This tutorial provides a fast-paced hands-on introduction to rapid precision machine design based on FUNdaMENTAL principles including theory and best practices. Topics include: initial error allocation to enable rapid design, principles of accuracy, repeatability and resolution, bearings, structures, and actuators.  Kinematic and elastic averaging-based designs and the implications for bearing life and dynamic performance are stressed with F=kx and w = sqrt(k/m) as recurring themes throughout the design of a machine.  Examples will be presented to show how FUNdaMENTAL principles are critically important for an engineer to understand in order to be able to most effectively use modern design tools such as solid modelling and finite element analysis in the design of precision machines.

Learning outcomes: 

Attendees should expect to leave with new design tools (spreadsheets) they feel comfortable applying and a host of new design ideas for selecting and integrating bearings structures and actuators in precision machines.

Intended audience:

This tutorial should be helpful for those at the beginning of their careers and also for those who wish to tune up their design approach with linking design approaches with first order analysis to develop designs more rapidly and to check output from FEA.

KU Leuven has a long-standing history in the field of EDM/ECM/laser-based manufacturing processes. In this course the fundamentals of two modern micromachining technologies namely micro-ECM and ultrashort pulse (USP) laser processing will be discussed. This tutorial will start with the review of the state of the art and the material removal mechanisms with micro-ECM and USP laser processing on different material classes ranging from metals to conductive-ceramics. The tutorial will also cover advanced developments in micro-ECM and laser micromachining carried out during past and ongoing projects at KU Leuven, specifically in process-monitoring, advanced sensing approaches, surface texturing strategies, on-machine metrology and process hybridization.

Advanced applications will be introduced such as machining of cermets and superalloys, fabrication of complex features and surface textures intended for several components including microelectronic devices, dental implants and injection moulds for high aspect ratio microneedles. The tutorial will also address the limitations of these technologies, and, finally, touch upon the possibilities of developing digital twins and advanced process sensing for micro-ECM and laser micromachining.

Topics covered:

• Fundamental principles of micro-ECM and ultrashort pulse (USP) laser processing
• Material removal mechanisms on different material classes ranging from metals to conductive cermets
• Advancements in processing capabilities and new materials
• Process-monitoring and advanced sensing technologies
• Applications: Micromachining of advanced materials and surface texturing
• Hybrid ECM processes
• Towards the development of digital twins for non-conventional micromachining technologies

Learning outcomes: 

The course covers the basics of micro-ECM and laser micromachining, from fundamentals to process monitoring and applications. It offers the participants a deeper scientific insight into these processes.

 Intended audience:

Graduates, postgraduate engineers, post-doctoral researchers, micromachining enthusiasts plus industry technical staff working in micromachining. Interdisciplinary engineers keen to learn micromachining are welcome as well.

The tutorial gives a general overview of 2D and 3D roughness measurement techniques and devices. The advantages and limitations of tactile and optical profilers are discussed. The evaluation of 2D roughness parameters such as Ra, Rz (ISO 4278, 21920) but also the more novel areal surface parameters Sa, Sq (ISO 25178) is discussed at length, showing the common mistakes. Moreover, the advanced surface parameters (Smr, Str, Spd…) to quantify surface structures are explored in depth.

Real world sample data for turned, ground, milled and lasered surfaces show the best practice to achieve repeatable and correct standards.

Learning outcomes: 

• Choosing the correct measurement devices and methods
• ISO 4278 and ISO 25178, ISO 21920
• Troubles, Pitfalls, and easy mistakes when evaluating surface roughness
• Best practice for industrial engineers

Intended audience:

This tutorial is aimed at both industrial engineers, manufacturing specialist and researchers that work with roughness measurements.

Huddersfield University has been involved in fundamental and applied research into modelling and correcting the errors in manufacturing machines since the early 1990s. This tutorial is delivered from a research group that was founded by experts from the machine tool industry and grew to encompass industrial robots and metrology instruments and the synergies (and conflicts) between them.

The interactive tutorial will cover the two key topics of metrology FOR machines and metrology ON machines. It will raise a number of questions, answer some of them and spark a conversation on the future of this vital topic in future precision manufacturing. Throughout the tutorial there will be reference to relevant ISO standards and how these play a role in establishing common ground, even where deviation from the letter of the standards is needed.

Topics covered:

• Fundamental principles of errors in manufacturing machines: the need for metrology
• Methods of measurement and sources of uncertainty: the good, the bad and the practical compromises
• Machine errors: avoid, compensate or correct?
• The pitfalls and opportunities for metrology on machines that were intended for machining
• The future: digital tools as part of “metrology” to support traditional measurement

Learning outcomes: 

This tutorial is designed for researchers and practitioners interested in machine measurement and the use of machines for measurement. One of the main outcomes is to establish a common language when discussing machine accuracy between builders, suppliers, end-users and those researching solutions to the myriad problems. You will get an overview of the problem and suggestions on how to go deeper into each of the topics.

Intended audience:

The community of researchers and practitioners working with manufacturing machines with a need for controlling accuracy. This includes graduates, postgraduate engineers, post-doctoral researchers, manufacturing engineers and those involved in procurement of manufacturing machines.