The Texas A&M Flight Research Laboratory (FRL) recently received delivery of its newest aircraft, the Velocity XL-5 RG. The Velocity can fly faster than the other aircraft owned by the FRL and does not have a propeller in the front of the aircraft to disrupt the air flow. These are definite advantages that make the Velocity an attractive addition to the FRL inventory to be used in boundary-layer stability and transition control. Possible mounting locations built into the aircraft for future projects include hard points in the wings and roof of the fuselage. One of the drawbacks of the aircraft is that it has a canard ahead of the main wing that could disrupt the incoming flow for a wing glove or research requiring test pieces mounted to the hard point in the wing. Therefore, it is necessary to understand the influence the canard and the impact of its wake on the wing of the aircraft before any in-depth aerodynamic research could be completed on the aircraft. A combination of in-flight measurements of the canard wake and Computational Fluid Dynamics (CFD) were used to provide a clear picture of the flowfield around the aircraft. The first step of the project consisted of making a 3-D CAD model of the aircraft. This model was then used for the CFD simulations in Fluent. 2-D, 3-D, inviscid, and viscous simulations were preformed on the aircraft. A pressure rake was designed to house a 5-hole probe and 18 Pitot probes that extended forward of the main wing to measure the location and strength of the canard wake at various flight conditions. There were five primary test points that were recorded at multiple times over the course of three flights. Once all of the data were collected from the flights, the freestream conditions became the inputs into the final, 3-D CFD simulations on the aircraft. The good agreement between the CFD results and the in-flight measurements provided the necessary verification of the CFD model of the aircraft. These results can be used in the future planning and execution of experiments involving the Velocity XL-5 RG.

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Nowadays, the need for three-dimensional miniaturized components is increasing in many areas, such as electronics, biomedics, aerospace and defence, etc. To support the demands, various micro-scale fabrication techniques have been further introduced and developed over the last decades, including micro-electric-mechanical technologies (MEMS and LIGA), laser ablation, and miniature machine tools (mMTs). Each of these techniques has its own benefits, however miniature machine tools are superior to any others in enabling three-dimensional complex geometry with high relative accuracy, and the capability of dealing with a wide range of mechanical materials. Thus, mMTs are emerging as a promising fabrication process. In this work, various researches have been carried out based on the mMTs. The thesis presents micro-machining, in particular, micro-milling force model and three relevant subsystems for miniature machine tools (mMTs), to enhance machining productivity/efficiency and dimensional accuracy of machined parts. The comprehensive force model that predicts micro-endmilling dynamics has been developed. Unlike conventional macro-machining, the cutting mechanism in micro-machining is complex with high level of non-linearity due to the combined effects of edge radius, size, and minimum chip thickness effect, etc., resulting in no chip formation when the chip thickness is below the minimum chip forming thickness. Instead, part of the work material deforms plastically under the edge of a tool and the rest of the material recovers elastically. The developed force model for micro-endmilling is effective to understand the micro-machining process. As a result, the micro-endmilling force model is helpful to improve the quality of machined parts. In addition, three relevant subsystems which deliver maximum machining productivity and efficiency are also introduced. Firstly, ultrasonic atomization-based cutting fluid application system is introduced. During machining, cutting fluid is required at the cutting zone for cooling and lubricating the cutting tool against the workpiece. Improper cutting fluid application leads to significantly increased tool wear, and which results in overall poor machined parts quality. For the micro-machining, conventional cooling methods using high pressure cutting fluid is not viable due to the potential damage and deflection of weak micro-cutting tools. The new atomization-based cutting fluids application technique has been proven to be quite effective in machinability due to its high level of cooling and lubricating. Secondly, an acoustic emission (AE)-based tool tip positioning method is introduced. Tool tip setting is one of the most important factors to be considered in the CNC machine tool. Since several tools with different geometries are employed during machining, overall dimensional accuracy of the machined parts are determined by accurate coordinates of each tool tip. In particular, tool setting is more important due to micro-scale involved in micro-machining. The newly developed system for tool tip positioning determines the accurate coordinates of the tool tip through simple and easy manipulation. At last, with the advance of the 3D micro-fabrication technologies, the machinable miniaturized components are getting complex in geometry, leading to increased demand on dimensional quality control. However, the system development for micro-scale parts is slow and difficult due to complicated detection devices, algorithm, and fabrication of a micro-probe. Consequently, the entire dimensional probing system tends to become bulky and expensive. A new AE-based probing system with a wire-based probe was developed to address this issue with reduced cost and size, and ease of application. / Graduate