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Micro and nano manufacturing

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Nanoscale cutting, nano and micro machining, micro turning and microdrilling with videos as per RTU syllabus

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Micro and nano manufacturing

  1. 1. Micro and Nano Manufacturing (7ME6.1A)- Part I Mohit Ostwal Assistant Professor Department of Mechanical Engineering Jodhpur Institute of Engineering and Technology- Coed, Jodhpur
  2. 2. Nano scale cutting
  3. 3. Nano scale cutting
  4. 4. Nano scale cutting
  5. 5. Chip formation in micro cutting
  6. 6. Chip formation in micro cutting
  7. 7. Chip formation in micro cutting
  8. 8. Diamond cutting tool
  9. 9. Example of nano scale cutting
  10. 10. Micro turning
  11. 11. Micro turning • Characteristic Features and application • Swiss-type machine tools, ultra-precision lathes for diamond turning and miniature desktop machines, are used to perform micro turning operations on parts made of different materials. • Maximum Machining Diameter – 7 mm Maximum Machining Length – 40 mm • Hard to machine surfaces such as electroless nickel, glass , ceramics, quartz etc. without any subsurface damage. • Mirror surfaces of less than 10 nm surface finish can be obtained. • Ultra-precision diamond turning – electroless nickel dies – plastic optical parts for LCD Tv’s (less than 6 nm)
  12. 12. Micro turning • Micro turning tools and tooling system • Miniaturized tools with clamping – Swiss type lathe or multi purpose tooling system – Used as a tool block • Monolithic carbide tools – boring and grooving – smallest diameter of 0.2 mm to 4 mm maximum.
  13. 13. Micro turning • Micro turning tools and tooling system (contd.) • Special tooling system – turning, boring, cutt-off and drilling. • System consists of clamping unit and cutting unit. • Machine uptime reduce to 25-40%
  14. 14. Rotating tool head for micro turning operation
  15. 15. Micro turning Machine tools for micro turning • In general – CNC automatic lathe, sliding head mechanism • Swiss type Lathe • Swiss type turning centers with milling, drilling, boring – single setup with lower cost –upto 4mm dia.. • Sliding head stock – 32 mm max. dia. with bar feeder. • 12000 rpm – with guide bushes and 16000 rpm without guide bushes. • 10000 rpm – sub spindles for milling, drilling.
  16. 16. Micro turning
  17. 17. Micro turning
  18. 18. Micro turning
  19. 19. Micro drilling
  20. 20. Micro drilling • Characteristic Features and application • Holes – tens of micrometers – PCB • Inkjet printers – single row of 251 holes – 50 μm dia. • Used below 0.5 mm. • Minimum diameter of micro drills -> 5-50 μm. • Advantages of micro drilling: 1. Metals, plastics and composites can be drilled – electrical properties do not influence the workpiece (wire EDM). 2. Controllability • Disadvantages of micro drilling: 1. Inclination of holes 2. Brittle and hard materials – break micro drills – diamond drills.
  21. 21. Micro drilling • Microdrills and tooling system • HSS(resistant to breaking) to carbide(stiffer but brittle). • Diameter range – 0.12 mm to 2.8 mm. • Drilling of Aircraft Al, Titanium, SS, Steel. • 10 mm length with shank.
  22. 22. Micro drilling • Microdrills and tooling system • 0.3 mm HSS micro drill
  23. 23. Micro drilling (contd.) Micro drills of the smallest obtainable diameter of approximately 6 μm with a D-shape cross-section and a cutting edge radius of 0.5 μm can be fabricated by wire electro-discharge grinding
  24. 24. Micro drill • Machine tools for microdrilling
  25. 25. Micro drill • Machine tools for microdrilling (contd.) • Precision to eliminate hand finishing – Air bearing spindle – 500000 rpm(max.) – 180000(current) – 160000(ball bearing).
  26. 26. Micro drill • Machine tools for microdrilling (contd.) • Precision to eliminate hand finishing – Air bearing spindle – 500000 rpm(max.) – 180000(current) – 160000(ball bearing).
  27. 27. Micro drill -USM
  28. 28. Micro Drilling
  29. 29. Burr formation
  30. 30. MEMS Parts- silicon mirror assembly
  31. 31. Micro milling example • Used to create 3D features in the range of a few microns to a few hundred microns. • Micro milling is capable of the fabricating holes several tens of micrometers in size for practical applications.
  32. 32. Micro manufacturing example • A mite measuring 500m long sits on a mirror array used for optical data switching. • The mirror [flat in the left image, folded in the right] is positioned with a gear mechanism
  33. 33. A focused ion beam created this two-micron-wide gear, seen here at 50,000x magnification

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