Micro molding milling
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Micromolding and micromilling are specialized microfabrication techniques. Micromolding uses injection molding machines capable of high injection speeds and pressures to mold parts weighing 0.001-0.1 grams. It requires intricate tooling and specialized extraction of tiny parts. Micromilling uses single crystal diamond or tungsten carbide tools to mill complex 3D structures and micro-features with surface roughnesses below 1 micron. Both techniques are used to fabricate parts for medical devices, microfluidics, and other micro-applications. Key challenges include demolding of tiny structures and achieving high aspect ratio micro-features.
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This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which is a hybrid process that combines ECM and EDM, allowing it to machine both conductive and non-conductive materials. The document outlines the principle, material removal mechanisms, and process parameters of ECSM. It also summarizes electric discharge diamond grinding (EDDG) and discusses its basic configuration, parameters, advantages, and applications. Finally, the document provides an overview of recent trends in micro-machining including various advanced mechanical and thermal micro-machining processes.
Unit 5 ucm
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on the working principles, key components, process parameters, advantages and disadvantages of these processes. Specifically, it explains that ECSM is a hybrid of electrochemical machining and electric discharge machining that can machine both conductive and non-conductive materials. It also outlines the basic configuration, factors affecting parameters, and applications of EDDG for precision grinding.
Unit 5 ucm
This document discusses various hybrid and non-traditional machining processes. It describes electrochemical spark machining (ECSM) which combines electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. Electrical discharge diamond grinding (EDDG) uses sparks to grind materials with diamond abrasives. Electron beam micromachining uses a focused stream of electrons to melt and vaporize material for microfabrication.
UCM - Unit 5 recent trends in non-traditional machining processes
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). ECSM uses sparks generated between a cathode tool and workpiece in an electrolyte solution to remove material. Key parameters for ECSM include supply voltage, tool diameter, electrolyte composition, and gap distance. EDDG uses sparks to soften and abrade workpiece surfaces with diamond abrasives. Factors like wheel speed, current, and pulse time affect the EDDG process. Thermal processes like electric discharge micromachining (EDMM) and electron beam micromachining precisely shape conductive materials by localized melting/vaporization using electric
UNIT 5 UCM.pptx
This document discusses various hybrid and non-traditional machining processes including electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on:
1) The principles and components of ECSM, which uses sparks to machine conductive and non-conductive materials.
2) The principles, configuration, parameters and advantages/disadvantages of EDDG, which uses sparks and diamond abrasives to precision grind materials.
3) Various advanced micro-machining processes like abrasive jet, waterjet, and ultrasonic machining and how they operate at the micro scale.
UNIT 5 -Recent Trends in Non-Traditional Machining Processes.pptx
This document discusses various hybrid and non-traditional machining processes such as electrochemical spark machining (ECSM) and electrical discharge diamond grinding (EDDG). It provides details on the working principles, advantages and limitations of these processes. Specifically, it describes how ECSM works by combining electrochemical machining and electric discharge machining to machine both conductive and non-conductive materials. It also explains that EDDG uses sparks to grind materials with diamond abrasives, achieving higher accuracy than EDM. The document outlines the key parameters and applications of these hybrid machining techniques.
Microfactory
Microfactory and Micro Machine Tools is a seminar presented by Todkar Mahesh S. that discusses:
1. What microfactories and micro machine tools are, including their proposed size and components.
2. Examples of micro machine tools developed in Japan in the 1990s like the micro-lathe and micro-milling machine and their specifications.
3. The advantages of microfactories and micro machine tools in saving space, power, and material while improving precision and production rates.
Edm micromaching [autosaved]
This document discusses EDM micro machining. It begins by defining miniaturization as the process of making components smaller, noting demands for micro parts in fields like electronics and biomedicine. Micro parts may be a few millimeters in size but have microscale features from 1 to 500 micrometers. The history of microEDM is then summarized, including its demonstration in 1986 for drilling small holes. Key aspects of microEDM like the spark phenomenon and components like pulse generators are also briefly introduced. The document concludes by noting microEDM's advantages like machining complex shapes in hard materials and applications in medical, automotive, and other industries.
Micro mach
This document discusses recent trends in non-conventional micromachining techniques. It describes several methods such as electrochemical micro-machining (EMM), micro-electrodischarge machining (MEDM), laser micro-machining (LMM), ultrasonic micro-machining (USM), and chemical micro-machining (CMM). For each method, it explains the basic principles, micro-machining processes, applications for micro components, and potential for future development at the nanoscale. The document also explores emerging nanomachining techniques using tools like atomic force microscopes and various top-down and bottom-up fabrication processes.
SSM
a case study with my teammates for our college project ( casting course ) about the semi-solid metal for Faculty of engineering ain shams university mechanical department
Advances in micro milling: From tool fabrication to process outcomes
This document summarizes a review article on advances in micro milling. It discusses micro milling cutter geometry, materials, fabrication techniques, material removal mechanisms, design and optimization methods, and performance when used for micromanufacturing. Key aspects covered include micro milling cutter designs like solid cutters and welded cutters, common materials like cemented carbides and coatings, modeling cutting forces and tool wear, and experimental studies of temperature and forces at the microscale.
UNIT 4 ADVANCED NANO FINISHING PROCESSES.pptx
Abrasive flow machining, chemo-mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, magneto rheological abrasive flow finishing their working principles, equipments, effect of process parameters, applications, advantages and limitations
UCM - Unit 4 advanced nano finishing processes
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic processes use magnetic fields to control abrasives.
ADVANCED NANO FINISHING PROCESSES
This document discusses several advanced nano finishing processes including abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. It provides details on the working principles, process parameters, advantages, limitations and applications of abrasive flow machining and chemo mechanical polishing. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching with mechanical polishing to smooth and planarize surfaces.
Unit 4 ucm
This document provides an overview of advanced nano finishing processes. It describes abrasive flow machining, chemo mechanical polishing, magnetic abrasive finishing, magneto rheological finishing, and magneto rheological abrasive flow finishing. For each process, it outlines the basic principles, construction and working, process parameters, advantages, limitations, and applications. Abrasive flow machining uses a semisolid abrasive media to remove small amounts of material from surfaces. Chemo mechanical polishing combines chemical etching and abrasive polishing, while magnetic abrasive finishing uses magnetic particles to form an abrasive brush for finishing. Magneto rheological finishing takes advantage of smart fluids that change viscosity in magnetic fields for precision mach
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Micro molding milling
- 1. MICRO MOLDING & MICRO MILLING 7ME6.1A- Part II Er. Mohit Ostwal Assistant Professor Department of Mechanical Engineering Jodhpur Institute of Engineering and Technology- Coed, Jodhpur
- 2. What is Micromolding? • Micromolding is defined as a very unique Injection Molding process requiring specialized molding machine capable of delivering high injection speed , high injection pressure, precise shot control, uniform melt temperature and ultra fine resolution using servo-electric drives and sophisticated controls.
- 3. Micromolding Features • Part weight… 0.1 to 0.001 gram • Part size….0.100 in. diameter • Specialized machines • Intricate tooling • Specialized part extraction • Micromolding Technical expertise • Microscope to see part geometry
- 5. Micro Molding Processes • Injection Molding Process
- 6. Micro Molding Processes • Hot Embossing
- 7. Micro Molding Processes • LASER assisted Embossing
- 10. Micro Molding Tools • Micro structured mold inserts and tools • Requirements of Mold inserts:- • Friction on sidewalls of microstructure – demolding • Small inclination angle • Tools and ejection system – metal processing • Mechanical micromachining • Laser structuring • EDM • Lithographic : X-rays/UV rays • Electroplating- for plastics and silicon etc. materials
- 11. Micro Mold Design • Demolding - wear and tear of mold inserts • Inclination angle of 2⁰ reduces demolding forces – important than roughness of sidewalls. • Demolding forces – shrinkage of polymers • Delicate microstructures, such as pins with high aspect ratios, can be protected against shearing forces resulting from shrinkage and mold filling by neighboring auxiliary structures that are stable enough to withstand these forces. • If a mold insert is covered with areas microstructures of different height, or varying density, then these areas should be arranged symmetrically on the mold insert. • In this way, tilting of the mold insert during molding is avoided.
- 12. Application
- 13. Application
- 14. Application
- 15. Application
- 16. Application
- 17. Application
- 19. Limitations for micromolding • Structures of only few tens of nanometers in size are replicated very well. • Limitations in achieving high aspect ratios of columns, grooves, walls etc. • De-molding of microstructure. • FEM calculations are only for mold filling but recently FEM calculations for demolding are available.
- 20. MICRO MILLING
- 21. Micro Milling • Characteristics features and applications
- 22. Micro Milling • Characteristics features and applications • Complex 3-D mold cavities, chemical micro-reactors, fluidic parts, flow passages for micro compact heat exchangers, Lithography method complement. • Micro-column arrays can be produced. • Single crystal diamond – CER of 50nm- non ferrous – Brass, Al, Cu, electroless nickle. • Tungsten Carbide tools – small CER – Rz<0.8μm. • This method allows us to produce V-shaped grooves with high shape accuracy without burrs and surface roughness of 48 nm (Rz).
- 23. Micro Milling • Micromills and tooling systems • Diamond tools – limited to non ferrous • Tungsten Carbide tool – grain size smaller than 600 nm.
- 24. Micro Milling • Micromills and tooling systems
- 25. Micro Milling • Machine Tools for Micro milling • High speed machining – 40,000 to 50,000 rpm – CAM programming. • Stable Spindle – minimize vibration and thermal expansion.- small vibrations are amplified relative to tool diameter as it is reduced. • CNC automated milling center – Ultra compact CNC mill. • Direct change type spindle. • Smart Machines – CNC operated.
- 26. Micro Milling • Machine Tools for Micro milling
- 27. Micro Milling
- 28. ALL THE BEST