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Autonomous robot‐based finishing of surfaces with a reduction of the programming effort can be achieved by teaching the desired trajectory locally in the object reference frame. Thus, the flexibility of the programmed task increases and also moving surfaces can be finished. This paper aims to focus on this control concept.

The developed concept relies both on the use of a new slip sensor which is able to measure relative motion between the robot end‐effector and the machined object surface as well as on a continuous slip and force control algorithm. First experimental results were used to validate the concept.

The presented results were promising enough to encourage the application of the proposed concept scheme in connection with the slip sensor in industrial finishing applications.

The first investigations provide a basis for the development of more accurate software solutions in order to optimise the performances of the slip sensor.

The developed slip sensor provides a cheap and flexible solution for measuring relative motion between tool and surface. Combined with the use of a force sensor, the proposed scheme can be introduce more autonomy in industrial application like polishing or deburring.

The paper introduces a novel slip and force control concept for coping with the industry requirement of introducing more automation in the finishing of surfaces. Such a control concept allows on one hand the finishing of moving parts and at the same time increases the flexibility of the programming and reduces the user effort.

This paper focuses on the comparative study on reliability performance of various surface coatings. Only brief descriptions of coating processes, material physical properties, costs, and their applications are given.

Optimised concrete components are often of complex geometries, which are difficult and costly to cast using traditional formworks. This paper aims to propose an innovative formwork system for optimised concrete casting, which is eco-friendly, recyclable and economical.

In the proposed formwork system, ice is used as mould pattern to create desired geometry for concrete member, then sand mould is fabricated based on the ice pattern. A mix design and a mixing procedure for the proposed sand mould are developed, and compression tests are also performed to ensure sufficient strength of the sand mould. Furthermore, surface preparation of the sand mould is investigated for easy demoulding and for achieving good concrete surface quality. Additionally, recyclability of the proposed sand mould is tested.

The proposed mix design and mixing procedure can provide sufficient strength for sand mould in concrete casting. The finished components exhibit smooth surfaces and match designed geometries, and the proposed sand mould can be fully recycled with satisfactory strength.

To the best of the authors’ knowledge, this is the first study that combines ice pattern and sand mould to create recyclable formwork system for concrete casting. The new techniques developed in this research has great potential to be applied in the fabrication of large-scale concrete structures with complex geometries.

This research investigated the use of two relatively new technologies, abrasive flow machining (AFM) and stereolithography (SL), to minimize the time to develop a finished prototype. Statistical analysis was used to determine effects of media grit size, media pressure, build style, build orientation and resin type on flatness, material removal rate and surface roughness. Results indicated that media pressure, grit size, and build orientation were significant in at least one of the experiments performed. Scanning electron microscope (SEM) images showed the stair‐stepping effect of the SL process before AFM and the removal of the stair‐stepping after AFM. The SEM images showed a lack of typical AFM flowlines on the surface and suggested that the workpiece material is removed by brittle fracture. Data dependent systems analysis techniques were also used to study the surface roughness profiles.

This paper aims to investigate the dimensional accuracy consisting of thickness, grip section width, full length, circularity, cylindricity and surface finish of printed polyurethane dog-bone samples based on American Society for Testing and Materials D638 type V standard, which were optimally printed by fused deposition modelling (FDM).

The experimental approach focuses on determining main effects of printing parameters, including nozzle temperature, infill percentage, print speed and layer height on dimensional error and surface finish of the printed samples, followed by the confirmation tests to warrant the reproducibility of experimental results.

This study shows that layer height has the most significant impact on dimensional accuracy and surface finish of printed samples compared to other printing parameters, whereas infill density has no significant effect on all sample dimensions.

This paper presents a comprehensive study relating to various dimensional accuracies in terms of full length, grip section width, thickness, circularity, cylindricity and surface finish of dog-bone samples printed by FDM to improve the printability and processibility via additive manufacturing.

When building parts in a stereolithography apparatus (SLA), the user is faced with many decisions regarding how the part will be built. The quality of the build can be controlled by the user by changing one of several build style variables, including part orientation, cross sectional layer thickness, and laser hatch density. A user will probably have preferences for the part build (i.e. accuracy or speed), but may not understand how to vary the build style variables to produce the desired results. A method based on response surface methodology and multiobjective decision support is described in this paper for relating build goals to the build style variables to provide support for making build style decisions. The method is applied to the build style of a circuit breaker handle. Results indicate the method’s usefulness in supporting build style decisions. Expected behaviors of the goals with respect to the variables were confirmed and quantified. Additionally, response surface methodology was shown to be accurate and effective in modeling the relationships among variables and goals.

Describes a project to develop an intelligent robot system to mechanize the finishing of dies and moulds. Examines the concept of the finishing of surfaces and the distinction between grinding and polishing.

The purpose of this paper is to investigate the influence of different finish processes on the surface integrity and tribological behaviour of cylinder running surfaces for internal combustion engines.

The cutting force during finishing and the resulting surface topography was measured for a variety of cylinder running surfaces made of EN-GJL-250, EN-GJV-400 and thermal sprayed aluminium alloy. A separate conditioning tool was developed and tested. Different analysis methods (SEM, EDX, SIMS and FIB) for the characterisation of the boundary conditions were used. By an oscillating friction wear test and a single cylinder floating liner engine, the running-in and frictional behaviour was rated.

It was shown that honing with low cutting forces and silicon carbide cutting material decreases the friction in operation. The characteristics of the boundary layers after running-in depend on the finish machining process. A preconditioning with a separate tool can adjust the boundary layer and running-in behaviour. Based on the experimental results, a multi-body and computational fluid dynamics simulation was developed for the floating liner engine.

The results demonstrate the potential of finishing with low process forces to reduce friction and the need for a complete consideration of the tribological system piston ring/cylinder liner surface.

The purpose of this paper is to study the integration between this technology and barrel finishing (BF) operation to improve part surface quality. Fused deposition modeling (FDM) processes have limitation in term of accuracy and surface finishing. Hence, post-processing operations are needed. A theoretical and experimental investigations have been carried out.

A geometrical model of the profile under the action of machining is proposed. The model takes into account FDM formulation and allows to predict the surface morphology achievable by BF. The MR needed in the model is obtained by a particular profilometer methodology, based on the alignment of Firestone–Abbot (F–A) curves. The experimental performed on a suitable geometry validated geometrical model. Profilometer and dimensional measurements have been used to assess the output of the coupled technologies in terms of surface roughness and accuracy.

The coupling of FDM and BF has been assessed and characterized in terms of obtained part surfaces and dimension evolution. Deposition angle strongly affects the BF removal speed and alters nominal dimensions of part. The geometric profile model gave interesting information about profile morphology and machining mechanism; moreover, the height prevision allows to estimate BF working time to accomplish part requirements.

The prediction of the geometric profile as a function of FDM fabrication parameters is a powerful tool which permits to investigate surface properties such as mechanical coupling or tribological aspects. The coupling of BF and FDM has been assessed and now optimization of this process can be performed just evaluating effects of parameters.

This research has been focused to an industrial application, and results can be used in a computer-aided manufacturing. The prevision of surface obtainable by this integration is a tool to find the part optimum orientation to accomplish the drawing requirements. Both the experimental findings and the model can guide operator toward a proper process improvement, thus reducing or eliminating expensive trial and error phase in the post-processing operation of FDM prototypes.

In this paper, a novel model has been presented. It allows to know in advance profile morphology achievable by a specific surface of a FDM part after a determined BF working time. A particular application of FA curves gives the MR values.

Outlines research work into the assessment of light‐scattering techniques for manufactured surfaces inspection. Describes the three type of commercial sensors that have been available so far: glossometers, peak intensity meters and light distribution measuring instruments and how they work. Describes the laboratory rig supporting equipment and analysis methodologies employed in order that numerous surfaces could be examined and classified. The outcome was an atlas of typical manufactured surfaces and a small ruggedized test bed sensor. Concludes that by using this rig and the atlas the whole 3‐dimensional light scatter image can be examined to select the appropriate sensor.