DEVELOPMENT OF AN MULTIPURPOSE MICRO MANUFACTURING SYSTEM USING MODULAR AND ITERATIVE LEARNING CONTROL ALGORITHMS

Devam Eden Proje

Tubitak 1001

SUMMARY

In this project proposal, submitted for the March 2013 period, development of a micro manufacturing system which can produce precision parts is proposed using the results and investment (i.e. knowledge, hardware, software and experience) from the previous project. Due to the flexible nature of the system, different controller and device topography and manufacturing methods including micro laser machining, rapid micro prototyping and micro milling will be studied using a common modular MIMO control algorithm. This kind of systems where multiple manufacturing methods are used on one single machine is known as hybrid manufacturing systems in the literature.

Development of an Multipurpose Micro Manufacturing System using Modular and Iterative Learning Control Algorithms

RELATED PUBLICATIONS

  • Karpat, Y. (2023). "Investigating elastic recovery of monocrystalline silicon during plunging experiments with chamfered diamond tools", Precision Engineering, v.84 p.119-135 (in press)
  • Masrani, A., Y. Karpat (2023). "Using micro-milled surface topography and force measurements to identify tool runout and mechanistic model coefficients", The International Journal of Advanced Manufacturing Technology, v.125(11-12) p.5323–5343
  • E. Guven, Y. Karpat, M. Cakmakci (2022). "Improving the dimensional accuracy of micro parts 3D printed with projection-based continuous vat photopolymerization using a model-based grayscale optimization method", Additive Manufacturing, v.57(102954)
  • Karpat, Y. (2022). "Surface integrity of monocrystalline silicon nanostructured with engineered multi-tip diamond tools", The International Journal of Advanced Manufacturing Technology, v.120(5-6) p.3893-3993
  • A. Aksın, Y. Karpat (2022). "A model-based investigation of tool-chip friction during precision micro cutting of commercially pure titanium alloy", International Journal of Mechatronics and Manufacturing Systems, v.15(1) p.57-69
  • Y. Karpat (2022). "Investigating flank face friction during precision micro cutting of commercially pure titanium via plunging tests with diamond grooving tools", Journal of Materials Processing Technology, v.299(117376)
  • Y. Karpat, U. Karagüzel, O. Bahtiyar (2020). "A thermo-mechanical model of drill margin-borehole surface interface contact conditions in dry drilling of thick CFRP laminates", International Journal of Machine Tools and Manufacture, v.154(103565)
  • Y. Karpat (2019). "Influence of diamond tool chamfer angle on surface integrity in ultra-precision turning of singe crystal silicon", Int. Journal of Advanced Manuf. Tech., v.101(5-8) p.1565-1572
  • S. Oliaei, Y. Karpat (2019). "Modeling and Analysis of Tool Deflections in Tailored Micro End Mills", International Journal of Mechatronics and Manufacturing Systems, v.12(1) p.20-37
  • S. Oliaei, Y. Karpat, J. Paulo Davim, A. Perveen (2018). "Micro Tool Design and Fabrication: A Review", Journal of Manufacturing Processes, v.36 p.496-519
  • M. Ahmadi, Y. Karpat, Ö. Acar, E. Kalay (2018). "Microstructure effects on process outputs in micro scale milling of heat treated Ti6Al4V titanium alloys", Journal of Materials Processing Technology, v.252 p.333-347
  • S Oliaei, Y. Karpat (2018). "Polycrystalline diamond end mill cutting edge design to improve ductile-mode machining of silicon", Precision Engineering, v.51 p.403-414
  • E. Gozu, Y. Karpat (2018). "Uncertainty analysis of force coefficients during micromilling of titanium alloy", International Journal of Advanced Manufacturing Technology, v.93(1-4) p.839-855
  • Y. Karpat, S. Oliaei, M. Kanlı (2018). "Mikro Frezeleme İşleminin Takım Eksen Sapması Göz Önüne Alınarak Mekanistik Modellemesi", Gazi Üniversitesi Mühendislik-Mimarlik Fakültesi Dergisi
  • Oliaei, S., Karpat, Y. (2017). "Built-up edge effects on process outputs of titanium alloy micro milling", Precision Engineering (in press)
  • Oliaei, S., Karpat, Y. (2017). "Investigating the influence of friction conditions on finite element simulation of micro scale machining with the presence of built-up edge", The International Journal of Advanced Manufacturing Technology (in press)
  • Karpat, Y., Oliaei, S.N. (2016). "Influence of tool wear on machining forces and tool deflections during micro milling", The International Journal of Advanced Manufacturing Technology, v.84 p.1963-1980
  • Karpat, Y., Oliaei, S.N. (2016). "Investigating the influence of built-up edge on forces and surface roughness in micro scale orthogonal machining of titanium alloy Ti6Al4V", Journal of Materials Processing Technology, v.235 p.28-40
  • Karpat, Y., Bahtiyar, O. (2015). "Tool geometry based prediction of critical thrust force while drilling carbon fiber reinforced polymers", Advances in Manufacturing, v.3 p.300-308
  • Zeinali, S., Çetin, B., Oliaei, S., Karpat, Y. (2015). "Fabrication of continuous flow microfluidics device with 3D electrode structures for high throughput DEP applications using mechanical machining", Electrophoresis, Special Issue on Dielectrophoresis, v.36(13) p.1432-1442, DOI: http://onlinelibrary.wiley.com/doi/10.1002/elps.201400486/full
  • Oliaei, S., Özdemir, C., Karpat, Y. (2014). "Fabrication of Micro Ball End Mills Using Micro Electro Discharge Machining", Int. J. of Mechatronics and Manufacturing Systems
  • Karpat, Y., Değer, B., Bahtiyar, O., Kaftanoğlu, B. (2014). "A Mechanistic Approach to Investigate Drilling of UD-CFRP Laminates with PCD Drills", CIRP Annals – Manufacturing Technology, v.63
  • Karpat, Y., Değer, B., Bahtiyar, O. (2014). "Experimental Evaluation of Polycrystalline Diamond Tool Geometries while Drilling Carbon Fiber Reinforced Plastics", Journal of Advanced Manufacturing Technology, v.71/5 p.1295-1307
  • Karpat, Y., Değer, B., Bahtiyar, O. (2012). "Mechanistic Force Modeling for Milling of Unidirectional Carbon Fiber Reinforced Polymer Laminates", International Journal of Machine Tools and Manufacture, v.56 p.79
  • Karpat, Y., Değer, B., Bahtiyar, O. (2012). "Drilling Thick Fabric Woven CFRP Laminates with Double Point Angle Tools", Journal of Materials Processing Technology, v.212 p.2117
  • Karpat, Y. (2011). "Temperature Dependent Flow Softening of Titanium Alloy Ti6Al4V: An Investigation Using Finite Element Simulation Of Machining", Journal of Materials Processing Technology, v.211 p.737
  • Karpat, Y. (2010). "A Modified Material Model for the Finite Element Simulation of Machining Titanium Alloy Ti6Al4V", Machining Science and Technology, v.14 p.390
  • Karpat, Y. (2009). "Investigation of the Effect of Cutting Tool Edge Radius on Material Separation due to Ductile Fracture in Machining", International Journal of Mechanical Sciences, v.51 p.541
  • Y. Karpat and T. Özel (2008). "Process Simulations for 3-D Turning using Uniform and Variable Micro-Geometry PcBN Tools", International Journal of Machining and Machinability of Materials, v.3(3)
  • Karpat, Y., Özel, T. (2008). "Mechanics of High Speed Cutting with Curvilinear Edge Tools", International Journal of Machine Tools and Manufacture, v.48 p.195
  • Karpat, Y., Özel, T. (2008). "Analytical and Thermal Modeling of High-Speed Machining with Chamfered Tools", ASME Journal of Manufacturing Science and Engineering, v.130 p.011001
  • Özel, T., Karpat, Y., Srivastava, A. (2008). "Hard Turning with Variable Micro-Geometry PcBN Tools", CIRP Annals, v.57 p.73
  • Karpat, Y., Özel, T. (2007). "Multi-Objective Optimization For Turning Processes Using Neural Network Modeling And Dynamic-Neighborhood Particle Swarm Optimization", International Journal of Advanced Manufacturing Technology, v.35 p.234
  • Özel, T., Karpat, Y. (2007). "Identification of Constitutive Material Model Parameters for High-Strain Rate Metal Cutting Conditions Using Evolutionary Computational Algorithms", Materials and Manufacturing Processes, v.22 p.659
  • Özel, T., Karpat, Y., Figueira, L., Davim, J. (2007). "Modeling of Surface Finish and Tool Wear in Hard Turning of AISI D2 Steel Using Ceramic Wiper Inserts", Journal of Materials Processing Technology, v.189 p.192
  • Karpat, Y., Özel, T. (2006). "Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process. Part I: Predictions of Tool Forces, Stresses and Temperature Distributions", ASME Journal of Manufacturing Science and Engineering, v.128 p.435
  • Karpat, Y., Özel, T. (2006). "Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process. Part II: Effect of Tool Flank Wear on Tool Forces, Stresses and Temperature Distributions", ASME Journal of Manufacturing Science and Engineering, v.128 p.445
  • Özel, T., Karpat, Y. (2005). "Predictive Modeling of Surface Roughness and Tool Wear in Hard Turning using Regression and Neural Networks", International Journal of Machine Tools and Manufacture, v.45 p.467
  • Karpat, Y., Bahtiyar, O. (2015). "Comparative analysis of PCD drill designs during drilling of CFRP laminates", Procedia CIRP, v.31 p.316-321
  • Oliaei, S., Karpat, Y. (2014). "Experimental Investigations on Micro Milling of Stavax Stainless Steel", CIRP High Performance Cutting Conference
  • Oliaei, S., Özdemir C.,, Karpat, Y. (2013). "Fabrication of Micro Ball End Mills Using Micro Electro Discharge Machining", 7th International Conference And Exhibition on Design and Production of Machines and Dies/Molds
  • Karpat, Y., Değer, B. B. O. (2012). "Mechanistic Force Modeling for Milling of Unidirectional Carbon Fiber Reinforced Polymer (CFRP) Laminates", 5th CIRP Conference on High Performance Cutting, Zurich