Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Fabrication of Microstructures on RB-SiC by Ultrasonic Cavitation Assisted Micro-Electrical Discharge Machining

Ultrasonic cavitation assisted micro-electrical discharge machining was used to fabricate microstructures on reaction-bonded silicon carbide. To aid the removal of debris from the machining gap and to obtain a good surface finish, carbon nanofibers were added into the dielectric fluid. The suspension of carbon nanofibers in the dielectric fluid and the cavitation bubble effect induced by the vibration of the dielectric fluid proved to be effective in reducing the deposition of tool material on the workpiece surface. The tool material deposition rate was found to be significantly affected by the vibration amplitude and the distance between the oscillator and the workpiece. With a hemispherical electrode and inclined workpiece, high accuracy micro-dimples could be obtained within a short time. A nanometer-level surface finish was successfully obtained on a hard-brittle RB-SiCmoldmaterial

Development of Powder Metallurgy (PM) compacted Cu-TaC electrodes for EDM

The main aim of this paper is to investigate the properties of Cu-TaC electrodes produced by Powder Metallurgy (PM) method. The design of Experiment (DOE) method was used to plan the investigation. Two different compositions of the powders (Cu-TaC with 30 and 55 % wt TaC) were used. The major properties which determine suitability of electrodes for Electro Discharge Machining (EDM) are electrical conductivity, thermal conductivity and to some extent density. These properties were measured for the green compacted electrodes, analyzed and compared with their sintered counterparts. This is the initial stage to determine the suitability or otherwise of the compacted electrodes. The results showed that the compacted electrodes in green form can be suitable for EDM, since the electrical conductivities are very high (94.96-189.92�-1m-1). The thermal conductivity is good (29.70-33.20W/ m K). The density ranges between 6.13 and 9.80 g/cm3. The sintered electrodes were found to be unsuitable at the specified conditions, because they became non-conductive electrically after sintering. Current efforts are geared towards improving these properties for the sintered ones and also determining their optimum levels

Role of Heat Transfer on Process Characteristics During Electrical Discharge Machining

This book comprises heat transfer fundamental concepts and modes (specifically conduction, convection and radiation), bioheat, entransy theory development, micro heat transfer, high temperature applications, turbulent shear flows, mass transfer, heat pipes, design optimization, medical therapies, fiber-optics, heat transfer in surfactant solutions, landmine detection, heat exchangers, radiant floor, packed bed thermal storage systems, inverse space marching method, heat transfer in short slot ducts, freezing an drying mechanisms, variable property effects in heat transfer, heat transfer in electronics and process industries, fission-track thermochronology, combustion, heat transfer in liquid metal flows, human comfort in underground mining, heat transfer on electrical discharge machining and mixing convection. The experimental and theoretical investigations, assessment and enhancement techniques illustrated here aspire to be useful for many researchers, scientists, engineers and graduate students

Can A Low Cost Sensing System Be Exploited For High Precision Machining

Abstract The aim of the present study is the assessment of the integration of a low cost optical measurement device into a high-precision machine tool for micro manufacturing applications. The measurement system can be effectively integrated into the working volume of different types of machines allowing both tool and workpiece measurements and avoiding its disassembly from the machine stage for off-line measurements and, consequently, reference losses. The fast measurements of tool and workpiece during the machining contribute to increase the accuracy and reduce the overall machining-measurement iterations. The assessment is achieved by a test case where a low cost USB microscope is applied to a micro-EDM machine. The low cost device has been applied for tool electrode measurements and tool wear evaluation after an accuracy enhanced calibration procedure and high performance image processing algorithms, which effectively reduce the lack of the hardware performance. The measurement performance gives a feedback on the deviations of the machined features from nominal geometry and allows their compensations by an adequate machining strategy

Blisk blades manufacturing technologies analysis

Ponencia presentada a 8th Manufacturing Engineering Society International Conference, MESIC 2019, 19-21 June 2019, Madrid, SpainThe paper presents blisk blades manufactured by different manufacturing processes. In this sense, different milling trajectories are presented, and, super abrasive machining strategies and EDM technologies are also tested. Machining times, costs and surface finish are analysed in order to determine optimal machining process for blisk manufactured in low machinability materials.The authors wish to acknowledge the financial support received from HAZITEK program, from the Department of Economic Development and Infrastructures of the Basque Government and from FEDER founds, related to the projects with acronym HARDCRAFT and TURALOY. Besides, thanks are also addressed to the Vice chancellor of innovation, social compromise and cultural action from UPV/EHU (Bizialab program from Basque Government) and to Spanish Project MINECO RTC-2017-6039-5

Effects of electrical discharge machining (EDM) jet flushing setting on the machining of tool steel workpiece

Electrical Discharge Machining (EDM) is one of the most accurate manufacturing process for creating complex or simple shape and geometries within parts and assemblies. EDM works by eroding material in path of electrical discharges that form an arc between an electrode tool and the work piece. The objective of this thesis project is to determine effect of EDM jet flushing setting on the machining of tool steel workpiece. The most important parameters of EDM are the material removal rate (MRR) and surface roughness (Ra). The non-electrical factors are considered in this experiment where the electrical factor has been fixed. In this thesis the influence of electrode material, flushing, electrode dimension and depth of cut on EDM performance is discussed. The analysis of the influence of these factors was carried out by adopting a complete factorial experiment. Graphite and Copper are used as electrode to machine the workpiece. Flushing is used in EDM to remove the eroded particle from the gap for efficient cutting. There are two level of flushing setting, for low level flushing is not used and at high level flushing is used. Electrode dimension for low level is 10 mm and high level is 30 mm. the factor for depth of cut is 10 mm at low and 20 mm at high level. The dielectric fluid is used kerosene. The effects of jet flushing was analyzed and discussed. The result had proved that flushing is very important to influence MRR and Ra result

Proceedings of the 4th International Conference on Innovations in Automation and Mechatronics Engineering (ICIAME2018)

The Mechatronics Department (Accredited by National Board of Accreditation, New Delhi, India) of the G H Patel College of Engineering and Technology, Gujarat, India arranged the 4th International Conference on Innovations in Automation and Mechatronics Engineering 2018, (ICIAME 2018) on 2-3 February 2018. The papers presented during the conference were based on Automation, Optimization, Computer Aided Design and Manufacturing, Nanotechnology, Solar Energy etc and are featured in this book

Design of Manufacturing Process of Mould for Die Casting by EDM Technology with the Computer Aided

At present, we cannot imagine a modern production process without computer support. At the same time, its integral part is the implementation of advanced and highly sophisticated production processes and technologies. Their aim is first and foremost to ensure quality production of products with high economic efficiency of the production process. EDM technology is one of the currently active progressive technologies. This is a technology that in practice is characterized by high product quality. The high quality of products not only through this progressive technology, but also other, whether conventional or progressive, is difficult to achieve without computer support. The aim of the paper is therefore to demonstrate the process of manufacturing a die-casting mould using progressive EDM technology using computer support