Professional Documents
Culture Documents
S . I N
T U N OTE
K
1
Page
S . I N
precision (sub-micro or nano scale) in terms of surface, profile and dimensional accuracy
OTE
becomes essential for products for their performance.
Methods for micromaching
K T U N
The technique for fabrication of 3D and 2D structures on the micrometre scale. Micro-
machining process can be classifies as follows;
from aerospace, medical appliance and the automotive world, the potential for product
Page
S . I N
OTE
optical lenses and mirrors. Diamond turn machining can produce surface finish and tolerance to
nano scale especially required for optical elements. To effect a smooth shearing action, a very
T U N
sharp edge and uniform cutting tool edge of the order of a few to tens of nanometer is
K
essential. Such fine edge radius is possible with hard single crystal materials such as
diamond.
Diamond only softens at 13500C and melts at 3027 0C, and is also the hardest material in the
world. The high hardness is important for reducing wear rate and enable machinability of
glass and ceramic materials. Cutting edge radius of single point diamond tool can be
sharpened down to 20nm. Its sharp edge can be retained without major wear. Micro-
machining using diamond tool could be performed at high speeds and generally fine speeds to
produce good surface finish such as mirror surfaces and high dimensional accuracy in non-
ferrous alloys and abrasive non-metallic materials. Most single point diamond tool is used
with computer numerical control (CNC) machine tools. Diamond turned surfaces have a high
specular brightness and require no additional polishing or buffing, unlike other
conventionally machined surfaces
3
Page
K T U
Fingerprint Scanners
N
Barcode Scanners
Material removal mechanism in micro-machining
The mechanism for material removal involved plastic deformation, micro-fracture and
dislodgement of grains. In nano and micromachining processes the material removal can be
limited to few atoms or layers of atoms. The single point diamonds tool is sharpened to edge
radius as fine as 100 nm, sometimes even up to 20–40 nm. The concept of ductile mode machining
has developed for machining brittle materials, such as glass, Si, Ge and Sic Mechanism of material
removal are governed by the tool edge radius and microstructural effects.
The brittle materials could be machined in the ductile mode when appropriate cutting conditions
and tool geometry were used. Achieving surfaces with high form accuracy, fine surface roughness
and low surface and subsurface damage.
4
Page
S . I N
T U N OTE
K
The AFM process utilizes an abrasive media applied at high pressure to through a work piece.
One-way flow AFM processing pushes abrasive media through the work piece in only
one direction, allowing the media to exit freely from the part.
Two-way flow AFM process uses two vertically opposed cylinders to extrude an
abrasive media back and forth through or around passages formed by the work piece
and tooling.
AFM may be performed once, as a one-way flow process, or repeatedly as a two-way flow
process. In the two-way flow process, a reservoir of medium exists at either end of the work
5
piece, and the medium flows back and forth through the work piece from reservoir to
Page
reservoir
S . I N
OTE
8. Cross sectional area
K T U N
It was observed that pressure, abrasive size and percentage of abrasive concentration in media
are the most significant parameters for material removal and improvement in surface
roughness. Also viscosity of media was found as significant parameter for material removal
for the considered size and shape of the work piece.
AFM is capable to produce surface finish (Ra) as good as 0.05 µm. Best surface finish that
has been achieved as 50nm and tolerances +/- 0,5 µm
Application of AFM
It is widely used for finishing process to finish complicated shapes and profiles. Process used
in aerospace, medical and automobile, tool and die industries to achieve
1. Better surface roughness values and tight tolerances.
2. Improve surface quality
3. Reduction in Friction
4. Eliminate imperfection
AFM is particularly well suited for use on gas turbine engine components because these
components usually have complex geometries.
6
Page
S . I N
T U N OTE
K
When inserting a cylindrical work piece in such a processing field giving revolution, feed and
Page
vibration in axial direction, surface and edge finishing are carried out by magnetic brush.
S . I N
OTE
3. Finishing of bearing.
4. Aerospace components.
K T U N
5. Electronics components with micro meter or submicron-meter ranges.
Process parameters
Process parameters: magnetic abrasive type, abrasive particles, magnetic device, work piece
material, working gap, grinding oil, rotational speed, and axial vibration) and
MRR and surface roughness
The magnetic abrasive type, abrasive particles, magnetic device, work piece material,
working gap, grinding oil, rotational speed, and axial vibration are known as the significant
input parameters in the MAF process because they have significant influence on the MAF
process.
Ra = AS GOOD AS 8 nm
8
Page
S . I N
10 microns of carbonyl iron dispersed in a non-magnetic carrier medium like silicone oil,
mineral oil or water.
T U N OTE
K
Magnetic particles (µm /nm) size suspended within the carrier oil are distributed randomly
Under magnetic field, microscopic particles align themselves along the lines of magnetic flux
9
Page
. I N
The rheological properties of MRP-fluid depend on carbonyl iron particle size (CIP), silicon
S
OTE
carbide (SiC) particle size, their volume concentration, magnetic properties and magnetic
K T U N
field strength. The MR fluid temporarily stiffens and conforms to the surface of the
component being finished. This allows geometries of almost any shape to be polished as
easily as a spherical optic
The MRP fluid is extruded back and forth through the passage, material removal will take
place.
S . I N
T U N OTE
K
Structure formed with abrasives trapped and embedded between iron chains, in the presence
of finite magnetic field.
11
Page
S . I N
T U N OTE
K
The surface finish obtained was 4 nm Ra and 40 nm Rmax. The best sphericity obtained of the Si3N4
balls was 0.15 to 0.2 µm. Finished surfaces relatively free of scratches, pits, etc. were obtained.
The magnetic float polishing technology that has been developed has the following
characteristics.
1. High material removal rate
2. Excellent surface finish – crack free surface
3. Good sphericity
12
Page
. I N
float polishing finds use in precision polishing of ceramic balls.
S
U N
Elastic Emission Machining (EEM)
T OTE
K
A process of machining where material is removed by the elastic fracture without plastic
deformation in the order of atomic size is called EEM. Using ultra fine particles to collide
with the work piece surface, it may be possible to finish the surface by the atomic scale
elastic fracture without plastic deformation. This new process is termed as Elastic Emission
Machining.
EEM processing is conducted in a machining slurry in which powder particles are suspended
in pure water. The slurry is continuously supplied to a machining point by a tool, which leads
to the powder particles attacking the surface. EEM is a non-contact machining process,
differing from conventional polishing, which uses an abrasive pad. Therefore, atomic-order
smoothness without crystallographic damage can be achieved.
The removal process in EEM solely depends on the contact between powder particles and the
work piece surface. Fine powder particles are brought to the work piece surface by a flow of
pure water, and the chemical reaction between the surfaces of the work piece and the particles
results in the removal of surface atoms from the work piece
The powder particles chemically react with the surface, thus removing the surface. A rotating
sphere is used as a tool in EEM. The rotation of the sphere close to the work piece surface
produces the flow of slurry with dynamic pressure at the gap. This enables the powder
particles to attack the surface while maintaining the noncontact state between both surfaces.
13
Page
I N
by a variable speed motor. The axis of rotation is oriented at an angle of 45º relative to
S .
OTE
the surface of the work piece to be polished. The work piece is submerged in slurry of
K T N
ZrO2 or Al2O3 abrasive particles and water.
U
The material removal rate for the work piece was found to be linear with dwell time at a
particular location, allowing the total thickness of material removed to be controlled to
within 20 nm. The removal rate, however, was found to vary non-linearly with
concentration of abrasives in the slurry.
The proposed mechanism of material removal due to slurry and work piece interaction
involves erosion of the surface atoms by the bombardment of abrasive particles without
the introduction of dislocations. Surface roughness as low as 0.5 nm rms have been
reported on glass and a surface roughness of ≤ 1nm rms was obtained when polishing
single crystal Silicon.
14
Page
***************************************
. I N
The low viscosity MR fluid is pumped through a shaping nozzle onto a vertical, rotating
S
OTE
wheel. At the apex of the wheel, the fluid stiffens into a ribbon, under the influence of a dc
K T N
magnetic field. The work piece is placed into the ribbon and forms a converging gap.
U
Shaping and smoothing are accomplished simultaneously as the rotating work piece is moved
through the ribbon under computer control.
An electromagnet, located below the polishing wheel, has specially designed pole pieces that
extend up to the underside of the apex of the wheel rim. These pole pieces exert a strong local
magnetic field gradient over the upper side of the wheel. When the magnetorheological fluid
passes through the magnetic field, it stiffens in milliseconds, then returns to its original fluid
state as it leaves the field, again in milliseconds. This precisely controlled zone of magnetized
fluid becomes the polishing tool. When an optical surface is placed into the fluid in this zone,
the stiffened fluid ribbon is "squeezed" from its original thickness of about 2 mm, to about l
mm. The "squeezing" results in significant shear stress and subsequent polishing pressure
over that section of the optical surface. At the same instant, the MR fluid conforms to the
local curvature of the part being polished.
15
Page
S . I N
T U N OTE
K
Rapid Prototyping (RP), also known as Solid Freeform Fabrication (SFF) builds complex
shapes through additive processes, producing components without the use of tools.
The advantages of RP
1. Physical models of parts can be manufactured in a matter of hours and allow the rapid
evaluation of manufacturability and design effectiveness. In this way, rapid
prototyping serves as an important tool for visualization and concept verification. This
helps the user in knowing how the final product will look like.
2. As the development costs are reduced, Rapid prototyping proves to be cost effective.
3. The process itself reduces waste, as unused materials can be recycled.
4. It is easier to find the design flaws in the early developmental stages.
5. There is better communication between the user and designer as the requirements and
expectations are expressed in the beginning itself.
6. High quality product is easily delivered by way of Rapid prototyping.
In short why use Rapid Prototyping
1. To increase effective communication.
2. To decrease development time.
3. To decrease costly mistakes.
4. To minimize sustaining engineering changes.
16
S . I N
OTE
While there are many ways in which one can classify the numerous RP systems one of the
K T N
better ways is to classify RP systems based on the material that the prototype or part is built
U
with. In this manner, all RP systems can be easily categorized into
(1) Liquid-based
(2) Solid-based and
(3) Powder-based.
Liquid-based RP systems have the initial form of its material in liquid state. The Stereo
lithography Apparatus (SLA) falls into this category.
Solid-based RP systems encompass all forms of material in the solid state. In this context, the
solid form can include the shape in the form of wire, roll, laminates, pellets and powders. The
Selective Laser Sintering (SLS), Three-Dimensional Printing (3DP) Fused Deposition
modelling (FDM) fall into this definition
Another classification of Rapid prototyping into following groups
Subtractive (Removal of material)
Conventional methods of prototyping (by machining or other process0
Additive (adding of material): Build parts in layer by layer (slice by slice as stacking a
loaf of bread)
o Stereo lithography
o Fused Deposition Modelling (FDM)
17
. I N
just below the resin surface. An X-Y electronic motor driver optical scanning mirrors directs
S
OTE
the laser beam, which cures the borders and cross sections of the built parts one layer at a
K T N
time on the surface of the resin. Photopolymers are converted into solid state instantly after
U
irradiation of laser beam. The elevator then lowers the newly built layer by a distance of one-
layer thickness after a short period of time to allow the newly formed layer to increase the
green strength. The process is repeated until the object is completed and object is taken out
by raising the elevator and object is removed from the vat.
Advantages
1. Accuracy and precision parts (Tolerances= 0.0125mm)
2. Good surface finish
3. Less time taken (depends upon the size and complication of the part)
4. Wide shape and complex geometries can made
5. Pattern for all casting and moulding can be made economically
Disadvantages
1. Expensive
2. Size of object (50*50*60 cm) is limited
3. Fragility of product
Applications
1. Medical and Healthcare parts
2. Electronics; Packaging, Connectors
18
S . I N
Advantages
1.
T U N OTE
FDM process part can be high strength,
2.
3.
K
Cost-effective and waterproof.
Easy material change
4. Thin parts can be made
5. Tolerance of +/- 0.005”
6. Low temperature operation
Disadvantages
1. Part strength is weak perpendicular to build axis
2. Seam line between layers
3. Temperature fluctuation during production lead to de-lamination
4. Support requirement is difficult
Application
Used for making concept and functional models in many industries.
Concept models — Test form and fit, communicate design intent
Functional prototypes — Tough prototypes that can be used for functional tests
Support parts (jigs, fixtures, helps) can be produced directly
Typical applications include automotive, aerospace or any application where your part needs
19
S . I N
First cylinder moves up so that a layer of material can be send to the second cylinder. In
OTE
second cylinder after receiving a layer of material, it is processed using laser beam. Then
second cylinder moves down to receive the next layer from the first cylinder as it moves up to
T U N
supply the next layer of materials. The processes continue till final product forms.
Advantages K
1. SLS offers the freedom to quickly build complex parts that are more durable and
provide better functionality over other rapid prototyping technologies.
2. Fast build times/ production rate
3. Variety of materials can be process
4. Raw materials are inexpensive
5. Simultaneous production of work is possible
Disadvantages/ Limitations
1. Typical SLS parts have little rough & porous (not good surface finish) not as smooth
as SLA surface
2. The larger shrink rates of SLS increase the tendency for the prototype to warp
3. Material changeover difficult compared to FDM & SLA.
4. Some post-processing / finishing required
Materials used
Polyamide
Polystyrene
20
Nylon etc
Page
S . I N
T U N OTE
K
Advantages
1. Fast production, less time is required
2. No support structure is required
3. Relatively large parts may be made, because no chemical reaction is necessary
4. Low cost due to readily available raw material
Disadvantages
1. Dimensional accuracy is slightly less than that of stereo-lithography and selective
laser sintering but no milling step is necessary.
2. The life of LOM product is limited
3. Poor surface finish
21
S . I N
T U N OTE
K
Advantages of LBW
1. Laser beam can be transmitted through air rather than requiring a vacuum,
2. The process is easily automated
3. LBW results in higher quality welds.
4. Thermal damage is minimum
5. Filler material is not required
6. High precision weld
Limitations
1. Low welding speed
2. Thickness of weld is limited
3. Certain materials cannot be welded (Mg)
Application
1. To produce micro weld
2. Dissimilar material welding
22
Page
Advantages
. I N
1. Can be used to repair parts as well as fabricate new ones
S
OTE
2. Can fabricate strong functional metal product
3. Net shape product
K T U N
4. Less wastage and less secondary finishing process is required
5. Product can undergo light finishing machining and heat treatment process
Disadvantages
1. Has a rough surface finish, may require machining or polishing
2. Some constrain in geometry shape of product
Application
1. Fabrication and repair of injection molding tools
2. Fabrication of large titanium & other exotic metal parts for aerospace applications
3. Parts have been fabricated from stainless steel alloys, nickel-based alloys, tool steel
alloys, titanium alloys etc
Liga processes
The LIGA-process is used to manufacture micro structures by deep X-ray lithography. Using
the process, microstructures can be manufactured from different plastic materials and metals.
The LIGA consists of three main processing steps;
1. Lithography,
2. Electro-forming/electroplating
23
3. Molding.
Page
S . I N
partly covered with a strong X-ray absorbing material. Chemical removal of exposed (or
T U OTE
unexposed) photoresist results in a three-dimensional structure, which can be filled by the
N
electrodeposition of metal. The resist is chemically stripped away to produce a metallic mold
K
insert. The mold insert can be used to produce parts in polymers or ceramics through
injection molding.
Advantages
1. Capability to make large aspect ratio structures
2. To produce Micro- structural components
3. Wide range of part sizes is feasible
4. Close tolerances are possible and high surface finish.
5. High production is possible
Disadvantages
X-ray LIGA is expensive due to the equipment required.
Slow process.
Complex process
Applications
MEMS Components
Sensors
Actuators
Trajectory Sensing Devices
24
Working
Dry air or gas is filtered, compressed and regulated (pressure and flow rate) while passed into
the mixing chamber. In the mixing chamber, abrasive powder is fed and is thoroughly mixed
S . I N
with air. The nozzle increases the velocity of the mixture at the expense of its pressure.
T U OTE
Nozzles direct abrasive jet in a controlled manner onto work material. The velocity of the
N
abrasive stream ejected through the nozzle is generally of the order of 330m/sec.
K
Advantages of Abrasive Jet Machining (process capabilities)
1. Surface of the work piece is cleaned automatically.
2. Smooth surface finish can be obtained.
3. Equipment cost is low.
4. Hard materials and materials of high strength can be easily machined.
5. Narrow slot can be produced
S . I N
OTE
from figure that MRR increase with nozzle tip distance or Standoff distance up to certain
distance and then decreases. Decrease in SOD improves accuracy, decreases kerf width, and
T U N
reduces taper in machined groove.
K
Applications
1. Used for cutting thin fragile components like germanium, silicon etc.
2. Most suitable for machining brittle and heat sensitive materials like glass, quartz,
sapphire, mica, ceramics germanium, silicon and gallium.
3. De-flashing small castings, engraving registration numbers on toughened glass used
4. AJM is useful in manufacture of electronic devices, drilling of glass wafers, making
26
of nylon and Teflon parts permanent marking on rubber stencils, cutting titanium foils
Page
**********************************
steps leading to material removal by EBM and explain the process. (12 marks)
30. In Plasma Arc Machining, how a transferred is are processes different from a non-
Page
**************************************************************
36. What is meant by kerf width in AJM? How does it relate to the nozzle tip distance?
37. Illustrate and explain the Abrasive Water Jet Machining process and state the
advantages, limitations and applications of the process.
38. Draw graphs to relate the following process parameters to the material removal rate in
abrasive jet machining
a. Nozzle tip distance.
b. Abrasive flow rate.
c. Abrasive grain size
39. Discuss abrasive water jet machine.
40. List any two advantages of AJ M process.
41. Discuss any four process parameters involved in AJM.
42. List the various elements of AJM process and explain their influence on process
parameters.
43. Explain the process parameters which influence Metal Removal rate in Abrasive Jet
Machining
S . I N
T U OTE
44. What are the limitations of abrasive jet machining?
N
45. Describe, in detail, metal removal by abrasive jet machining.
K
*******************************************************
46. Why are abrasive slurry is used in ultrasonic machining? _
47. Sketch and explain Ultrasonic Machining.
48. Explain the principle of ultrasonic machining. What are the limitations of USM?
49. Why is frequency tuning a must in Ultrasonic Machining?
50. What is the function of a concentrator in Ultrasonic Machining?
*********************************************************************
51. `What is rapid proto-typing?
52. Briefly explain the types, process and advantages of Rapid prototyping process.
53. Explain the fused deposition modelling and laminated object manufacturing methods
used in Prototyping process.
54. List out the any four advantages of Rapid. Prototyping.
55. What do you mean by Virtual and Physical prototyping?
56. Name the different types of Rapid prototyping.
57. Explain basic steps involved in Rapid prototyping with flow diagram.
58. What are the advantages of` rapid prototyping?
28
**********************************************************************
S . I N
T U N OTE
K
29
Page