Mecatronics Engineering

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https://hdl.handle.net/20.500.11888/10119

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CNC FOUR AXES -FIVE DEGREES OF FREEDOM-MILLING MACHINE SOFT MATERIAL
(2025-02-26) “Mohammad Tariq” Fares; Yazan Mousa (11924269); Mohammad Allan (11925611)
Abstract In the ever-evolving field of mechatronics engineering, the application of Computer Numerical Control (CNC) technology has become a pivotal aspect of modern industrial manufacturing. This project focuses on the development and implementation of a CNC four-axis milling machine with five degrees of freedom, designed specifically for the processing of soft materials such as plastics, wood, aluminum, and copper. The primary aim is to enhance precision, reduce time and effort, and lower costs compared to traditional three-axis CNC machines. By integrating an additional axis, this innovative technology allows for the fabrication of more complex and precise parts, broadening the scope of applications in various industrial sectors including automotive, aerospace, electronics, and construction. The project involves a comprehensive study of the mechanical and electronic design elements essential for the construction of the CNC milling machine. This includes the development of a robust structure capable of withstanding high precision operations, the integration of advanced stepper motors and control systems, and the implementation of G-code programming for precise tool path generation. A detailed analysis of the selection and testing of suitable materials ensures that the machine can efficiently handle a variety of soft materials, maintaining high accuracy and quality in production. Furthermore, the project explores the historical evolution of CNC technology, highlighting the advancements that have led to the current state of the art in four-axis CNC machining. This historical context provides a foundation for understanding the significance and potential of the developed machine. The study also delves into the cost implications of CNC technology, emphasizing the cost-effectiveness of the designed machine in comparison to high-end commercial CNC machines. This aspect is particularly crucial for small and medium-sized enterprises looking to adopt advanced manufacturing technologies without incurring prohibitive costs. The control design aspect of the project is meticulously detailed, focusing on the core control components, the integration of the rotary axis, and the development of a user-friendly interface for machine operation. The G-code programming, a critical component for CNC operation, is thoroughly explored to ensure seamless and accurate machining processes. The project also addresses the challenges associated with machining different types of soft materials, providing solutions to optimize the milling process and enhance the machine’s versatility. The culmination of this research and development effort is a cost-effective, efficient, and versatile CNC milling machine that meets the demands of modern manufacturing. It is designed to offer increased precision, reduced production time, and significant cost savings, making it an ideal solution for various industrial applications. The project not only contributes to the field of mechatronics engineering but also provides a practical tool for enhancing manufacturing capabilities, improving product quality, and increasing operational efficiency in competitive and innovative manufacturing environments.
Pellet 3D printer
(2024-09-26) Osama Muhammad Daoud; Sabeeh Omar Daher; Abdullah Wael Fakhry Ass
3D printers will undoubtedly continue to increase the capabilities of small- and mid-sized manufacturers well into the future. The most exciting advances are yet to come. And the biggest winners out there will be the manufacturers with the vision to foresee the possibilities these revolutionary machines can unlock. This report focuses on the design and development of a Pellet 3D printer Starting from the mechanical design, then the electric and controller selection, followed by the software, programing. Throughout this project, we delved into various 3D printing methodologies, focusing on Fused Deposition Modeling (FDM). This falls within the realm of additive manufacturing (AM), where filament, such as PLA material, serves as the primary material. FDM employs a three-mechanism movement, and for our project, we utilized the Creality Ender 3 printer, which operates on a conventional 3-axes CNC mechanism. Then we talked about plastic extrusion, a process involving the melting and shaping of raw plastic. Subsequently, we embarked on the task of designing a novel printer head using Creo Parametric. This included creating essential components through 3D printing, assembly of the extruder, and its installation onto the printer, replacing the original head. The final step involved calibrating the printer, this step is the most important step where we will make the controller deal with the mass of pellets instead of the length of filaments, setting the stage for its subsequent use in the examination of diverse material samples.
Development of a Low-Cost Service Dog Robot for Enhanced Assistance
(2024-08-07) Abd Alrahman Marshoud; Abdallatif Joqa; Saif Dabbas
Abstract This graduation project aims to develop a low-cost Dog Robot that utilizes robotics technology to provide it to a wide range of users. The project seeks to address the growing demand for innovative solutions in various fields that can benefit from the use of robotics. The suggested method is centered on creating and building a low-cost Service Dog Robot with superior sensing capabilities, mobility, and interactive features. The robot, which is equipped with sensors, can sense and understand its surroundings, allowing it to move, plan pathways, avoid obstacles, and execute activities suited to the user’s individual demands. The Service Dog Robot supports with daily tasks such as object retrieval and delivery. Its versatility and learning skills enable it to tailor its help to the changing demands of individual users, making it a versatile and long-lasting solution. To ensure accessibility and usability, the project prioritizes the selection of cost-effective components that do not compromise performance. Additionally, the utilization of open-source resources facilitates knowledge-sharing and collaboration within the robotics community. This project aims to develop a low-cost robot that to a wide range of users in different settings. By focusing on affordability and ease of use, this initiative hopes to make robotics technology more accessible and encourage collaboration across different fields. The deployment of this technology will benefit both users and researchers in the robotics industry and drive further advancements in the sector. The goal of this graduation project is to create a low-cost, highly capable service dog robot that can benefit a wide range of users. The team aims to develop a robot with superior sensing, mobility, and interactive features, empowering it to autonomously navigate, plan routes, avoid obstacles, and execute tasks tailored to individual user needs. To ensure accessibility, the team will select cost-effective components without compromising performance, and utilize open-source resources to facilitate knowledge-sharing and collaboration within the robotics community. By prioritizing affordability and user-friendliness, the project aspires to make robotics technology more accessible, stimulate further advancements, and encourage interdisciplinary cooperation. 2
Polymer Melt Flow in 3D Printing
(2024-02-12) Ahmed Qadi; Abdul Hakim Futyan
Abstract Material extrusion additive manufacturing is a widely used process for producing complex parts from thermoplastic polymers. However, the quality of the final product is heavily influenced by the flow behavior of the polymer melt through the hot-end and the nozzle. In order to optimize the extrusion process, reduce defects such as extrusion inconsistencies, and improve the quality and performance of the final product, a comprehensive understanding of the flow behavior is essential. In this project, the flow behavior of polymer melts in fused filament fabrication 3D printing technology through the extrusion mechanism known as the hot-end will be investigated experimentally. A test setup was built to extrude polymer melts at different melt temperatures while measuring the force exerted using load cell. The goal is to develop a control system that can optimize the extrusion process and interpret the force data to achieve optimal results. Additionally, a key objective of this study is to conduct a comparative analysis of PLA (Polylactic acid) and TPU (thermoplastic polyurethane) materials, assessing how each responds to varying extrusion conditions. This comparison aims to uncover the distinct properties and behaviors of these polymers, offering valuable insights for their application in 3D printing. The results of this comparison are crucial for understanding material-specific requirements and tailoring the extrusion process accordingly. Data from the test setup were collected and analyzed using MATLAB. A key challenge encountered was the non-linear behavior of the heater model, which led to the development of the advanced Hammerstein model. However, due to complexities in designing a controller for this model, a PID Controller was employed. Utilizing MATLAB's PID tuner, optimal values for Kp, Ki, and Kd were determined to effectively control the heater. The study demonstrates that extrusion parameters like speed, temperature, and feeding force critically affect the quality of 3D prints. It thoroughly investigates how these factors interact, enhancing our understanding of their role in 3D printing. This research significantly advances the field by providing deeper insights into material properties and suggesting ways to improve 3D printing techniques, laying groundwork for future advancements
Photovoltaic Grass Cutter
(2024-02-07)
The continuing increase in fuel costs and the impact of gas emissions from burned fuel into the atmosphere makes it necessary to use the sun's plentiful solar energy as a source of electricity to run a lawn mower. Based on the fundamentals of mowing, a solar-powered lawn mower was created. The direct current (D.C.) motor, a rechargeable battery, a solar panel, a stainless-steel blade, and a control switch make up the intended solar lawnmower. An app is used to operate the solar- powered lawnmower, which shuts the circuit and allows current to pass through the motor, which drives the blade used for cutting grass. Through the solar charging controller, the battery is recharged.

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