reduced to sub-micrometer level, the location of components should be modified because the Abbe offset and the offset of the driving force from the inertial force must be shortened.

Robots have entered human life, and closer relationships are being formed between humans and robots. It is desirable that these robots be flexible and lightweight. With this as our goal, we have developed an artificial muscle actuator using straight-fiber-type artificial muscles derived from the McKibben-type muscles, which have excellent contraction rate and force characteristics. In this study, we compared the steady state and dynamic characteristic of straightfiber-type and McKibben-type muscles and verified the usefulness of straight-fiber-type muscles.