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A Multiprocess Machine Tool For Compound Micromachining

This document is a seminar report on developing a multiprocess machine tool for compound micromachining. It discusses combining multiple micromachining processes like microturning, micromilling, micro-EDM, and WEDM on a single machine with minimal setup changes. It also covers on-machine tool fabrication, measurement, and inspection to improve functionality and productivity. The goal is to enable high-precision machining of miniaturized parts with high aspect ratios through an integrated approach to machine tool development, process control, and process development.

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Mukesh Muraleedharan Nair
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85 views6 pages

A Multiprocess Machine Tool For Compound Micromachining

This document is a seminar report on developing a multiprocess machine tool for compound micromachining. It discusses combining multiple micromachining processes like microturning, micromilling, micro-EDM, and WEDM on a single machine with minimal setup changes. It also covers on-machine tool fabrication, measurement, and inspection to improve functionality and productivity. The goal is to enable high-precision machining of miniaturized parts with high aspect ratios through an integrated approach to machine tool development, process control, and process development.

Uploaded by

Mukesh Muraleedharan Nair
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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A

Seminar Report
On

A multiprocess machine tool for compound


micromachining
Submitted in partial fulfillment of the requirements for the award of the degree of

Master of Technology
in
Manufacturing Technology
by
MUKESH. M
M090096ME

DEPARTMENT OF MECHANICAL ENGINEERING


NATIONAL INSTITUTE OF TECHNOLOGY CALICUT
CALICUT-673601, KERALA
CERTIFICATE

This is to certify that the report entitled ” A multiprocess machine tool for compound
micromachining ” is a bonafide record of the seminar done by MUKESH M (Roll No.
M090096ME), under my supervision, in partial fulfillment of the requirements for the award of
the degree of Master of Technology in Mechanical Engineering from National Institute of
Technology Calicut, and this work has not been submitted elsewhere for the award of a degree.

Place: NIT CALICUT Dr. ALLESU KANJIRATHINKAL


Date : 02/05/2010 (GUIDE)
Professor
Dept. of Mechanical Engineering.
ACKNOWLEDGEMENT

I sincerely express my deep felt gratitude to Dr. Allesu kanjirathinkal, Professor


Department of Mechanical Engineering, for their valuable guidance, critical views,
encouragement and help at each and every phase of this work. I particularly express my heartfelt
thanks for their supervision, inspiration and timely help towards me in completing this work.

I am also indebted to Dr.S.Jayaraj, Professor and Head of Department, Mechanical


Engineering for giving me this opportunity.

I would like to thank all my classmates for their co-operation and support in making my
seminar a success.

MUKESH.M
CONTENTS

LIST OF FIGURES

1. INTRODUCTION 1
2. MULTIPROCESS MINIATURE MACHINE TOOL FOR COMPOUND
MICROMACHINING 2

3. MOTION AND PROCESS CONTROL FOR COMPOUND MICROMACHINING 3

4. STRAIGHT ELECTRODE FABRICATION FOR MICRO-EDM USING MOVING


BEDG PROCESS 4

5. COMPOUND OF MICRO-EDM AND MICROTURNING PROCESSES

5.1. Ultra sharp micro turning tool fabrication by micro-EDM 7

5.2. Cutting scheme 8

5.3. Micro-EDM with electrode fabricated by micro turning 10

6. HIGH ASPECT RATIO MICROFABRICATION 11

7. CONCLUSIONS 13

REFERENCES
LIST OF FIGURES

Figure 1 - Technologies required for micromachining.


Figure 2 - Different processes that can be performed on universal miniature multi process
machine tool.
Figure 3 - Machining with square electrode on 150-μm-thick plate.
Figure 4 - Concept of moving BEDG process for on-machine tool fabrication.
Figure 5 - Illustrates the resolution of cutting forces in Fx and Fy components in commercial tool
Figure 6 - PCD insert
Figure 7 - Chronological development of the microshaft.
Figure 8 - Illustrates the concept of the micro turning-EDM compound machining
Figure 9 - Brass electrode fabrication
Figure 10 - Four holes machined on 50 microns stainless steel plate
Figure 11 - Small pyramid
Figure 12 - Two 10 micron thru slots on 50-microns thick stainless steel
ABSTRACT

Compound micromachining is the most promising technology for the production of


miniaturized parts and this technology is becoming increasingly more important and popular
because of a growing demand for industrial products, with an increased number not only of
functions but also of reduced dimensions, higher dimensional accuracy and better surface finish.
Compound micromachining processes that combine multiple conventional and non-conventional
micromachining processes have the capability to fabricate high aspect ratio microstructures with
paramount dimensional accuracy.

Such machining should be carried out on the same machine with minimum change of
setups. At the same time, on-machine tool fabrication along with on-machine tool and workpiece
measurement facilities should also be available for further enhancement of the functionality of
the machine and higher productivity.

In order to achieve effective implementation of compound micromachining techniques,


this seminar seeks to address four important areas, namely (a) development of a machine tool
capable of both conventional micromachining including microturning, micromilling, etc., and
non- conventional micromachining including microelectrical discharge machining (micro-EDM),
wire-cut electrical discharge machining (WEDM), etc.; (b) process control; (c) process
development to achieve the necessary accuracy and quality and (d) on-machine measurement and
inspection. An integrated effort into these areas has resulted in successful fabrication of
microstructures that are able to meet the miniaturization demands of the industry.

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