High precision smart machining has tremendous potential and is becoming the next generation of precision machining technology. Smart machining processes will enable a level of adaptability, which also lead to high process reliability, high precision, machining process optimization, plug-and-produce operations, and bespoke high value applications.
This presentation will present some innovative design concepts and, in particular, the development of three types of smart cutting tools: a force-based smart cutting tool, a temperature-based internally-cooled smart cutting tool, and a fast tool servo (FTS) as required for precision and micro manufacturing purposes. Practical implementation and application issues for these smart cutting tools are explored and discussed, considering the requirements for smart machining from a number of industrial applications, such as contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications. Additional research on smart tooling implementation aspects will also be presented including: (a) plug-and-produce design principle, (b) novel cutting force modelling and the associated implementation algorithms, (c) piezoelectric film and surface acoustic wave transducers to measure cutting forces, (d) critical cutting temperature reduction and control in real-time machining, (e) in-process calibration through machining trials, (f) Multi-physics based design and analysis of smart cutting tools, and (g) application exemplars on smart machining.
The presentation will conclude with further discussion on the potentials and applications of smart tooling development for a broader manufacturing
Professor Kai Cheng holds the chair professorship in Manufacturing Systems at Brunel University. His current research interests focus on precision and micro manufacturing, design of high precision machines, smart tooling, and sustainable manufacturing and systems. Professor Cheng has published over 160 papers in learned international journals and referred conferences, authored/edited 6 books and contributed 6 book chapters.
Professor Cheng is a fellow of the IET and IMechE. He is the head of the Micro/Nano Manufacturing Theme at Brunel University, which consists of 12 academics and over 50 research assistants/fellows and PhD students. Professor Cheng and the team are currently working on a number of research projects funded by the EPSRC, EU 7th Framework Programs, Technology Strategy Board (UK), KTP Programs and the industry. Professor Cheng is the European editor of the International Journal of Advanced manufacturing Technology and a member of the editorial board of International Journal of Machine Tools and Manufacture. Professor Cheng is also honored with the ‘Qianren’ professorship at Harbin Institute of Technology.
Professor Kai Cheng BEng MSc PhD FIMechE FIET CEng
Chair in Manufacturing Systems
Institute of Materials & Manufacturing
College of Engineering, Design and Physical Sciences
Brunel University, UK