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Micrometer-Scale Machining of Metals and Polymers Enabled by Focused Ion Beam Sputtering

Description: This work combines focused ion beam sputtering and ultra-precision machining for microfabrication of metal alloys and polymers. Specifically, micro-end mills are made by Ga ion beam sputtering of a cylindrical tool shank. Using an ion energy of 20keV, the focused beam defines the tool cutting edges that have submicrometer radii of curvature. We demonstrate 25 {micro}m diameter micromilling tools having 2, 4 and 5 cutting edges. These tools fabricate fine channels, 26-28 microns wide, in 6061 aluminum, brass, and polymethyl methacrylate. Micro-tools are structurally robust and operate for more than 5 hours without fracture.
Date: December 22, 1998
Creator: Adams, D.P.; Benavides, G.L. & Vasile, M.J.
Partner: UNT Libraries Government Documents Department

Analysis of the Rotopod: An all revolute parallel manipulator

Description: This paper introduces a new configuration of parallel manipulator call the Rotopod which is constructed from all revolute type joints. The Rotopod consists of two platforms connected by six legs and exhibits six Cartesian degrees of freedom. The Rotopod is initially compared with other all revolute joint parallel manipulators to show its similarities and differences. The inverse kinematics for this mechanism are developed and used to analyze the accessible workspace of the mechanism. Optimization is performed to determine the Rotopod design configurations which maximum the accessible workspace based on desirable functional constraints.
Date: May 16, 1998
Creator: Schmitt, D.J.; Benavides, G.L.; Bieg, L.F. & Kozlowski, D.M.
Partner: UNT Libraries Government Documents Department

A process for the agile product realization of electromechanical devices (A-primed)

Description: This paper describes a product realization process developed at Sandia National Laboratories by the A-PRIMED project that integrates many of the key components of ``agile manufacturing`` (Nagel & Dove, 1992) into a complete, step-by-step, design-to-production process. For two separate product realization efforts, each geared to a different set of requirements, A-PRIMED demonstrated product realization of a custom device in less than a month. A-PRIMED used a discriminator (a precision electro mechanical device) as the demonstration device, but the process is readily adaptable to other electro mechanical products. The process begins with a qualified design parameter space (Diegert et al, 1995). From that point, the product realization process encompasses all facets of requirements development, analysis and testing, design, manufacturing, robot assembly and quality assurance, as well as product data management and concurrent engineering. In developing the product realization process, A-PRIMED employed an iterative approach whereby after each build, the process was reviewed and refinements were made on the basis of lessons learned. This paper describes the integration of project functions and product realization technologies to develop a product realization process that on repeated iterations, was proven successful.
Date: February 1, 1996
Creator: Forsythe, C.; Ashby, M.R.; Benavides, G.L.; Diegert, K.V.; Jones, R.E.; Longcope, D.B. et al.
Partner: UNT Libraries Government Documents Department

A process for the agile product realization of electro-mechanical devices

Description: This paper describes a product realization process developed and demonstrated at Sandia by the A-PRIMED (Agile Product Realization for Innovative Electro MEchanical Devices) project that integrates many of the key components of ``agile manufacturing`` into a complete, design-to-production process. Evidence indicates that the process has reduced the product realization cycle and assured product quality. Products included discriminators for a robotic quick change adapter and for an electronic defense system. These discriminators, built using A-PRIMED, met random vibration requirements and had life cycles that far surpass the performance obtained from earlier efforts.
Date: September 1, 1995
Creator: Forsythe, C.; Ashby, M.R.; Benavides, G.L.; Diegert, K.V.; Jones, R.E.; Longcope, D.B. et al.
Partner: UNT Libraries Government Documents Department

Achieving agility through parameter space qualification

Description: The A-primed (Agile Product Realization of Innovative electro-Mechanical Devices) project is defining and proving processes for agile product realization for the Department of Energy complex. Like other agile production efforts reported in the literature, A-primed uses concurrent engineering and information automation technologies to enhance information transfer. A unique aspect of our approach to agility is the qualification during development of a family of related product designs and their production processes, rather than a single design and its attendant processes. Applying engineering principles and statistical design of experiments, economies of test and analytic effort are realized for the qualification of the device family as a whole. Thus the need is minimized for test and analysis to qualify future devices from this family, thereby further reducing the design-to-production cycle time. As a measure of the success of the A-primed approach, the first design took 24 days to produce, and operated correctly on the first attempt. A flow diagram for the qualification process is presented. Guidelines are given for implementation, based on the authors experiences as members of the A-primed qualification team.
Date: February 1, 1995
Creator: Diegert, K. V.; Easterling, R. G.; Ashby, M. R.; Benavides, G. L.; Forsythe, C.; Jones, R. E. et al.
Partner: UNT Libraries Government Documents Department