Reconfigurable Machine Tools (RMTs) have been developed in response to agile manufacturing demands. The prevalent modular approach for reconfigurability, in which a machine configuration is assembled for a given part, can be a demanding task time-wise and accuracy-wise, especially for smaller-scale Reconfigurable meso-Milling Machine Tools (RmMTs).

Research in the field of Parallel Kinematic Mechanisms (PKMs) has paved the way for the design of Redundant Reconfigurable Machine Tools (RRMTs) based on such accurate mechanisms. Reconfigurability in RRMTs can be manifested through topological and geometric reconfiguration, without disassembly of the structure. The main challenge in structural design of RRMTs is selecting the optimal architecture with the required level of redundancy for the set of parts at hand. The best RRMT architecture can be selected only after decisions are taken on the design variables, and the variables that manage the redundant reconfigurability. Namely, effectively locking/unlocking dof and selecting the optimal trajectory that each joint should follow. However, to date, no comprehensive design methodology addresses the challenges that are related to design of RRMTs.

The objective of this Dissertation is, thus, to develop a design methodology for RRMTs. The methodology proposes an approach towards enhancing the performance of RMTs and attaining required machining conditions, while taking into account the possible inherent redundant reconfigurability of serial, parallel and hybrid mechanisms.

The design process is combined from two engines:​ synthesis and optimization. These individual tasks, which are often solved in series, are addressed here through an integrated multi-tiered optimization-based design approach. The multi-tiered optimization comprises an iterative process that transfers decisions, which are generally taken throughout the design process, to a lower or upper tier to improve the overall result. The decisions are taken on a large number of continuous/discrete parameter's values that mutually depends upon one another in a structured manner, one that yields optimal values for a set of design variables to satisfy required process parameters.

The applicability of the proposed methodology is demonstrated through a design test case of a PKM-based Redundant RmMT (RRmMT) that can attain high stiffness while satisfying the high feed-rate requirement. The design process resulted in a new 3Ă PRPRS RRmMT that can be reconfigured into several different PKMs.