nano machining and surface finishing

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MGM’S COLLEGE OF ENGIINEERING, NANDED Guide:- Mr. Sawale Presented by Mr. AKASH BAGE Mr. Akshay U Kumbhar MECHANICAL MECHANICAL NANOMACHINING AND SURFACE FINISHING ADVANCE MANUFACTURING IN

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INTRODUCTION Micro and nano machining technique appears to be very promising as a future technology since in many areas of applications it offers several advantages. In this paper a review is presented on current research, development and industrial practice of micro and nano fabrication. The micro machining can effectively be used for high precision machining operations. Further research activities of MICROMACHINING will open up many challenging opportunities for effective utilization in different mechanical machining process

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Mechanical Micromachining • Lithography and/or etching methods not capable of making true 3D structures e.g. free form surfaces • Also, limited in range of materials • Mechanical machining is capable of making free form surfaces in wide range of materials • Can we scale conventional/non-traditional machining processes down to the micron level? Yes!

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Mechanical Micromachining • Two approaches used to machine micron and sub-micron scale features – Design ultra precision (nanometer positioning resolution) machine tools and cutting tools • Ultra precision diamond turning machines – Design miniature but precise machine tools • Micro-lathe, micro-mill, micro-EDM, etc

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Mechanical Micromachining Process Description • Can produce extremely smooth, precise, high resolution true 3D structures • Expensive, non-parallel, but handles much larger substrates • Precision cutting on lathes produces miniature screws, etc with 12 μm accuracy • Relative tolerances are typically 1/10 to 1/1000 of feature • Absolute tolerances are typically similar to those for conventional precision machining

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Mechanical Micromachining ROBOnano Micro Machine Micro Lathe Micro Milling Machine Nano ECM Drilling/cutting

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Miniature Machine Tools Micro Lathe Micro Factory

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Micro Turning Micro Milling

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Micro Milling Machine . Micro Milling Machine Rouge figure pocketing Honeycomb 4mm pitch 2mm deep ˙ Spindle: diameter= 27 mm 80 watt, 300,000 rpm ˙ Position resolution: 50 nm ˙ High spindle rotation, high feed rate and small depth-of-cut reduce the machining force Micro Milling Machine

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Drilling/Cutting An intelligent boring tool capable of manufacturing holes with cylindricity of less than 5 micron Simultaneously boring and measuring the hole Correct the cut position dynamically An actuator captures and compensates the deformations of spindle and drilling wall, and eliminates subsequent finishing steps

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ELID-Grinding System with wheel, grinding fluid and a power supply Anode - grinding wheel; Cathode – electrode ˙Metal-bonded wheel is necessary Electrochemical dissolution of binding material

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Laser Micro Drilling                                        Laser drilling can be used to produce micro-holes in almost any material. Very high position and diameter tolerances can be achieved.

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Micro Manufacturing Laser Beam Focused Ion Beam

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Micro EDM Lathe ˙Some obvious advantages compared with the traditional lathe due to the mechanism of EDM Simplify tool fabrication No direct mechanical force Stepped Cavity

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Micro EDM Micro EDM -- Use kerosene as a dielectric medium -- Make the masks for organic thin film transistors ˙ Micro ECM -- Use faster pulse rate for better precision -- Simulation of the ECM process has been conducted for designing the tool

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Micro EDM Exploring the possibility of increasing MRR in micro EDM Minimizing the open circuits by improving the gap regulation

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Multi-functional four axis micro CNC machining center Pagoda (1.25mm X 1.75 mm) machined by Micro-Wire EDM Four Integrated functions -- Mechanical Milling -- Micro EDM -- Micro Wire EDM -- Online measurement module for flatness, circularity, concentricity, dimensions, and geometrical tolerance

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Micro ECM Micro ECM introduces an innovative process for metal removal through selective electrolytic dissolution of geometric features in the micron range. Applications can vary from motor bearing grooving to airflow turbulator contours

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Conclusions The overall activity is constrained by the limited market need Extensive research and development efforts are required for the expected breakthrough of micro manufacturing Main problems are scaling effects, devices to generate and deliver required energy, precision, scalability for producing large quantities, and development of micro scale machines and micro factories

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Barriers Current education and curriculum focus on micro fabrication based on polymers and semiconductors rather than wider range of materials and processes Lack of planning and initiatives for the implementation of research outcomes Limited exchange of technology and knowledge among manufacturers

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REFERENCES:- RECENT DEVELOPMENTS IN MICRO ECM LEADING TOWARDSNANO FABRICATION-Prof. B. Bhattacharyya. DIAMOND TURNING PROCESS-Prof. Mr. Balsubramaniam.BARC MUMBAI FUTURISTIC MFG. CHALLENGES & OPPORTUNITIES –Dr.S.K.Basu. DEVELOPMENT OF INTEGRATED HYBRID MICROMACHINING SYSTEM -Prof.M.Rahman CALLENGES IN MESO,MICRO & NANO MFG.-Prof. V. Radhakrishnan. WEBLINK:- WWW.GOOGLE.COM WWW.YAHOO.COM