MICRO-MACHINING
TECHNIQUES
Presented by:
Firoz .D. Chowki
Contact no: 8419952545.
College: MIT Academy Of Engineering , Alandi Pune.
IMechE No: 80451931.
Email Id: [email protected]
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• CONTENTS:
Introduction to Micro-Machining.
Classification of Traditional and Advanced Micromachining techniques.
Needs of Micromachining.
Micromachining Techniques. (with reference to its classification).
Properties of work materials to be machined.
Accuracy and Dimensional control of the micro-machining processes.
Applications of micromachining.
Conclusion.
References.
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• INTRODUCTION TO MICRO-MACHINING:
Micro-machining is the most basic technology for the production of such
miniature parts and components.
Micromachining is the basic technology for the fabrication of the
components of. size in the range of 1µm to 999µm .
Micromachining is also known as the ‘Superfinishing’. It is a metal
working process that improves the surface finish.
This is achieved by removing just the thin amorphous surface layer left by
the last process.
Nano level surface finish on complex geometries which are impossible to
achieve by any traditional methods (e.g., thousand soft turbulated cooling
holes in a turbine blades, for producing micro holes in electrically
conducting and non-conducting materials (say, glass, quartz, ceramics.).
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• NEEDS FOR MICRO-MACHINING:
Micromachining techniques fulfills the demand for industrial products
with increased number of functions and of reduced dimensions.
To produce features with the dimensions from 1 m to 999 m or when the
volume of the material removed is at the micro level.
Minimizing energy and materials used in manufacturing.
Reduction of the power budget.
Increased selectivity and sensitivity.
Improved reliability and accuracy.
Cost performance advantages.
Integration with electronics and simplifying systems.
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• CLASSIFICATION OF TRADITIONAL AND
ADVANCED MMP’S:
MICROMACHINING PROCESSES
TRADITIONAL ADVANCED
MECHANICAL THERMAL CHEMICAL/ELECTRO-
CHEMICAL
µ-MILLING AJMM µ-LBM ECMM
AWJMM µ-EBM PCMM
µ-TURNING
WJMM µ-PAM
µ-GRINDING
USMM µ-EDM/
µ-DRILLING µ-WEDM
• Some of the Hybrid Micro-Machining Processes are:
μ-ECSM, μ-ECG, μ-EDG, ELID, etc.
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• MECHANICAL ADVANCED MACHINING PROCESS
1. Ultrasonic Micro-Machining (USMM) :
Ultrasonic Micro-Machining (USMM) is capable of making almost any
three dimensional microstructure with high aspect ratio on most of
materials, mainly on brittle materials.
The USMM uses a tool Ultrasonic Vibration with combination of favorable
abrasive slurry to create accurate cavities of any shape through the impact
grinding of fine grains.
The machining process is non thermal, non-chemical, non-electrical and
thus produces high quality surface finish.
However, the micro-USM is not capable
of drilling of micro holes smaller than
100um for lack of corresponding co-axial
micro tools.
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2. Abrasive Jet Micro-Machining (AJMM):
Fine abrasive particles like silicon-carbide, aluminum-oxide, or the sodium
bicarbonate with high kinetic energy (K .E.) hits the work piece at an angle
and removes the material in the form of micro/ nano-chips.
If the KE of the abrasive particles is high enough, the nit will remove the
material by shear deformation in case of ductile work piece material and
by brittle fracture if work piece material is brittle.
Holes up to 66 μm deep can be drilled without employing special
techniques.
Micro burrs are clearly visible.
This process is also useful for producing
the micro-cavity.
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3. Abrasive -Water Jet Micro-Machining (AWJMM):
This process is totally similar to that of the abrasive jet machining except
that, here the mixture of abrasive slurry particles and the water is impacted
at a high velocity on the work piece.
Holes or the indentations of almost 20 µm to 100 µm can be obtained.
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4. Water Jet Micro-Machining (WJMM) :
This process is totally similar to that of the abrasive jet machining except
that, here the high pressurized water jet/ stream is pumped through the
Hydraulic pumps and the Intensifier, which is then impacted on the work
piece.
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• THERMAL – ADVANCED MICRO-MACHINING:
1. Laser Beam Micro- Machining (µ-LBM):
Laser technology has been qualified as a capable micro manufacturing
technology because of its high lateral resolution with the minimized focus-
ability down to a few microns, or even smaller, low heat input and high
flexibility.
The laser machining process is controlled by switching the laser on and
off, changing the laser pulse energy, and other laser parameters and by
changing the position of the laser focus or the work piece.
Thus, the removal of the metal surface is combining, which is carried out
with the melting and the evaporation process.
A laser machine consists of the laser, mirrors for the beam guidance, a
focusing optic and a positioning system.
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1. Laser Beam Micro- Machining (µ-LBM):
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2. Plasma- Arc Micro-Machining (µ-PAM):
Plasma-arc micro-machining is based on the principle in which, “The
removal of the material is carried out by directing the high velocity ,high
temperature jet of ionized gas on the work piece”.
The plasma arc torch the volume of the gas , such as H2, N2, O2, is passed
through the small chamber where the high frequency spark is maintained
between the cathode and the anode.
Thus ,the collision of the gas molecules and the electrons generated by arc,
results into the ionization of the atoms, causing a large amount of the
thermal energy to be liberated.
Thus, the plasma arc melts the work piece .
And, the high velocity gas stream blows the molten metal away.
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2. Plasma- Arc Micro-Machining (µ-PAM):
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3. Electron- Beam Micro-Machining (µ-EBM):
Electron beam is generated in an electron beam gun.
Electron beam gun provides high velocity electrons over a very small spot
size.
Electron Beam Machining is required to be carried out in vacuum.
Otherwise the electrons would interact with the air molecules, thus they
would loose their energy and cutting ability.
Thus the work piece to be machined is located under the electron beam and
is kept under vacuum.
The high-energy focused electron beam is made to impinge on the work
piece with a spot size of 10 – 100μm.
The kinetic energy of the high velocity electrons is converted to heat
energy as the electrons strike the work material.
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3. Electron- Beam Micro-Machining (µ-EBM):
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4. Electric-Discharge Micro-Machining (µ-EDM)/
/Wire Electric-Discharge Micro-Machining (µ-WEDM):
A. Electric-Discharge Micro-Machining (µ-EDM) :
It is based on the principle of, “metal removal by the erosion of the
metals by an interrupted electric spark discharge between electric tools
(cathode) and the work piece (anode)”.
The work piece (anode) and the tool (cathode) are electrically connected
to the DC power supply.
A spark gap of 0.005mm to 0.05mm is maintained between the work
piece and the tool.
Thus ,the part of the metal may vaporize and the metal is removed from
the workpiece.
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A. Electric-Discharge Micro-Machining (µ-EDM) :
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B. Wire Electric-Discharge Micro-Machining (µ-WEDM):
In this process ,a slowly moving wire electrode travels over a prescribed
path, and removes the material from the work piece.
µ-WEDM uses the electro-thermal mechanisms to cut the electrically
conductive materials.
the material is removed by the series of descript-discharges between the
wire electrode and the work piece in the presence of the die-electric fluid.
The surface to be melted and removed is heated at an extremely high
temperature.
The removed particles are flushed away by the flowing die-electric fluid.
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B. Wire Electric-Discharge Micro-Machining (µ-WEDM):
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• CHEMICAL/ ELECTRO-CHEMICAL ADVANCED
MICROMACHINING (µ-ECM/µ-ChM):
Electrochemical Micro-Machining (ECMM).
Chemical Micro-Machining (ChMM).
Photo Chemical Micro-Machining (PCMM).
Electrochemical Spark Machining (ECSM).
Electrochemical Micro-Deburring (ECMDe).
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• PRINCIPLE OF ELECTROCHEMICAL & CHEMICAL
MICRO MACHINING PROCESSES:
1. Electro-Chemical Micromachining (µ-ECM) :
Electro chemical metal removal is an alternate wet etching process
The work piece made an anode and the tool as cathode in an electrolyte
cell in which an on toxic salt solution is used as an electrolyte
Controlled metal removal takes place when the current (smooth D.C. Or
Pulse D.C.) flow through the electrolytic cell.
It is also called as the reverse electroplating.
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1. Electro-Chemical Micromachining (µ-ECM):
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• PROPERTIES OF THE WORK PIECE TO BE
MACHINED:
Applicable only for electrically conducting materials: ECM, EDM,
EBM.
Applicable for both electrically conducting & non -conducting
materials: USM , AJM, LBM, etc.
Applicable for non –magnetic materials : MAF, MRF, etc.
Thermal conductivity, reflectivity, etc. Also play an important role in
some cases: LBM based.
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• APPICATIONS OF AMMP’s:
Integrated Circuit (I.C.) Design.
Printed electronic board, name plates and printer plates.
Measurements : strain gauges, galvanometers, mirror frames, etc.
Electronics industry: shadow masks for CRT’s Magnetic recording heads,
etc.
Fabrication of spinnerets.
3D springs, gear manufacturing, coils, Bearings, etc.
Food industry, automotive and rail road components.
Machining of semi-conductors.
In nozzle for the diesel fuel-injectors.
In inkjet printer manufacturing.
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CONCLUSION
As regards micro-machining, dimensions of the product is on the good
indicators of the levels of technology and advancements in production
technologies.
However, the level of requests from the industries varies widely due to
the demand of higher accuracy and tolerances.
The need for products containing micro-holes has shown a steady growth
in recent years.
This research aims to alleviate the problem of flushing of debris by
machining micro holes.
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REFERENCES
# BOOKS:
01. ”Micro-Manufacturing Processes”, by Prof. V . K. Jain.
02. “Micro-Machining Methods” by J.A. Mc GEOUGH, Champan and Hall,
LONDON.
# WEBSITES:
01. http://www.slideshare.net.
02. http://www.home.iitk.ac.in/vkjain/MMPs.
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ANY QUESTIONS ??
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