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(Đồ án hcmute) analysis and optimization design new 1 dof compliant stage based on additive manufacturing method with circular hinge for highly position accuracy

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MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT MAJOR MECHANICAL ENGINEERING TECHNOLOGY RESEARCH AND IMPLEMENTATION OPTIMIZATION DESIGN NEW 1-DOF COMPLIANT STAGE BASED ON ADDITIVE MANUFACTURING METHOD WITH CIRCULAR HINGE FOR HIGHLY POSITIONING ACCURACY ADVISOR: DR DANG MINH PHUNG STUDENT: NGUYEN QUOC HUY DO PHAN TUONG VY SKL009919 Ho Chi Minh city, February 2023 HO CHI MINH UNIVERSITY OF TECHNOLOGY AND EDUCATION FALCUTY FOR HIGH QUALITY TRAINING DEPARTMENT OF MACHINERY MANUFACTURING TECHNOLOGY BACHELOR THESIS RESEARCH AND IMPLEMENTATION OPTIMIZATION DESIGN NEW 1-DOF COMPLIANT STAGE BASED ON ADDITIVE MANUFACTURING METHOD WITH CIRCULAR HINGE FOR HIGHLY POSITIONING ACCURACY SUPER VISOR: M.E DANG MINH PHUNG STUDENT NAME: NGUYEN QUOC HUY DO PHAN TUONG VY STUDENT ID: 18144022 18144061 Ho Chi Minh City, February, 2023 HO CHI MINH UNIVERSITY OF TECHNOLOGY AND EDUCATION FALCUTY FOR HIGH QUALITY TRAINING DEPARTMENT OF MACHINERY MANUFACTURING TECHNOLOGY BACHELOR THESIS ANALYSIS AND OPTIMIZATION DESIGN NEW 1-DOF COMPLIANT STAGE BASED ON ADDITIVE MANUFACTURING METHOD WITH CIRCULAR HINGE FOR HIGHLY POSITIONING ACCURACY SUPER VISOR: M.E DANG MINH PHUNG STUDENT NAME: NGUYEN QUOC HUY DO PHAN TUONG VY STUDENT ID: 18144022 18144061 Ho Chi Minh City, February, 2023 CỘNG HOÀ XÃ HỘI CHỦ NGHĨA VIỆT NAM Độc lập - Tự – Hạnh phúc PHIẾU NHẬN XÉT ĐỒ ÁN TỐT NGHIỆP (Dành cho giảng viên hướng dẫn) Họ tên sinh viên: Nguyễn Quốc Huy MSSV:18144022 Hội đồng: 02 Họ tên sinh viên: Đỗ Phan Tường Vỹ MSSV:18144061 Hội đồng: 02 Tên đề tài: NGHIÊN CỨU THIẾT KẾ ĐỊNH VỊ 01 BẬC TỰ DO TÍCH HỢP CƠ CẤU KHUẾCH ĐẠI CHUYỂN VỊ SỬ DỤNG CƠ CẤU MỀM CHO HỆ THỐNG ĐỊNH VỊ CHÍNH XÁC Ngành đào tạo: Mechanical Engineering Technology Họ tên GV hướng dẫn: ThS Đặng Minh Phụng Ý KIẾN NHẬN XÉT Nhận xét tinh thần, thái độ làm việc sinh viên: Nhận xét kết thực ĐATN 2.1.Kết cấu, cách thức trình bày ĐATN: 2.2 Nội dung đồ án: (Cơ sở lý luận, tính thực tiễn khả ứng dụng đồ án, hướng nghiên cứu tiếp tục phát triển) 2.3.Kết đạt được: 2.4 Những tồn (nếu có): Đánh giá: Mục đánh giá TT Hình thức kết cấu ĐATN Điểm Điểm đạt tối đa 30 Đúng format với đầy đủ hình thức nội dung 10 mục Mục tiêu, nhiệm vụ, tổng quan đề tài 10 Tính cấp thiết đề tài 10 Nội dung ĐATN 50 Khả ứng dụng kiến thức toán học, khoa học kỹ thuật, khoa học xã hội… Khả thực hiện/phân tích/tổng hợp/đánh giá 10 Khả thiết kế chế tạo hệ thống, thành phần, 15 quy trình đáp ứng yêu cầu đưa với ràng buộc thực tế Khả cải tiến phát triển 15 Khả sử dụng công cụ kỹ thuật, phần mềm chuyên ngành… Đánh giá khả ứng dụng đề tài 10 Sản phẩm cụ thể ĐATN 10 Tổng điểm 100 Kết luận:  Được phép bảo vệ  Không phép bảo vệ TP.HCM, ngày tháng năm 2023 Giảng viên hướng dẫn ((Ký, ghi rõ họ tên) CỘNG HOÀ XÃ HỘI CHỦ NGHĨA VIỆT NAM Độc lập - Tự – Hạnh phúc PHIẾU NHẬN XÉT ĐỒ ÁN TỐT NGHIỆP (Dành cho giảng viên phản biện) Họ tên sinh viên: Nguyễn Quốc Huy MSSV:18144022 Hội đồng: 02 STT: 28 Họ tên sinh viên: Đỗ Phan Tường Vỹ MSSV:18144061 Hội đồng: 02 STT: 28 Tên đề tài: NGHIÊN CỨU THIẾT KẾ ĐỊNH VỊ 01 BẬC TỰ DO TÍCH HỢP CƠ CẤU KHUẾCH ĐẠI CHUYỂN VỊ SỬ DỤNG CƠ CẤU MỀM CHO HỆ THỐNG ĐỊNH VỊ CHÍNH XÁC Ngành đào tạo: Mechanical Engineering Technology Họ tên GV phản biện: PGS.TS Phạm Huy Tuân Ý KIẾN NHẬN XÉT Kết cấu, cách thức trình bày ĐATN: Nội dung đồ án: (Cơ sở lý luận, tính thực tiễn khả ứng dụng đồ án, hướng nghiên cứu tiếp tục phát triển) Kết đạt được: Những thiếu sót tồn ĐATN: Câu hỏi: Đánh giá: Mục đánh giá TT Hình thức kết cấu ĐATN Điểm Điểm đạt tối đa 30 Đúng format với đầy đủ hình thức nội dung 10 mục Mục tiêu, nhiệm vụ, tổng quan đề tài 10 Tính cấp thiết đề tài 10 Nội dung ĐATN Khả ứng dụng kiến thức toán học, khoa học kỹ thuật, khoa học xã hội… 50 Khả thực hiện/phân tích/tổng hợp/đánh giá 10 Khả thiết kế, chế tạo hệ thống, thành phần, 15 quy trình đáp ứng yêu cầu đưa với ràng buộc thực tế Khả cải tiến phát triển 15 Khả sử dụng công cụ kỹ thuật, phần mềm chuyên ngành… Đánh giá khả ứng dụng đề tài 10 Sản phẩm cụ thể ĐATN 10 Tổng điểm 100 Kết luận:  Được phép bảo vệ  Không phép bảo vệ TP.HCM, ngày tháng năm 2023 Giảng viên phản biện ((Ký, ghi rõ họ tên) ACKNOWLEDGMENT We would like to express my sincere gratitude for Dang Minh Phung, my guidance, through all his support on our academic journey His vast knowledge and expertise have inspired us to strive for excellence and have made a significant impact on my growth and development as a student We are grateful for the time and effort my advisor put into providing us with a challenging and stimulating learning experience His passion for the subject and his dedication to teaching have made the classes enjoyable and memorable Thank you for being a mentor, a role model and a source of inspiration Your encouragement and support have been invaluable and I am grateful to have had the opportunity to learn from my advisor, M.E Dang Minh Phung i a) Effect of S1 and S2 on safety factor b) Effect of S2 and S3 on safety factor 59 c) Effect of S3 and S4 on safety factor d) Effect of S4 and U on safety factor Figure Response simulation affected on safety factor 60 CHAPTER MANUFACTURING AND EXPERIMENT 5.1 Manufacturing method 5.1.1 Water jet cutting Water jet cutting is a cutting method that uses a high-velocity or high-pressure jet of water to cut materials The material remove process is a type of erosion caused by high pressure water flows with typical forces of Ib Abrasive powders are mixed with water to cut hard metals, stone, composites, and ceramics Pure water jets are significantly less powerful than abrasive power jets [36] Water jet cutting has the following advantages: • It can perform high precision cutting, beveling, piercing, etching, and slotting with accuracies of 0.005 • This technique can be used to cut a wide variety of materials • They, like laser cutting, eliminate distortions caused by heat or burning • The edges of the parts can be produced smooth • They can cut a variety of materials up to inches thick Figure Water Jet cutting 5.1.2 Wire cutting method Wire cutting method is a type of manufacturing process used for creating complex shapes from metal or other materials It involves the use of a wire-like tool, made of electrical 61 discharge machining (EDM), to remove material and create the desired shape The wire acts as an electrode and creates sparks that erode the material, forming the desired shape This method is commonly used in the production of molds and dies, and it is preferred for hard materials that are difficult to machine using traditional methods Advantages of wire cutting method are: ● High precision: The method is capable of producing precise and accurate shapes with tight tolerances ● No physical contact: The wire never touches the workpiece, eliminating wear and tear of the cutting tool and reducing the risk of damaging the material ● Wide material compatibility: Wire cutting can be used on a variety of materials including metals, ceramics, and composites ● Hard material machining: It is suitable for machining materials that are difficult to cut using traditional methods, such as heat-resistant alloys and high-hardness steels ● Complex shapes: The method is suitable for machining complex shapes and geometries, including deep cavities and internal features ● No thermal damage: Unlike traditional cutting methods, wire cutting does not generate heat that can cause thermal damage to the material Figure Wire cutting theory Because of the benefits of wire cutting, the compliant mechanism is cut using this technique Since the material is 7075 aluminum because the yield strength to young's modulus 62 ratio is high, allowing for greater deflection before failure [2] The DoF stage sample was machined using this method not only for its advantages, but also because it is more costeffective compared to water cutting 5.2 Experiment The sample of DoF stage can be found in Figure 5.3 the complete experimental setup is depicted in Figure 5.4 Once the components are manufactured and assembled, the experiments are conducted with a laser sensor, as shown in Figure 5.5, to observe the mechanism's behavior when the actuators are in operation The experiments are carried out by manually activate the displacement instrument The displacement of the 1-DOF stage is measured on sensor display A small dot displacement is applied at the LAM, as depicted in Figure 5.5, and the point of output is calculated from the camera images mounted on the laser sensor Figure Sample of DoF stage 63 The complete experimental setup is shown in Figure 5.5 After the parts are manufactured and the setup is assembled, the experiments shown in Figure 5.5 are performed to observe the behavior of the mechanism when the displacement instrument are activated Figure Setting up the experiment 64 Figure 5 Measuring the DoF stage 65 Table Measuring experiments data Number Input displacement Output displacement (μm) (μm) 59 790 58 782 58 777 59 791 57 771 57 769 58 781 59 791 59 788 10 58 779 Ave 58.2 781.9 Table Error comperasion Simulation Experiments Error Displacement ratio 13.9 13.43 3.4% A displacement ratio between simulation and real experiments error is acceptable However, it is important to consider the specific requirements and constraints of the system being analyzed, as well as the purpose of the simulation, when evaluating the acceptability of the displacement ratio In conclusion, the acceptability of a displacement ratio error is 3.4% between simulation and real-life measurements will depend on the specific requirements and constraints of the system being analyzed, as well as the purpose of the simulation It is important to consider these factors and evaluate the error in the context of the overall design and analysis process 66 CHAPTER CONCLUSION In this research have proposed and developed a micro-drive amplification system that operates with an improved level of precision and accuracy The system was designed to operate without the need for any additional force or displacement, which was achieved by using simulations and experiments to assess its dynamic performance, and motion The results of this study showed that the system had exceptional dynamic performance, and precise linear motion, which made it a highly desirable solution for various applications One of the key features of the system was its adjustable amplify ratio, which enabled it to be secure and accurate even in the absence of non-motion direction forces or displacement This feature was instrumental in ensuring that the system could operate effectively in a variety of different scenarios Furthermore, this research conducted a detailed analysis of the system's motion performance, including Finite Element Analysis based on Response Surface Method and experiments, which showed that the system had a maximum linearity of 14 Based on the results of this research, it suggest that future work could be undertaken to further improve the design and accuracy of the system This could include developing more advanced simulations and experiments, as well as exploring alternative materials and designs to improve its performance even further Ultimately, the goal is to make the micro-drive amplification system even more reliable, precise, and effective for various applications, which would make it an even more valuable tool for engineers and designers 67 REFERENCE [1] Lobontiu N., "Compliant Mechanisms design of flexure hinges", CRC Press, 2003 [2] Howell L L., "Compliant Mechanisms", John Wiley & Sons, 2001 [3] Speich J., Goldfarb M.,” A compliant mechanism based three degree of freedom manipulator for small scale manipulation”, Robotica, Vol 18, pp 95-104, 1999 [4] Shorya A., “Synthesis and Analysis of Parallel Kinematic XY Flexure Mechanisms”, Ph.D Thesis, Massachusetts Institute of Technology, Cambridge MA, 2003 [5] Smith S T and Chetwynd D G., "Foundations of Ultraprecision mechanism design", Gordon and 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