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Stoney Stanton, United Kingdom

Huo D.,Brunel University | Cheng K.,Brunel University | Wardle F.,UPM Ltd.
International Journal of Advanced Manufacturing Technology | Year: 2010

High-accuracy three-dimensional miniature components and microstructures are increasingly in demand in the sector of electro-optics, automotive, biotechnology, aerospace and information-technology industries. A rational approach to mechanical micro machining is to develop ultra-precision machines with small footprints. In part 1 of this two-part paper, the-state-of-the-art of ultra-precision machines with micro-machining capability is critically reviewed. The design considerations and specifications of a five-axis ultra-precision micro-milling machine-UltraMill-are discussed. Three prioritised design issues: motion accuracy, dynamic stiffness and thermal stability, formulate the holistic design approach for UltraMill. This approach has been applied to the development of key machine components and their integration so as to achieve high accuracy and nanometer surface finish. © Springer-Verlag London Limited 2009. Source

Bai Q.,Brunel University | Bai Q.,Harbin Institute of Technology | Ivanov A.,Brunel University | Cheng K.,Brunel University | Wardle F.,UPM Ltd.
Proceedings of the 12th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2012 | Year: 2012

The electrochemical micromachining (μECM) machine using nanosecond pulses is the key facility for manufacturing miniature/micro parts or micro/nano scale structures in high precision and productivity. In this paper, a holistic design approach for μECM machine is presented particularly focusing the design exercise and innovative aspects of the machine. The key factors related to mechanical, electrical and chemical aspects of the machine have been holistically addressed in the machine system design and configuration. Dynamics driven finite element (FE) analysis for the spindle, mechanical structure and enclosure of the machine are conducted so as to obtain the machine optimal performance. The vibration modes in various inherent frequencies and their effects have been analyzed in detail particularly on the inter electrode gap (IEG) between tool anode and workpiece cathode. The electrolyte filtration system for the machine is designed by taking account of the compact design requirements. The holistic design approach is greatly helpful in reducing the machine development cycle, increasing the machine reliability and enabling the machine setup right at the first time. The paper concludes with further discussions on the potential and application of the approach for design of other high precision machines. Source

Wardle F.P.,UPM Ltd. | Bond C.,Loadpoint Ltd | Wilson C.,Delta Tau Europa | Cheng K.,Brunel University | Huo D.,Brunel University
International Journal of Advanced Manufacturing Technology | Year: 2010

Direct-drive air-bearing slides have the inherent advantages of high positioning accuracy and smoothness of motion, but due to low damping in the air bearings, they generally lack dynamic stiffness. The rigidity of the drive, both statically and dynamically, can also be low compared to mechanical equivalents. In this paper, the dynamic response of an air-bearing slide fitted with a novel design of oil-lubricated squeeze film damper and driven by a fastresponse, high-resolution control system is reported. The results show that the damper produces a substantial improvement in dynamic stiffness and that sufficient drive stiffness can be obtained to enable the slide to be used in some precision-machining applications. © Springer-Verlag London Limited 2009. Source

UPM Corporation | Date: 2003-06-03

herbicides for domestic and agricultural use, featuring a prepackaged delivery device, sold filled for delivery of herbicides.

Huo D.,Brunel University | Cheng K.,Brunel University | Wardle F.,UPM Ltd.
International Journal of Advanced Manufacturing Technology | Year: 2010

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micromanufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this twopart paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool-UltraMill-is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations. © Springer-Verlag London Limited 2009. Source

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