Vibration assisted machining is an advanced non-conventional precision machining technique aiming at improving the machining performance by superimposing a small amplitude, high-frequency vibration either on the tool or on the workpiece. This article presents the mechanical design, electromechanical simulation, and experimentation on the developed prototype of the flexural hinged micro XY stage for the vibration-assisted micro-milling system. The micro XY stage comprises three layers of flexural hinge structure surrounding the central parallel kinematic structure. The finite element analysis method is adopted to evaluate the static structural stiffness and harmonic behaviour. Two multilayer piezoelectric stack actuators drive the micro XY stage in X and Y directions. The experimental results show that the micro XY stage has a vibrating work area of 17.06 µm × 17.11 µm with a hysteresis nonlinearity and cross-coupling displacements on both axes. Therefore, an electromechanical model is essential to compensate for the hysteresis behaviour and cross-coupling displacements. Open-loop tracking control experiments determine the accuracy of the developed electromechanical model. Implementing a combined hysteresis and cross-coupling displacement compensation approach into the electromechanical model resulted in an open-loop tracking error of 7% for the synchronised circular path and a maximum deviation of 0.6 µm from the linear path.

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This research focuses on the fabrication of Al6061/B4C/Gr metal matrix composites as well as the mechanical and wear properties analysis. A liquid metallurgy stir casting process was used to cast the Al6061 alloy matrix composites with specific wt.% of B4C and constant wt.% of graphite. In this work, newly developed composites of Gr (particle grain size: 0–20[Formula: see text][Formula: see text]m) and B4C (particle grain size: 0–30[Formula: see text][Formula: see text]m) are reinforced with Al6061 pure alloy, which enhanced the mechanical and wear properties when compared to Al6061 pure alloy. Microstructure analysis was carried out concerning the developed mechanical properties. Furthermore, the dry sliding wear behavior of Al6061/B4C/Gr metal matrix composites was investigated at a sliding speed of 1[Formula: see text]m/s and a sliding distance of 1500[Formula: see text]mm against a hardened EN-31 disc under the corresponding load of 19.68[Formula: see text]N. The minimum wear rate is [Formula: see text][Formula: see text]mm3/m found at 15[Formula: see text]wt.% B4C and 2[Formula: see text]wt.% graphite and the coefficient of friction is 0.54 that decreases with graphite addition, with the lowest value obtained with 5[Formula: see text]wt.% B4C and 2[Formula: see text]wt.% graphite. Al6061/10[Formula: see text]wt.% B4C/2[Formula: see text]wt.% Gr particles-reinforced composite material demonstrated the highest tensile and flexural strengths. The hardness,compressive and tensile strength of the Al6061/15[Formula: see text]wt.% B4C/2[Formula: see text]wt.% Gr particles-reinforced composite material were the highest. Scanning electron microscopy was used to examine the worn surfaces of wear specimens. The main objective of this work is to develop hybrid Al6061/B4C/Gr composites with improved mechanical and wear properties when compared with the base alloy. Al6061 is widely used in automobiles parts like engine block, piston rings, alloy wheels, marine industries, etc. B4C used in the composite improves strength and is used commonly in armed bullet proof. The Gr present in the composite improves wear resistance, and therefore applied in wear-resistant parts like brake, piston with cylinder, etc.