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The proposed machine design consists of a steel support structure, similar to a crane, onto which purchased pre-manufactured components and drive systems are mounted. All drives are multi-axis modular systems designed to perform the required panel handling operations. The components and multi-axis modular systems are operated with the use of pneumatics, and have basic connecting and mounting assembly arrangements. All the modular drive systems proposed as part of the machine design are combined with similar interface systems. Solutions to required stroke, load and position specifications were met by selecting appropriate multi-axis drive systems. The use of modular drive systems offered numerous advantages and included the following: a simplified and time-saving design and project planning process, a rapid system assembly, a high mechanical rigidity and the availability of existing CAD drawings for standardized design. Three main pneumatic driven modular systems are proposed within the team’s design. Two linear gantries allow for horizontal and vertical translation of the panels, two actuated swivel drive systems perform the 180° panel rotations and two gripper jaws serve to secure the panels during all handling operations.

The proposed machine design consists of a steel support structure, similar to a crane, onto which purchased pre-manufactured components and drive systems are mounted. All drives are multi-axis modular systems designed to perform the required panel handling operations. The components and multi-axis modular systems are operated with the use of pneumatics, and have basic connecting and mounting assembly arrangements. All the modular drive systems proposed as part of the machine design are combined with similar interface systems. Solutions to required stroke, load and position specifications were met by selecting appropriate multi-axis drive systems. The use of modular drive systems offered numerous advantages and included the following: a simplified and time-saving design and project planning process, a rapid system assembly, a high mechanical rigidity and the availability of existing CAD drawings for standardized design. Three main pneumatic driven modular systems are proposed within the team’s design. Two linear gantries allow for horizontal and vertical translation of the panels, two actuated swivel drive systems perform the 180° panel rotations and two gripper jaws serve to secure the panels during all handling operations.

Active magnetic bearing (AMB) is a substitute of conventional bearing, which provides electromagnetic force to support the rotating part respecting the stator. The utilization of electromagnetic force makes this bearing “active”. The attraction force of an AMB system can be control by manipulating the input so that the rotor can be levitate at required position. As lot of limitation exist in passive magnetic bearing, the AMB is very useful in modern applications. Due to frictionless nature of magnetic bearing and non-necessity of lubricants, now-a-days AMB is taking place as the alternate of any other bearing in multiple applications of growing industry. Adequate knowledge of essential components is necessary for successful implementation of any active magnetic bearing design. So, In this paper, the magnetic analysis has been analyzed for the different types of single and multi-axis AMB using ANSYS Maxwell with extensively reviewed components.

A point absorber wave energy converter (WEC) which converts wave energy into electrical energy with a multi‐axis power‐take‐off (PTO) system is considered here. Previous wave tank trials have proved the ability of the multi‐axis WEC to absorb wave power. In this study, the boundary element method (BEM) based software Ansys@ AQWATM was applied to model and analyze the power absorption performance of the multi‐axis WEC for a wider range of regular and irregular waves. To verify the numerical model, a laboratory‐scale physical model was manufactured and tested. Results show that the multi‐axis WEC can absorb more power from the incident regular wave power compared to single‐axis WECs and the efficiency reaches up to 45%. It is found that the wave frequency and incident angle significantly influence the amount of absorbed power from different motion modes and PTO axes. Then the numerical model is simulated at 12 nearshore locations in East and South China Sea. The results indicate that the multi‐axis WEC can absorb up to 5 kW and the efficiency can reach up to 29% at the most energetic site Shengshan. In addition, considerable differences of mean absorbed power efficiency can be found between sea states.

The purpose of this paper is to propose a general precision allocation method to improve machining performance of CNC machine tools based on certain design requirements. A comprehensive error model of machine tools is established by using the differential motion relation of coordinate frames. Based on the comprehensive error model, a reliability model is established by updating the primary reliability with an advanced importance sampling method, which is used to predict the machining accuracy reliability of machine tools. Besides, to identify and optimize geometric error parameters which have a great influence on machining accuracy reliability of machine tools, the sensitivity analysis of machining accuracy is carried out by improved first-order second-moment method. Taking a large CNC gantry guide rail grinder as an example, the optimization results show that the method is effective and can realize reliability optimization of machining accuracy.

Maintaining minimal levels of geometric error in the finished workpiece is of increasing importance in the modern production environment; there is considerable research on the identification, verification and calibration of machine tool kinematic error, and the development of Postprocessor implementations to generate NC-code optimised for machining accuracy. The choice of multi-axis positioning function at the controller, however, is an often-overlooked potential source of kinematic error which can be responsible for costly mistakes in the production environment. This paper presents an investigation into how mis-management of the positional error parameters that define the rotary-axes’ pivot point can lead to unintended variations in multi-axis positioning. Four approaches for kinematic positioning on a Fanuc-based controller are considered, which reference two separate parameter locations to define the pivot point – managing the kinematics within the Postprocessor itself, full five-axis positioning with a fixture offset, full five-axis with rotation tool centre point control and 3+2-axis with a tilted workplane. Error vectors across four sets of rotary-axis indexations are simulated based on the theoretical kinematic model, to highlight the expected differences in geometric error attributable to mismatched pivot point parameters. Finally, the simulation results are verified experimentally, demonstrating the importance of maintaining a consistent approach in both programming and operation environments.

Multi-axis fused deposition modelling (FDM) 3D printing technology has been paid attention to by more and more people. However, existing FDM extruders are usually short and fat, which significantly restricts the popularization of multi-axis FDM 3D printing technology because one significant trend of additive manufacturing is the use of long and thin extruders to avoid collisions between extruders and workpieces in the printing process. This paper presents the design of a throat-extended FDM extruder to print complex-shaped workpieces with details. The main contributions in this paper include: (i) presenting a novel extruder structure including an extended-throat, a smaller heater block, and a cooling mini-fan; (ii) designing an optimized heater block using the shapes of its components and the milling tool as constraints to make its volume as little small as possible; (iii) Construct experimental and simulation methods to examine the temperature distribution of the throat to optimize the shapes of the heat dams of nozzle throats and the wind speed of the heat-dissipation fan. Based on the throat-extended FDM extruder, a five-axis FDM 3D printer has been developed, and various complex-shaped workpieces have been printed without any support.

Tactile sensations are based on stimulation elicited on the skin through mechanical interactions between the skin and an object. Hence, it is important to consider skin properties as well as objects. In this article, we aim to develop wearable artificial fingers for quantitative evaluations reflecting individual differences in human fingers. In a previous study, a wearable skin vibration sensor was attached to artificial fingers and it was demonstrated that the skin vibrations differed according to the dimension of surface ridge and the artificial finger is useful for roughness evaluation. This article improved the artificial finger to measure the contact force and friction in addition to the skin vibration. A small three-axis force sensor was embedded into the base of the finger, and normal and friction forces were estimated via a multi-regression method. Furthermore, artificial fingers with different hardness were prepared and six different textures were used to investigate tactile evaluation. Experimental results showed that the artificial fingers could measure normal and friction forces along with the skin vibration and were useful to evaluate textures. Resulting distributions of the vibration intensity and friction coefficient were different for the soft and hard artificial fingers, indicating the complex influence of skin properties on tactile sensations.

Hollow blades, which are important components of aeroengines, have thin-walled structures and are subjected to vibrations in the machining process owing to its low rigidity and damping. This paper proposes an approach to enhance the machining stability of titanium hollow blades by introducing multiple damping and rigid supporters to the blade machining system in multi-axis milling process. A theoretical prediction model, considering the influence of original system, transmission and supporter, is established to predict the dynamic parameters of blade with a single damping or rigid supporter. Then, the model is applied in multi-supporter system and an optimization algorithm is used to determine reasonable positions of multiple supporters. The stability lobe diagrams of blade system with no supporter, optimized damping supporters and optimized rigid supporters are analysed and validated by blade machining experiment. The conclusion can be achieved that the sound signal is suppressed up to 40 % by adding optimized supporters and the machining stability is enhanced effectively.

The article discusses the features and areas of application of multi-axis electromagnetic mechatronic modules in modules of mechatronic and robotic systems that allow not only to increase productivity and improve the quality of manufactured products, but also by replacing heavy, monotonous and sometimes associated with a risk to human health, manual labor with a machine to release a person for creative constructive work. The generalized structure of a multi-axis mechatronic module is presented; multiple theoretical models of construction principles for the study of electromagnetic mechatronic modules of robots and robotic systems are constructed. In this case, the main attention is paid to the determination of the main and auxiliary sources of the magnetic field in such modules. An algorithm for the formation of equations for electromagnetic mechatronic modules is given on the example of an electromagnetic mechatronic module with linear motion, formed from electrical, magnetic and mechanical components interconnected with each other. The algorithm includes questions of constructing a structural model, the transition from a structural model to a structural-mode model, the choice of variables and connections between the electrical, magnetic and mechanical parts of the module, writing the equations of nodal parallel or contour sequential variables according to the structural-mode model, depending on the appropriateness of one or another method for specific components of the mechatronic module.

Purpose This study aims to investigate the relationship between part porosity and mechanical properties of short-fibre reinforced polylactic acid printed via multi-axis material extrusion (MAMEX) to establish guidelines for optimal process configurations. Design/methodology/approach Material properties graphs provide the basis for studying the relationship between porosity and mechanical behaviour. Using the correlations found in this study, the way to improve printing strategies and filament properties can be deducted directly from an analysis of the print path and the final influence on mechanical performance. Findings Some commercial brands of short-fibre reinforced filament present inherent porosity that weakens the mechanical behaviour of MAMEX components. Originality/value Low-cost MAMEX allows the production of components that do not present anisotropic behaviour and are mechanically optimised through the alignment of the filaments along with internal stresses. This paper also addresses the effects of multi-axis deposition strategies on the resulting porosity and proposes improvements to reduce residual porosity, thus increasing the mechanical performance in the future.

This paper deals with a method to optimize tool axis orientations in multi-axis milling toolpaths. The method is based on calculation of the actual cutting diameter and the cutting speed during the toolpath. Subsequently, the NC code is processed by the interpolator with a machine tool kinematic model. The result is a visualization of the actual cutting speed and the real feed-rate on the toolpath. Based on these results, the vectors used to orient the tool axis along the toolpath can be effectively set up in several iterations. The toolpath are optimized to achieve a more constant cutting speedwhich lead to an improvement in surface quality and increase in productivity.

This paper proposes a novel DVA (Dynamic Vibration Absorber) consisting of a ball-like mass embedded in a spherical viscoelastic material to meet practical demands for the multi-modal and multi-axis vibration reduction against elastic vibrations of structures. This DVA is called eMDVA (embedded Mass DVA) here, and the embedded mass can vibrate every direction in the viscoelastic medium. The unique concept of the eMDVA is inspired by the damping effect caused by passengers on railway vehicles. This paper describes a basic configuration of the eMDVA and some numerical studies using finite element (FE) vibration analysis to design the eMDVA. From the numerical investigation, it has been found that the natural frequency of a single-mass eMDVA can be controlled by changing the combination of the sizes of the viscoelastic sphere and the embedded mass. The frequency response function (FRF) of the acceleration of the embedded mass versus excitation force has a dominant single peak corresponding to one of the natural frequencies. These results indicate that the proposed eMDVA is suitable as a DVA, and it can be designed to tune the target vibration frequencies of host structures. As a more realistic analysis, numerical investigation for the thin and long plate-like host structure (a 1:10 scale model of the floor structure of a railway vehicle) was conducted, and multi-modal vibration reduction has been observed by applying the eMDVA consisting of two sets of viscoelastic spheres and embedded masses with different sizes. From these numerical investigations, it has been shown that the proposed eMDVA has promising potential as a multi-modal damper for elastic vibrations.

To clarify three-dimensional (3-D) spatiotemporal variations and horizontal–vertical transport processes in nitrogen dioxide (NO2) over urban areas, combined NO2 profile observations by multiple Multi AXis Differential Optical Absorption Spectroscopy (MAX-DOAS) and direct wind observations by 3-D coherent Doppler lidar were made over an urban area in Japan. MAX-DOAS measurements were conducted at Yakuin and Fukuoka University in Fukuoka urban area with high temporal resolution of four minutes. Enhanced NO2 concentrations were often observed over the city center. We conducted a case study on 29 November 2018 under clear sky conditions and NO2 profiles were well retrieved. Using MAX-DOAS at two locations, high NO2 concentrations were observed near the surface of the city center in the morning. Higher NO2 concentrations appearing gradually at higher altitudes over the city center and disappearing in the afternoon are explained using direct evidence of a 3-D wind field: an airmass with a high NO2 concentration was transported upward over the city center. Then, the airmass was advected landward by a sea breeze. Multiple MAX-DOAS combined with 3-D Doppler lidar constitutes a powerful tool for elucidating horizontal–vertical transport processes. It can contribute to the improvement of data retrieval by satellites for urban areas.

In this paper, an X-Y position stage simulates flexible loads completing handling or detection tasks in industrial applications are studied. The platform is driven by permanent magnet synchronous motors (PMSM) servo system, which has flexible beams with different natural vibration frequencies on the X-axis and Y-axis. The controller is designed to suppress the vibration of the flexible beams with different frequencies and reducing the contour error. The Euler-Bernoulli beam theory is adopted to obtain the mode shapes and natural frequencies of the flexible beam with clamped and endpoint mass boundary conditions. Analysis shows that the first-order vibration mode contributes the most to the displacement of the flexible beam. The trajectory motion profile based on time-shifted cosine jerk central angle interpolation (CJCI) contains prefilter to suppress low vibration frequencies in the two beams, which does not cause distortion of the actual contour. The linear phase lead iterative learning control (ILC) combined with the contour of CJCI is proposed to reduce the tracking errors of each axis, thereby reducing the overall contour error. The analysis and design process of ILC in frequency domains, which is applied to alleviate noise and disturbance effects. Comparison experiments confirm the effectiveness of the proposed method.

This paper presents the development of a sixaxis force/torque (FTS) sensor using crossbeams for a robotic arm. The sensor produced in this paper is a new unique design that was developed under rigorous trial and testing using finite element analysis (FEA) at every stage of development. Additionally, the FTS presented uses strain gauge technology and data-acquisition (DAQ) to measure and record forces in Fx, Fy, and Fz direction along with torque in Mx, My, and Mz direction. FTS was tested, calibrated, and fitted on a robotic arm to test its accuracy and repeatability

Using objective vibration evaluation to produce results highly consistent with real road ride comfort is challenging. The deficiencies in traditional evaluation indices, adopting an average operator, maximum operator, or cumulative operator as the main vibration information integration logic, are reported here through 19 designed road field tests in which major vibration information distribution covers all axes and vibration information is distributed in spacetime in various patterns. A new evaluation index which adopted a combination of maximum and cumulative operator is proposed to overcome these deficiencies and an interactive mechanism which standardized the process of selecting vibration information distributed among axes and spacetime is devised between the localized major vibrations. The results show that the proposed road ride comfort evaluation index is more consistent and accurate than the evaluation indices proposed by ISO 2631-1 and can be used more generally.

This paper presents a novel method to identify the squareness errors of computer numerical control (CNC) machine tools based on double ball bar (DBB) measurements. A series of spherical S-shaped paths are proposed to measure the squareness errors, instead of the generally used circular detection paths since the presented method requires only one experimental setup, and three translation axes are linked, which is more convenient and comprehensive. In this article, the coordinate transformation method and the method for dividing experimental paths evenly are used to solve the asynchronization between actual motion and DBB sampling process. The experimental data is then combined with the product of exponential (POE) model to calculate the three CNC machine tool squareness errors and applied to a spherical spiral testing path with the compensation of the diagnosed errors. The effectiveness of the method is verified by comparing the experimental results before and after the compensation.

Brass materials are widely used in many fields of machinery, especially plumbing applications. Parts produced from brass are processed in lathes or milling machines during the manufacturing phase. In this study, 6-corner pieces were produced by machining the MS58 brass alloy on the C-axis lathe with an end mill. As machining parameters, tool diameter, feedrate and rotation speed were selected. The effects of these parameters on average surface roughness (Ra), cutting time (t) and dimensional deviation (dev) were determined by the surface response method. Regression equations were created separately for surface roughness, cutting time and dimensional deviation. Later, parameter levels that optimize all three dependent variables together were obtained by grey relationship analysis. It was determined that the most effective parameter on surface roughness and dimensional deviation is the tool diameter. The most effective parameter on cutting time was found to be feedrate. The best combination of machining parameters was 10 mm tool diameter, 150 mm/min feedrate and 1000 rev/min rotation speed. The selection of parameters depends on the requirements based on better surface roughness, minimum cutting time, minimum dimensional deviation. Parameter levels that optimize surface roughness only are 10 mm tool diameter, 50 mm/min feedrate and 1000 rev/min rotation speed. Parameter levels that optimize cutting time only are 8 mm tool diameter, 143 mm/min feedrate and 1525 rev/min rotation speed. Parameter levels that optimize cutting time only: 10.31 mm tool diameter, 50 mm/min feedrate and 1000 rev/min rotation speed.

The high surface quality of free-form machined products is demanded by the industries. There were several different approaches proposed in the literature for improving the roughness/texture of machined surface, from tool path generation, tool orientation identification, tool geometry selection, to tool assembly error investigation on the causes and solutions. However, the traces caused by the asynchronous behavior of multi-axis tools were not widely discussed. This study explores the telltale surface characteristic left behind by a ball-end milling operation, using from the image process of scallops/cusps figure of the workpieces, through the spectrum/FFT (fast Fourier transform) plot to identify the parallel of the tool path and the types of traces. Using the distribution of peak frequency and related bandwidth as an index for the performance of synchronous machining, it will reveal the parameters setting of different motion control and the compliance of the dynamic synchronous motion. The tendency of performance index matched the measured roughness result of the workpieces.

In this paper, an optimized error sensitivity analysis (ESA) approach based on stream-of-variation (SOV) theory in multi-axis precise motion platform (MPMP) is introduced. Unlike the conventional ESA method, this approach utilizes stream-of-variation theory to establish error model firstly. By regarding each axis as a station, the error propagation and deviation accumulation processes are clear station by station. Through obtaining the deviations after each station, the sensitive stations can be developed, and corresponding error terms are collected. Thus, by analyzing the appearance frequency of the errors, a precise sensitive order can be developed, and a sensitivity results with different steps is given. Through ignoring the insensitive and irrelevant errors, the computational volume of error model can be saved, and the efficiency can be improved. A case study about a typical MPMP used in laser welding system (LWS) is carried out, and the results indicate that the optimized ESA approach is more efficient and accurate, and it is flexible as well. This ESA approach is not only accurate in developing sensitive levels, but also balancing the systematic accuracy and working efficiency, which is helpful to provide informative guide to engineers.

This paper presents a systematic approach for selecting the optimal moving order (MO) in a multi-axis precise motion system (MPMS). According to the proposed procedure, an optimal high-efficiency MO selection approach for high-efficiency and high-accuracy requirement is introduced. First, the characteristics of the giving MPMS are analysed, and the error model is established. The orthogonal test method is used to evaluate the influence on the MO caused by different MPMS configurations. Second, the number of possible MOs can be narrowed to limited and satisfied MO types. By calculating the deviations after each step, all directional movements can be arranged. Third, considering that both the accuracy and efficiency are important indexes, a series of systematic formulations are developed to select the optimal MO to balance accuracy and efficiency. A case for which a six-axis precise platform is adopted in an optoelectronic packaging system is implemented, and the methods of high-quality MO selection are verified by performing a series of experiments, and the methods are shown to be useful and effective. To balance the proportion of efficiency and accuracy, the formula and corresponding model are proposed to select the MO. The approach is not only beneficial to the accuracy improvement and trajectory planning of MPMS, but also helpful in terms of reducing the computational processing for the following algorithm. For the engineers using in precise industry area, the proposed approach can significantly improve the operative precision of MPMS with an optimal MO. This methodology of MO can also be the basis of references to error-related analyses on MPMS.

Tool path planning is critical to fully realise the producing capabilities of multi-axis machine tools and improve the precision and efficiency in multi-axis machining. Up to now, more than 400 art...

Severe plastic deformation (SPD) processing techniques are applied to polycrystalline metallic materials in order to refine the grain size up to the sub-micrometre or nanometer level. The decrease in grain size to a sub-micrometre level is related to beneficial mechanical properties such as very high strength. The most widely applied SPD method is equal-channel angular pressing (ECAP). In distinction to traditional cold rolling or drawing, SPD techniques frequently employ cyclic strain paths that can lead to an essentially unchanged shape of the material sample after processing. In this paper, multi-axis compression is applied by using the MAXStrain (R) unit to impose cyclic compression in two mutually orthogonal directions. This study is aimed to realize the evolution of microstructure and mechanical properties of AlMg5Si2Mn aluminium cast alloy subjected to multi-axis compression. The microstructure of the alloy in the as-cast and as deformed state was characterized by light and scanning electron microscopy. The results reveal that multi-axis compression has a great influence on the evolution of microstructure and final mechanical properties. The enhanced mechanical properties are associated with the progressive formation of refined microstructure which is heterogeneously distributed across the sample.

The demands for filleted end milling with high efficiency are increasing more and more. Path interval determination is one of the computational processes in the tool path generation, and its development can offer further improvement in multi-axis filleted end milling. However, to our knowledge, the practical approach has been hardly proposed so far. Hence, this study proposes a novel algorithm to determine a suitable path interval in multi-axis filleted end milling with a tool inclination. The procedure with wide applicability and robustness was described based on the 3D geometrical consideration of filleted end mill. Then, the characteristics of procedure were discussed with the visual data obtained from the computational results.

Vibration assisted machining (VAM) is a method that is widely used in improving the performance of machined products. External vibrations with high frequency to ultrasonic range along with an meso-micrometer amplitude are given to the cutting tool or workpiece. This will result in a periodic separation phenomenon, hence reducing the cutting force which has positive impacts on increasing tool life and machined surface quality. Among the high-precision machining processes, micro-milling which has the ability to produce complex components with 2D and 3D features, can also be applied with the vibration assisted method, known as vibration assisted micro-milling (VAMM). Based on the direction of vibration given in the machining process, there are 1D VAMM with linear vibrations and 2D VAMM with circular or elliptical trajectory vibrations. However to date, neither developed 1D nor 2D VAMM systems are still limited to the research of planar surfaces cutting using linear movement axes, meanwhile vibration assisted in inclination cutting of micro-milling using the rotational movement axes is still very rare. Therefore the purpose of this paper is to present the preliminary model in designing a 2D VAMM system for a 5-axis micro-milling machine. The system is powered using piezoelectric actuators as the vibration-producing actuators.

This research discusses the development and validation of a sustainable process chain for the efficient manufacturing of prototype gears for automotive applications. To reach the objectives, a selective laser hardening set-up has been integrated into a multi-axis machining platform. This allows to machine and harden gears in a single production center. In this research, 3 automotive drivetrain gears, representing a set of geometrical features (gear flanks,…) and materials, were manufactured and validated. Using the integrated laser hardening set-up, uniform hardness profiles were achieved on the different features while all measured quality parameters were within required tolerances.

In the process of multi-axis contour tracking control, the traditional time-invariant method could lead to a significant error in contour tracking due to the existence of two different motion conditions, namely single-axis independent motion and multi-axis coupled motion. In order to tackle this issue, a time-varying weighting matrix has been developed considering the trajectory and time-varying random disturbance. In this paper, a time-varying control method for multi-axis motion based on norm optimal cross-coupling iterative learning is proposed. Compared to the time-invariant control method, the simulation and experiment results demonstrate that the proposed method can effectively reduce the contour error improving the multi-axis control precision.

Additive manufacturing technology develops very dynamically in terms of new processes, materials and areas of application. Cost intensive post processing, especially removal of support structures is one big challenge in material extrusion (ME) processes and drives development of new machine designs like 5-axis printers. Currently, time intensive manual programming of machine code is necessary in order to slice parts for multi-axis printing. This paper deals with an experimental study of state-of-the-art 3D-printers developing a feature-based print method for multi-axis systems by using an adaptive layer height while reducing support structures and stair-step effect. Computer-aided manufacturing for ME is investigated in order to develop a geometric model for trajectory planning.

The multi-axis force–torque sensor is a key element of many accurate force and motion control systems, including intelligent robotic systems. This paper presents a novel elastic structure for multi-axis force–torque sensors that is easily manufacturable at low cost and has many detection points with high surface strains. By using the “design of experiment” method in the ANSYS software, we demonstrate that the designed elastic structure with four identical T-shapes has high surface strains and can provide various strain gauge configurations. The strain sensitivities of the elastic structure at predetermined points can be maximized manually by varying the thickness of the vertical and horizontal beams of the T-shaped components. The validity of the proposed elastic structure is demonstrated through the development of a low-cost six-axis force–torque sensor. Experimental results for the developed force–torque sensor with the proposed elastic structure demonstrate that the proposed structure is comparable to an expensive state-of-the-art commercial force–torque sensor.

The article deals with the description of the production of a shaped part composed of an outer pyramid and cylindrical surface, of inner cylindrical surfaces of different diameters and of an inner tongue groove. It describes the proposed tools and tool holders resulting from the technological process. In order to meet the required tolerances and shape deviations for the given component, the CTX alpha 500 two-spindle multi-axis CNC lathe was chosen for its production. Its control system enables the workshop method of programming and simulation of individual operations in automatic mode or in block-by-block mode. The design of the selected CNC lathe enables the machining of rotary parts in one clamping, which is ensured by the right and left spindle with chucks. The surface quality of the pyramidal surface and the internal diameter of D18H8 was measured using a Hommel Etamic W5 roughness gauge. The measured roughness values for the hole were: D = 18H8, Rz = 3.007 μm, Ra = 0.729 μm and for the pyramidal surface: Rz = 1.527 μm and Ra = 0.329 μm.

In recent decades additive manufacturing has transformed from a set of prototyping meth- ods to a mature set of industrial level manufacturing processes. To achieve predictable and high-quality end-use products, these processes require the application of high-quality process planning solutions. This research questions the common perception that the nature of additive manufacturing processes has led to making process planning for additive manufacturing a trivial step. It is shown that duplicating process planning strategies from subtractive process planning algo- rithms leads to suboptimal results for their additive counterparts. The main focus of the re- search is thus the development of multi-axis process planning strategies that take the specific requirements of direct material deposition techniques (FDM, DED) into account. The research presented in this thesis starts with the state of art on multi-axis additive man- ufacturing. CNC based subtractive manufacturing strategies and established subtractive process planning steps and terminology are used as a starting point to address the specific challenge of process planning for additive manufacturing. The next chapters describe the development of two novel algorithms for multi-axis additive manufacturing path planning. The first algorithm is based on geometry decomposition that partitions the main geometry into sections with similar functional requirements. Within a partition, material is deposited using constant printing settings, while between the partitions the main deposition direction is optimized. The second algorithm is focused on calculating continuous multi-axis tool paths following the part surface geometry, thus preserving smooth motion of nozzle orientation and collision freeness of the additive manufacturing process. Simulations and physical ex- periments have been executed to validate the strategies proposed. The developed algorithm for multi-axis additive manufacturing reduced the surface roughness due to stair-case effect by 57% compared to 2.5D AM for the test part used.

Flexure hinges are basic elements for constructing compliant mechanisms for micro/nano positioning. So far, few investigations have been presented on the multi-axis flexure hinges especially with revolute type notch due to the limitation of manufacturing. In this study, the revolute-notch type multi-axis flexure hinge with Circular-Elliptical-Arc-Hybrid (CEAH) notch profile is investigated. The analytical compliance equations of the CEAH flexure hinges are developed. Finite element analysis (FEA) is carried out to confirm the presented analytical model. Finally, application of the CEAH revolute-notch type flexure hinges is discussed. The presented study demonstrates that the CEAH revolute-notch type multi-axis flexure hinges have potential advantages in developing novel spatial monolithic compliant mechanisms for three dimensional micro/nano-positioning.