Recent Developments in Desktop-Sized Machine Tools

2017 ◽  
Vol 261 ◽  
pp. 425-431 ◽  
Author(s):  
Jan C. Aurich ◽  
Christopher Müller ◽  
Martin Bohley ◽  
Peter Arrabiyeh ◽  
Benjamin Kirsch
Keyword(s):  
Surface Roughness ◽  
Machine Tools ◽  
Micro Milling ◽  
Bottom Surface ◽  
Manufacturing Processes ◽  
Micro Machining ◽  
Machining Quality ◽  
Recent Developments ◽  
Micro Structures ◽  
Micro Tools

The miniaturization of components and the functionalization via micro structures demands for flexible and economic manufacturing processes. Micro machining, i.e. micro milling and micro grinding can meet these requirements. In this paper, desktop-sized machine tools and their components that were developed at our institute are presented. With those machine tools, micro tools can be machined and used in one clamping, allowing for increased machining quality. Grooves milled with such machine tools achieve a bottom surface roughness below 10 nanometer.

scholarly journals In-situ worn geometry effect over the surface roughness propagation during micro milling process

2020 ◽  
Vol 4 (1) ◽  
pp. 1-7
Author(s):  
Nurul Farhana Mohadzir ◽  
Ainur Munira Rosli ◽  
Ahmad Shahir Jamaludin ◽  
Mohd Nizar Md Razali
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Micro Machining ◽  
Cnc Milling ◽  
Machined Surface ◽  
Radial Depth ◽  
Micro Tools

High-precision miniaturized components for micro-machining operations has an increasingly demand for numerous developing sectors such as medical instrumentations, electronics components, computer manufacturing, aerospace and automotive engineering. Micro-milling has known as a flexible micro machining process and the most familiar micro mechanical machining method. Due to overcome a few difficulties in micro fabrication, micro milling is picked as an alternative way as it has potential and imperative for high accuracy machining. However, micro tools have low tool life as it is unpredictably and wear quickly. Furthermore, it also has tendency to break easily due to its micro size dimension. The study observe the behaviour of micro milling worn geometry during machining and includes a non-conventional method to measure surface roughness resulted by micro milling process in machining of mild steel AISI1045. The workpiece is prepared by using CNC milling machine with facing and slotting process. Then, the mild steel AISI1045 will undergo a machining process by a 1 mm size end mill diameter with different set of parameters which are spindle speed, feed rate, radial depth and axial depth. Lastly, for the results, the surface roughness of the machined surface will be observed and the condition of tool and the measurement of wear for the tool will be investigated.

Practical Dimensional Error Control and Surface Roughness Inspection in Turning

2002 ◽  
Author(s):  
M. Shiraishi ◽  
T. Yamagiwa ◽  
A. Ito
Keyword(s):  
Surface Roughness ◽  
Optical Method ◽  
Machine Tools ◽  
Error Control ◽  
Manufacturing Processes ◽  
Dimensional Error ◽  
Final Output

Monitoring of machine tools and optimization of manufacturing processes require accurate values of in process measured quantities such as dimensional error, force, and surface roughness. The measurement as workpiece is in particular important because the final output in machining is evaluated as the quality machined workpiece itself. A new hybrid sensor using pneumatic and optical method has been developed which can monitor the dimensional error and surface roughness in turning. Satisfactory results were obtained through several experiments.

Study on Micro Mill-Grinding Technology

2013 ◽  
Vol 390 ◽  
pp. 586-590 ◽  
Author(s):  
Chao Wang ◽  
Ya Dong Gong ◽  
Guo Qiang Yin ◽  
Xue Long Wen ◽  
Jun Cheng
Keyword(s):  
Surface Roughness ◽  
Abrasive Particle ◽  
Three Dimensional ◽  
Micro Milling ◽  
Mechanical Processing ◽  
Micro Machining ◽  
Micro Scale ◽  
Abrasive Grains ◽  
Machining System ◽  
Spraying Method

Micro mechanical processing is the effective method for machining micro scale parts. Micro mill-grinding technology is presented based on micro milling and micro grinding processes. The machining principle of micro mill-grinding is studied, and compound tools for micro mill-grinding are fabricated based on spraying technology. Experiments are performed on Al 6061-T6 with the three-dimensional micro machining system. The results show that submicron surface roughness can be obtained by micro mill-grinding. Abrasive grains of mill-grinding tools fabricated by spraying method shed easily. Smaller abrasive particle size improves the surface quality and increases the tool life.

scholarly journals Analysis on Characteristics of ZnO Surface Acoustic Wave with and without Micro-Structures

Micromachines ◽  
2019 ◽  
Vol 10 (7) ◽  
pp. 434 ◽  
Author(s):  
Huang ◽  
Chiang ◽  
Wu ◽  
Lin ◽  
Shen
Keyword(s):  
Thin Film ◽  
Acoustic Wave ◽  
Surface Acoustic Wave ◽  
Digital Signal ◽  
Rf Magnetron Sputtering ◽  
Manufacturing Processes ◽  
Micro Machining ◽  
Zno Thin Film ◽  
Measurement Signal ◽  
Micro Structures

In this paper, we fabricate a surface acoustic wave (SAW) device with micro-structures on a zinc oxide (ZnO) thin film and measure its signal response. The manufacturing processes of the SAW device include the fabrication of micro-structures of a SAW element and its interdigital transducer by silicon micro-machining and the fabrication of a thin film of ZnO by RF magnetron sputtering. We, then, measure the SAW properties. This research investigates the properties of sputtered thin films for various amounts of O2/(Ar + O2) using Zn and ZnO targets. Regardless of target, the growth rate of the ZnO thin film decreases as the oxygen content increases. When the SAW is sputtered ZnO thin film using 30% oxygen, the digital signal of the SAW has better performance. The measurement signal of the SAW with micro-structures is similar to that without micro-structures.

Experimental Study on Minimum Quantity Lubrication in Mechanical Micromachining

2012 ◽  
Vol 579 ◽  
pp. 193-200 ◽  
Author(s):  
Kuan Ming Li
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Minimum Quantity Lubrication ◽  
Green Manufacturing ◽  
Micro Milling ◽  
Experimental Investigations ◽  
Minimum Quantity ◽  
Green Manufacturing Technology ◽  
Micro Tools ◽  
Mechanical Micromachining

Mechanical micromachining is a promising technique for making complex microstructures. It is challenging to apply mechanical micromachining in the industry due to the low strength of micro tools. Therefore, it is not easy to accurately control the product dimension error and to raise the production rate. In this paper, the applications of minimum quantity lubrication (MQL) in micro-milling and micro-grinding are presented. MQL is considered as a green manufacturing technology in metal cutting due to its low impact on the environment and human health. This study compares the tool wear and surface roughness in MQL micromachining to completely dry condition based on experimental investigations. The supply of MQL in vibration-assisted grinding is also studied. It is found that the use of MQL results in longer tool life and better surface roughness in mechanical micromachining.

A Study on Micro-Milling of Aluminium 6061 and Copper With Respect to Cutting Forces, Surface Roughness and Burr Formation

2018 ◽  
Author(s):  
A. Sravan Kumar ◽  
Sankha Deb ◽  
S. Paul
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
End Milling ◽  
Micro Milling ◽  
Bottom Surface ◽  
Micro Channel ◽  
Al 6061 ◽  
Feed Force ◽  
Micro Channels ◽  
Burr Width

In the present study, micro-milling of aluminium 6061 alloy and copper was undertaken. TiAlN coated two-flute flat end milling cutters of 0.5 mm diameter were used for conducting micro-channel milling experiments with minimum quantity lubrication (MQL) as the cutting environment. The effect of process parameters namely cutting velocity (vc) and feed per flute (fz) on the cutting forces, surface roughness and burr width are reported. RMS values of longitudinal feed force (FX), transverse cutting force (FY) and vertical thrust force (FZ) were measured and the maximum values for Al 6061 are 0.33 N, 0.16 N and 0.21 N respectively, and the same for copper are measured to be 0.11 N, 0.17 N and 0.22 N respectively. Average surface roughness along the milling direction (Ra) at the bottom surface of the micro-channel was measured. Smoother surfaces were generated at lower feed per flute in both the materials. Ra is found to be varying from 28.2 nm to 86.9 nm for Al 6061, and for copper, the range is from 4.9 nm to 32.7 nm. SEM images of the micro-channels were analysed and top burr width was measured in both up-milling and down-milling directions. Higher feed per flute produced smaller burrs in both up-milling and down-milling directions. Maximum burr width for Al 6061 is measured to be 12.86 μm and 15.28 μm in up-milling and down-milling direction respectively, and for copper, the same are measured to be 12.84 μm and 20.46 μm respectively.

3D Milling by Micro Electrical Discharge Machining

2010 ◽  
Vol 659 ◽  
pp. 467-470
Author(s):  
Balázs Zsolt Farkas ◽  
Márton Takács
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Research Work ◽  
Milling Process ◽  
Physical Principle ◽  
Micro Milling ◽  
Micro Machining ◽  
Research Activity ◽  
Micro Electrical Discharge Machining ◽  
Micro Structures

One of the most important tasks of the manufacturing engineering of our accelerated world is giving suitable answer to the ever growing demand on miniaturization arising on every field of the industry. Our institute has been carried out theoretical and experimental research work on micro machining since 10 years. Micro machining can be defined as formation of structures smaller than 1 mm. Our previous research activity focused primarily on micro milling process carried out by carbide end mill. Milling offers the most various machining method among the chip removal processes. Investigation of formation of micro structures by electrical discharge machining (EDM) is a perfect continuance of the research work. A process similar to micro milling can be realized by the lateral moving of the miniature cylindrical electrode of an EDM machine, just the physical principle of material removing is different. This paper introduces the latest results of our research work, including

scholarly journals Experimental Study on Micro-Grinding of Ceramics for Micro-Structuring

2021 ◽  
Vol 11 (17) ◽  
pp. 8119
Author(s):  
Yung Na ◽  
Ui Seok Lee ◽  
Bo Hyun Kim
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Three Dimensional ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Bottom Surface ◽  
Depth Of Cut ◽  
Generator Circuit ◽  
Machining Of Ceramics ◽  
Micro Tools

In this study, micro-grinding was performed to investigate the machining characteristics of alumina and zirconia. The machining of ceramics remains highly challenging owing to their properties, such as high brittleness and wear resistance, which leads to a shorter tool life and high machining costs. Polycrystalline diamond (PCD) was selected as the tool material, as it is suitable for machining hard and brittle materials, and micro-electrical discharge machining (EDM) was used to fabricate PCD micro-tools. When using a resistor-capacitor generator circuit in micro-EDM, the discharging energy is related to the working capacitance, and by controlling the working capacitance, the different edge radii and the surface roughness of the tool can be easily achieved. The feed rate, depth of cut, and rotation speed were set as experimental parameters to investigate the grinding characteristics of the ceramics. During the experiment, the grinding force and roughness of the bottom surface were monitored, and the roughness of the machined surfaces was measured using a three-dimensional surface profiler. A working capacitance of 1000 pF was used to fabricate a tool with an edge radius of 3.5 µm. The lower radius of the tool edge resulted in a decrease of the cutting force by 50% at most and a surface roughness of 19 nm Ra.

scholarly journals Special Issue on Micro/Nano Machining – Processes, Systems and Control

2011 ◽  
Vol 5 (1) ◽  
pp. 3-3
Author(s):  
Mustafizur Rahman
Keyword(s):  
Machine Tools ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Micro Milling ◽  
Successful Implementation ◽  
Micro Machining ◽  
Special Issue ◽  
Machining Processes

In recent years, the trend in miniaturization of products is pervasive in areas such as information technology, biotechnology, environmental and medical industries. Micro-machining is the key supporting technology that has to be developed to meet the challenges posed by the requirements of product miniaturization and industrial realization of nanotechnology. Micro-machining techniques can be carried out by techniques based on energy beams (beam-based micro-machining) or solid cutting tools (tool-based micro-machining). Beambased micro-machining have some limitations due to poor control of 3D structures, low material removal rate and low aspect ratio. Moreover, these processes require special facilities and the maximum achievable thickness is relatively small. Some of these limitations can be overcome by tool-based micro-machining techniques using ultra precision machine tools and solid tools used as cutting elements to produce the micro-features with well controlled shape and tolerances. Tool-based micro-machining techniques essentially include precision machining processes as turning, milling, grinding and electrical discharge machining (EDM), whereby material removal is done at the micron level. The advantages of such processes are that almost every material such as metals, plastics and semiconductors can be machined with no limitation in machining shapes. Recently, combinations of conventional material removal processes, such as turning and milling, have been hybridized with non-conventional machining processes like EDM and EDG to fabricate micro-structures with high dimensional accuracy. In order to achieve meaningful implementation of compound micro-machining techniques three important areas are required to be addressed. These are: development of machine tools capable of performing compound micro-machining (i.e. micro turning, micro milling, micro EDM, etc. on the same machine and setup), understanding of process physics to provide relevant background for modeling,measurement, identification of control parameters and application of feedback control in order to control compound and hybrid manufacturing processes and development of compound and hybrid processes. An integrated effort in these areas is needed for successful implementation of tool-based micro-machining. An attempt has been made in this special issue to highlight latest articles on these areas. I would like to express my sincere appreciation to the authors, reviewers and editors for their invaluable contributions for this issue.

In Situ Topology Measurement of Micro Structured Surfaces with a Confocal Chromatic Sensor on a Desktop Sized Machine Tool

2016 ◽  
Vol 1140 ◽  
pp. 392-399
Author(s):  
Christopher Müller ◽  
Ingo G. Reichenbach ◽  
Martin Bohley ◽  
Jan Christian Aurich
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Machining Process ◽  
Measuring System ◽  
Micro Machining ◽  
Structured Surfaces ◽  
System A ◽  
Micro Structures ◽  
Tool Diameter

In this research a confocal chromatic point sensor was implemented in a desktop sized machine tool. The sensor was used to detect the surface in z-direction. Data from the machine control of the x- and y-axes is extracted and combined with the z- information of the sensor to directly scan surfaces. With the presented sensor, micro structures as small as 5 μm can be characterized. Based on the possibilities of this measuring system, face milling before the actual micro machining can be avoided by determining tilts and waviness of the workpiece. Also the effective tool diameter can be determined and compensated. After machining, the structure can be measured for quality control. Based on this measurement system, a micro machining process was developed broadening the potential for the use of desktop sized machine tools.

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