A Preliminary Study on Machinability of Polymethylmethacrylate (PMMA)/Multi-Walled Carbon Nanotube (MWCNT) Nanocomposites in Focused Ion Beam Micromachining

2011 ◽  
Author(s):  
Pengfei Li ◽  
Wei Xue ◽  
Dave Dae-Wook Kim ◽  
Young-Bin Park
Keyword(s):  
Carbon Nanotube ◽  
Material Removal Rate ◽  
Soft Lithography ◽  
Material Removal ◽  
Focused Ion Beam ◽  
Removal Rate ◽  
Ion Beam ◽  
Input Current ◽  
Multi Walled Carbon Nanotube ◽  
Solution Casting Method

This experimental study investigated the machinability of polymethylmethacrylate (PMMA)/multi-walled carbon nanotube (MWCNT) nanocomposites with 20 wt% MWCNTs in focused ion beam (FIB) micromachining. PMMA/MWCNT nanocomposites were fabricated using a solution casting method, in which PMMA and MWCNTs were dispersed in a solvent by ultrasonication. Microscale rectangular pockets were created on the PMMA/MWCNT nanocomposites to study the material removal mechanism in FIB. Effects of FIB input current and the ion beam overlap parameter (overlap %) on the material removal rate and geometric accuracy were studied. It was observed that the material removal rate increased with increasing input current and decreasing overlap %. Soft lithography was used to translate the ion-milled pockets on PMMA/MWCNT nanocomposites into microscale posts on polydimethylsiloxane (PDMS) for accurate measurement of the pocket geometries. A Scanning Electron Microscope (SEM) was used to investigate the characteristics of the micromachined features, nanocomposite surfaces, and replicated PDMS patterns. Our results demonstrated an effective method to produce microscale patterns on MWCNT-based nanocomposites.

scholarly journals Focused Ion Beam Milling of Single-Crystal Sapphire with A-, C-, and M-Orientations

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2871
Author(s):  
Qiuling Wen ◽  
Xinyu Wei ◽  
Feng Jiang ◽  
Jing Lu ◽  
Xipeng Xu
Keyword(s):  
Single Crystal ◽  
Surface Quality ◽  
Material Removal ◽  
Focused Ion Beam ◽  
Removal Rate ◽  
Ion Beam ◽  
Crystal Orientations ◽  
Aluminum Ions ◽  
Single Crystal Sapphire

Sapphire substrates with different crystal orientations are widely used in optoelectronic applications. In this work, focused ion beam (FIB) milling of single-crystal sapphire with A-, C-, and M-orientations was performed. The material removal rate (MRR) and surface roughness (Sa) of sapphire with the three crystal orientations after FIB etching were derived. The experimental results show that: The MRR of A-plane sapphire is slightly higher than that of C-plane and M-plane sapphires; the Sa of A-plane sapphire after FIB treatment is the smallest among the three different crystal orientations. These results imply that A-plane sapphire allows easier material removal during FIB milling compared with C-plane and M-plane sapphires. Moreover, the surface quality of A-plane sapphire after FIB milling is better than that of C-plane and M-plane sapphires. The theoretical calculation results show that the removal energy of aluminum ions and oxygen ions per square nanometer on the outermost surface of A-plane sapphire is the smallest. This also implies that material is more easily removed from the surface of A-plane sapphire than the surface of C-plane and M-plane sapphires by FIB milling. In addition, it is also found that higher MRR leads to lower Sa and better surface quality of sapphire for FIB etching.

Roughness Effects During Focused Ion Beam Repair of X-Ray Masks with Polycrystalline Tungsten Absorbers

1992 ◽  
Vol 279 ◽  
Author(s):  
R. R. Kola ◽  
G. K. Celler ◽  
L R. Harriott
Keyword(s):  
Material Removal ◽  
Etch Rate ◽  
Focused Ion Beam ◽  
Removal Rate ◽  
Ion Beam ◽  
Sidewall Roughness ◽  
X Ray ◽  
Polycrystalline Tungsten ◽  
Absorber Material ◽  
Defect Repair

ABSTRACTTungsten is emerging as the absorber material of choice for x-ray masks due to recent advances in the deposition of low stress films. For a practical technology, the masks must be free from defects. These defects may be in the form of excess or missing absorber. Finely focused ion beams have been used for defect repair on x-ray masks, both for removal of excess absorber material by physical sputtering and for addition of absorber material by ion-induced deposition. The eifect of ion channeling in polycrystalline tungsten films is spatially nonuniform material removal during sputtering. Different grains will have significantly different sputtering yields, depending on their orientation with respect to the direction of the ion beam. The repaired features then suffer from roughness on the bottoms and sidewalls of the sputter craters. We have investigated the use of XeF2 assisted sputtering with a 20 keV Ga+ focused ion beam to reduce this roughness. The chemical etching component of the material removal lessens the directional dependence and therefore the roughness during defect repair. It was also found that chromium etch rate was reduced in the presence of XeF2 gas while the etch rate of W was enhanced so that the removal rate of Cr is much less than that of W. We can take advantage of this etch selectivity by using a thin Cr layer under the W absorber as an etch stop layer to eliminate the roughness at the bottom of the features and a thin layer of Cr on top of the W as an etch mask for reducing the sidewall roughness.

scholarly journals Thermal Transport in an Individual Multi-Walled Carbon Nanotube Defected by Focused Ion Beam Irradiation

Netsu Bussei ◽  
2016 ◽  
Vol 29 (4) ◽  
pp. 179-184
Author(s):  
Masahiro Narasaki ◽  
Tatsuya Ikuta ◽  
Takashi Nishiyama ◽  
Koji Takahashi
Keyword(s):  
Carbon Nanotube ◽  
Thermal Transport ◽  
Focused Ion Beam ◽  
Ion Beam ◽  
Beam Irradiation ◽  
Ion Beam Irradiation ◽  
Multi Walled Carbon Nanotube

scholarly journals Micro Electro Discharge Machining of Polymethylmethacrylate (PMMA)/Multi-Walled Carbon Nanotube (MWCNT) Nanocomposites

2008 ◽  
Vol 17 (4) ◽  
pp. 096369350801700 ◽  
Author(s):  
Yi Wan ◽  
Dave (Dae-Wook) Kim ◽  
Young-Bin Park ◽  
Sung-Kwan Joo
Keyword(s):  
Carbon Nanotube ◽  
Material Removal ◽  
Supply Voltage ◽  
Removal Rate ◽  
High Energy ◽  
Material System ◽  
Micro Edm ◽  
Electro Discharge Machining ◽  
Multi Walled Carbon Nanotube ◽  
Mwcnt Loading

This study investigated micro electro discharge machining (micro-EDM) of Polymethylmethacrylate (PMMA)/Multi-Walled Carbon Nanotube (MWCNT) nanocomposites. PMMA/MWCNT nanocomposites were fabricated using solution casting, in which MWCNTs were dispersed in the polymer-solvent solution via high energy sonication, followed by precipitation and hot pressing. MWCNT loading was varied to investigate the effect of electrical conductivity of nanocomposites on the machinability. Micron-size holes were created to study the material removal mechanism in micro-EDM. The electro discharge phenomena may occur between electrically conductive MWCNT and the tungsten electrode during the process. As a result, PMMA/MWCNT nanocomposite samples with 10 to 35 wt% MWNTs were able to be EDMed with proper machining conditions. It was observed that the material removal rate increases with increasing micro-EDM supply voltage and MWCNT loading on the material system. Both optical microscope and scanning electron microscope (SEM) were used to investigate the characteristics of the machined holes and nanocomposite surfaces.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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