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Micro cutting is becoming increasingly important since miniature and micro components/products have become more and more demanded in precision engineering applications and consumer goods in a daily life. Meanwhile, it has not been thoroughly investigated yet. Scientific understanding of the fundamentals in micro cutting mechanics and physics is vital for micro manufacturing of micro or miniature components and products. Consequently, the scientific investigation on micro cutting mechanics is critically needed, particularly on its key fundamental aspects on which a systematic approach and key enabling technologies are developed for micro manufacturing. Therefore, three key fundamental aspects of micro cutting mechanics have been identified for this PhD project and a comprehensive systematic research has been performed through both theoretical and experiment-based investigations. The three aspects of micro cutting mechanics mainly include dynamic stiffness investigation, innovative micro cutting force modelling, and the study on micro cutting heat, temperature and their partitioned distribution. All experiment-based investigations are undertaken on a diamond turning machine test rig supported with a fast tool servo (FTS) using different reconfigured experimental setups. The finite element (FE)-based analysis is conducted to further support the in-depth analysis on the micro cutting phenomena especially the modelling and simulation of micro cutting force and temperature. Accordingly, both micro cutting force modelling and micro cutting temperature are investigated using modelling and simulation supported by well-designed experimental cutting trials and validations. The investigation on dynamic stiffness in the micro cutting system is focused on its effects on the micro cutting process and its control strategies. The burrs formation and machining accuracy are explored in relation with control of the dynamic stiffness. Furthermore, the control algorithm for dynamic stiffness is developed accordingly in order to minimise burrs formation and stabilize the micro cutting accuracy. The micro cutting force modelling is performed based on specific cutting force, i.e. modelling the cutting force at the unit cutting length or area as coined as the amplitude aspect of the proposed cutting force modelling. The cutting force against a dynamically varied cutting time interval is proposed as the spatial aspect of the cutting force formulation. The amplitude aspect can provide the insight into the micro cutting phenomena particularly in relation with the chip formation and size-effects. The spatial aspect, using a on the wavelet transform (WT) technique and standard deviation analysis can render the dynamic behaviour of the micro cutting force, particularly representing the dynamic effects of the cutting process and its correlation with tool wear. The micro cutting temperature is investigated to formulate the scientific understanding of cutting temperature, heat and their partitioned distribution particularly at the tool-workpiece-chip interface zone in ultraprecision and micro cutting using a diamond cutting tool. The contribution to knowledge at this aspect is to represent the partitioned cutting heat in the micro cutting process and their different behaviours compared to the conventional metal cutting. The scientific approach to modelling micro cutting application (MMCA), i.e. based on modelling-simulation combined with experimental validation, is further evaluated and validated to illustrate the overall benefits of this research investigation through micro cutting of single crystal silicon (for ultraprecision machining of large-sized infrared devices). This approach is established in light of combining all the three aspects of the above investigation on micro cutting mechanics. The research results show the approach can lead to industrial scale advantages for ultraprecision and micro cutting but driven by the scientific understanding of micro manufacturing technology. The systematic investigation on dynamic stiffness control, micro cutting force modelling, micro cutting heat and temperature and their integrated approach can contribute well to the future micro cutting applications.

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Thesis (M.S.)--Worcester Polytechnic Institute. / UMI no. 30-31030. Keywords: chip breaking; prediction; turning; grooved inserts. Includes bibliographical references (p. 113-121).

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The thesis deals with the design and production technology of the front hub for a mountain bike. The research focuses primarily on the various control systems of CNC machining apparatuses. The second chapter is devoted to the elemental differentiation of hubs, the concept of personal design of the hub, and the characteristics of the materials for its production and its verification using the FEM analysis. The third chapter deals with the design of a workpiece, instruments and the manufacturing process itself. The design of an NC program constructed in the SinuTrain 4.8. software is dealt with in the fourth chapter. The last part is devoted to the technical and economic evaluation of the proposed solution.

This diploma thesis deals and comprehensively unifies the theoretical knowledge in the field of turning, grooving and parting of material. Furthermore, the thesis also deals with the theory of cutting tool materials as well as tool’s construction and shape characteristics. In the practical part of the thesis there is proposed procedure and conditions necessary to perform the experiment of the tool force loaded measurements, as well as the technical description of the grooving process. Last but not the least, all the measured data is evaluated and plotted into dependencies, from which the results and recommendations for the optimal groove cutting with the particular cutting tool are made.

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This thesis is concerned with the structural analysis of dyestuffs in their natural solid state by the application of solid-state nuclear magnetic resonance. These dysetuffs are all derived from the phenylazobenzene group, but tautomerism can produce structural changes, which have so far been uncharacterised in the solid-state for many of the dyestuffs currently under investigation. The information obtainable from (^13)C and (^15)N chemical shifts, both isotropic and anisotropic will be applied in this structure determination. Under magic-angle spinning the anisotropic nature of solid-state interactions is partially averaged or removed. The rotational resonance technique will be presented, which reintroduces the homonuclear dipolar interaction allowing dipolar coupling constants to be measured. Second-order effects arising from the (^14)N quadrupole interaction broaden spin-1/2 lines (RDC) in such a manner that bond lengths can be determined. This RDC analysis will be applied to a series of hydrazone structures to determine the (^15)N-(^14)N bond length within the hydrazone linkage. Finally, the two-dimensional magic-angle turning experiment will be discussed and applied to both the (13)C and (^15)N nuclei for a range of dyestuffs to show that accurate shielding tensor information can be obtained from large molecules.