Shape memory Alloy Actuator for cross-feed in turning operation

A shape memory alloy (SMA) is an intermetallic compound able to recover, in a continuous and reversible way, a predetermined shape during a thermal cycle while generating mechanical work. In this thesis, its use in developing an actuator for a machining process is investigated. The actuator is to drive the tool cross feed into an aluminium workpiece in a finishing lathe operation. The actuator structure was designed with an output shaft to transfer the movement and force of the SMA wire outside the device. The actuator was fabricated and the experimental setup was assembled which also included a power supply control circuit, displacement sensor, temperature sensor and current sensor for feedback, and data collection and monitoring within software. PID control was implemented within the software that regulated the power supplied to the SMA, thereby providing the position control. This study covers the mechatronics system design and development of the actuator, the experiments carried out to determine performance and the results. Open loop tests were conducted to determine the maximum stroke, the effect of cooling and response to radial forces. These tests revealed the expected non-linearity of the SMA. The actuator achieved the rated maximum stroke of 3-4 percent. The forced cooling test showed a general improvement of approximately 65 percent with fans. The radial force tests showed the value of the maximum stroke remained unaffected by force. The results from the closed loop tests responses with a tuned PID controller produced a stable system for various displacement setpoints. The actuator had a feed rate of 0.25 mm/s and an accuracy of 0.0153mm, which was within the acceptable accuracy for turning operations. The system was deemed accurate for a conventional lathe machine cross feed