Keynote Speaker 3 : Prof Dr Mustafizur Rahman
Prof Dr Mustafizur Rahman
Department of Mechanical Engineering, National University of Singapore
Innovations in Tool-based Hybrid/Compound Micro/Nano-machining for
– An Integrated Approach
In recent years, there has been a remarkable development in manufacturing technologies and design of machine tools. This is in tandem with greater demand for better performance quality of products. Both ‘revolutionary’ and ‘evolutionary’ innovations are the keys to meet the challenges posed by the needs of functional requirement of products, miniaturization, and industrial realization of micro/nanotechnology. These limitations can be overcome by taking an integrated approach towards innovation through: (1) compound machining processes, and (2) development of proper machine tools supporting such machining processes to meet the demand for machining difficult-to-cut materials with quality and complexity.
Conventional machining processes (material removal processes, such as turning and milling), have been hybridized or compounded with non-conventional machining processes like EDM (electro discharge machining), EDG (electro discharge grinding), ECM (electro chemical machining), wire-EDM and Laser to fabricate micro-structures with high dimensional accuracy, and such processes are termed as ‘compound machining’. In order to achieve meaningful implementation of compound machining techniques, understanding of process physics to provide relevant background for modeling, measurement and identification of control parameters are of utmost importance. Implementation of this concept can be successfully carried out through the adaptation of Digital Manufacturing.
For successful implementation of such compound machining technique, design and development of machine tools capable of such complex machining (i.e. turning, milling, EDM, laser, etc. on the same machine and setup) are needed.
An integrated approach for successful implementation of material, manufacturing processes and design can only be achieved through a paradigm shift in thought and processes of conventional machining. This shift can only be materialized through revolutionary innovation rather than an evolutionary one.
An attempt has been made in this presentation regarding the mindset, activities and achievements of the author, his group members at National University of Singapore (NUS), and some research partners in other parts of the world for successfully achieving this objective.
Professor Mustafizur Rahman is currently with the Department of Mechanical Engineering at the National University of Singapore. His research interests include Ultra-precision machining, micro/nano machining, design and development of machine tools and devices for micro/nano machining, high speed machining of difficult-to-machine materials and large format machining. Some of his latest research areas are: Hybrid simultaneous EDM/ECM, Compound arc machining and gun drilling (CAMGD), ductile mode machining of brittle materials, Machining of freeform features based on Digital Images. He has received William Jonson Gold Medal for Life Time Achievement in Material Processing Research and Teaching in 2009, A M Strickland Prize from IMechE in 2009, the Leading Edge Manufacturing Achievement Award from the JSME in 2005, and IES Prestigious Engineering Achievement Award in 2003,. He has authored more than 470 journal and conference papers. He is in the editorial board for 10 International Journals.
Recently he has compiled a book on “Modern manufacturing processes” published by Elsevier, UK. It is most likely the first book on tool-based micro machining covering all possible means of materializing ultra-precision machining process.
Currently, he is also a director of a NUS spin-off company, Mikrotools Pte Ltd. (www.mikrotools.com) which produces machine tools for micro and nano machining.