Background

Smart chucks and smart collets are essential important for high throughput, high precision manufacturing particularly in the context of Industry 4.0. In modern advanced manufacturing, there is an ever-increasing demand and high value manufacturing trend for high precision machining of freeform surfaced optics, devices and components using diamond tools and/or micro features and micro holes in a highly productive manner. Smart chucks and smart collets can play as the enabling smart fixtures/tools for substantially improving the machining/operation efficiency and quality simultaneously, and also working in a highly competitive smart automation manner.

Technology Overview

This project presents the innovative design and development of two types of smart fixtures/tools, i.e. a Smart chuck  incorporated with concentricity and a range of variations in workpiece diameters for ultraprecision diamond turning purpose; and a Smart collet  (based on smart flexure design) applicable to high speed micro milling/drilling. 

Further Detail

Technical details on the Smart chuck can be found in the following research paper: Khaghani, A., Cheng, K. Investigation on an innovative approach for clamping contact lens mould inserts in ultraprecision machining using an adaptive precision chuck and its application perspectives. Int J Adv Manuf Technol 111, 839–850 (2020). https://doi.org/10.1007/s00170-020-05990-8 

Benefits

Smart chucks and smart collets can lead to the unique manufacturing advantages and benefits, including:

• Enabling the high-throughput precision machining
• Acting as the smart fixtures for swift and accurate changeover of workpieces and tools
• Reducing the centrifugal forces and thus improving the component surface finish
• Reducing the centrifugal forces and thus maximizing the cutting performance
• Acting as the smart fixtures and tools for better working with the high precision machining system and the machining performance 

Applications

• High-throughput high precision diamond turning and applications
• Precision fixtures manufacture
• High-throughput diamond turning of miniature devices, optics and components
• Smart diamond turning of freeform surfaced components and devices
• High-throughput micro milling
• High-throughput micro drilling
• High-throughput PCB drilling 

Opportunity

Brunel University is actively searching for a partner to further develop this technology with a view to commercialisation. Additionally, Brunel is looking for consultants.