Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling
Compliant mechanisms are often utilized in precise positioning systems but have not been thoroughly examined in vibration-aided fine CNC machining. This study aims to develop a new 02-DOF flexure stage for vibration-aided fine CNC milling. A hybrid displacement amplifier, featuring a two-lever mecha...
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MDPI AG
2025-07-01
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| Online Access: | https://www.mdpi.com/2072-666X/16/7/793 |
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| author | Minh Phung Dang Anh Kiet Luong Hieu Giang Le Chi Thien Tran |
| author_facet | Minh Phung Dang Anh Kiet Luong Hieu Giang Le Chi Thien Tran |
| author_sort | Minh Phung Dang |
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| description | Compliant mechanisms are often utilized in precise positioning systems but have not been thoroughly examined in vibration-aided fine CNC machining. This study aims to develop a new 02-DOF flexure stage for vibration-aided fine CNC milling. A hybrid displacement amplifier, featuring a two-lever mechanism, two Scott–Russell mechanisms, and a parallel leading mechanism, was integrated into a symmetric perpendicular series configuration to create an innovative design. The pseudo-rigid body model (PRBM), Lagrangian approach, finite element analysis (FEA), and Firefly optimization algorithm were employed to develop, verify, and optimize the quality response of the new positioner. The PRBM and Lagrangian methods were used to construct an analytical model, while finite element analysis was used to validate the theoretical solution. The primary natural frequency results from theoretical and FEM methods were 318.16 Hz and 308.79 Hz, respectively. The difference between these techniques was 3.04%, demonstrating a reliable modelling strategy. The Firefly optimization approach applied mathematical equations to enhance the key design factors of the mechanism. The prototype was then built, revealing an error of 7.23% between the experimental and simulated frequencies of 331.116 Hz and 308.79 Hz, respectively. The specimen was subsequently mounted on the fabricated optimization positioner, and vibration-assisted fine CNC milling was performed at 100–1000 Hz. At 400 Hz, the specimen achieved ideal surface roughness with a Ra value of 0.187 µm. The developed design is a potential structure that generates non-resonant frequency power for vibration-aided fine CNC milling. |
| format | Article |
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| institution | Kabale University |
| issn | 2072-666X |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
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| series | Micromachines |
| spelling | doaj-art-3f4f9aa2d512400a8799c97297f0553b2025-08-20T03:58:26ZengMDPI AGMicromachines2072-666X2025-07-0116779310.3390/mi16070793Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC MillingMinh Phung Dang0Anh Kiet Luong1Hieu Giang Le2Chi Thien Tran3Faculty of Mechanical Engineering, Ho Chi Minh City University of Technology and Education, Ho Chi Minh City 700000, VietnamFaculty of Mechanical Engineering, Ho Chi Minh City University of Technology and Education, Ho Chi Minh City 700000, VietnamFaculty of Mechanical Engineering, Ho Chi Minh City University of Technology and Education, Ho Chi Minh City 700000, VietnamFaculty of Mechanical Engineering, Ho Chi Minh City University of Technology and Education, Ho Chi Minh City 700000, VietnamCompliant mechanisms are often utilized in precise positioning systems but have not been thoroughly examined in vibration-aided fine CNC machining. This study aims to develop a new 02-DOF flexure stage for vibration-aided fine CNC milling. A hybrid displacement amplifier, featuring a two-lever mechanism, two Scott–Russell mechanisms, and a parallel leading mechanism, was integrated into a symmetric perpendicular series configuration to create an innovative design. The pseudo-rigid body model (PRBM), Lagrangian approach, finite element analysis (FEA), and Firefly optimization algorithm were employed to develop, verify, and optimize the quality response of the new positioner. The PRBM and Lagrangian methods were used to construct an analytical model, while finite element analysis was used to validate the theoretical solution. The primary natural frequency results from theoretical and FEM methods were 318.16 Hz and 308.79 Hz, respectively. The difference between these techniques was 3.04%, demonstrating a reliable modelling strategy. The Firefly optimization approach applied mathematical equations to enhance the key design factors of the mechanism. The prototype was then built, revealing an error of 7.23% between the experimental and simulated frequencies of 331.116 Hz and 308.79 Hz, respectively. The specimen was subsequently mounted on the fabricated optimization positioner, and vibration-assisted fine CNC milling was performed at 100–1000 Hz. At 400 Hz, the specimen achieved ideal surface roughness with a Ra value of 0.187 µm. The developed design is a potential structure that generates non-resonant frequency power for vibration-aided fine CNC milling.https://www.mdpi.com/2072-666X/16/7/793compliant mechanismFlexure 02-DOF mechanismfirefly algorithmvibration-aided fine millingsurface morphology |
| spellingShingle | Minh Phung Dang Anh Kiet Luong Hieu Giang Le Chi Thien Tran Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling Micromachines compliant mechanism Flexure 02-DOF mechanism firefly algorithm vibration-aided fine milling surface morphology |
| title | Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling |
| title_full | Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling |
| title_fullStr | Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling |
| title_full_unstemmed | Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling |
| title_short | Optimal Design for a Novel Compliant XY Platform Integrated with a Hybrid Double Symmetric Amplifier Comprising One-Lever and Scott–Russell Mechanisms Arranged in a Perpendicular Series Layout for Vibration-Assisted CNC Milling |
| title_sort | optimal design for a novel compliant xy platform integrated with a hybrid double symmetric amplifier comprising one lever and scott russell mechanisms arranged in a perpendicular series layout for vibration assisted cnc milling |
| topic | compliant mechanism Flexure 02-DOF mechanism firefly algorithm vibration-aided fine milling surface morphology |
| url | https://www.mdpi.com/2072-666X/16/7/793 |
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