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    Precision & Micromanufacturing (Course Code: MEL7430) : By, Ankur Gupta IIT Jodhpur

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    Arbaz Khan
    Precision engineering involves creating products with greater precision and value through micro- and nanotechnology. It forms the foundation of modern civilization. There are four categories of machining accuracy: normal, precision, high-precision, and ultra-precision machining. Microtechnology and nanotechnology allow creating miniature features and components through techniques originally developed for integrated circuits. Micromanufacturing is multi-disciplinary and involves physics, materials science, electrical, mechanical, chemical, and industrial engineering principles.

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    Precision & Micromanufacturing (Course Code: MEL7430) : By, Ankur Gupta IIT Jodhpur

    Uploaded by

    Arbaz Khan
    21 views18 pages
    Precision engineering involves creating products with greater precision and value through micro- and nanotechnology. It forms the foundation of modern civilization. There are four categories of machining accuracy: normal, precision, high-precision, and ultra-precision machining. Microtechnology and nanotechnology allow creating miniature features and components through techniques originally developed for integrated circuits. Micromanufacturing is multi-disciplinary and involves physics, materials science, electrical, mechanical, chemical, and industrial engineering principles.

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    Precision engineering involves creating products with greater precision and value through micro- and nanotechnology. It forms the foundation of modern civilization. There are four categories of machining accuracy: normal, precision, high-precision, and ultra-precision machining. Microtechnology and nanotechnology allow creating miniature features and components through techniques originally developed for integrated circuits. Micromanufacturing is multi-disciplinary and involves physics, materials science, electrical, mechanical, chemical, and industrial engineering principles.

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    21 views18 pages

    Precision & Micromanufacturing (Course Code: MEL7430) : By, Ankur Gupta IIT Jodhpur

    Uploaded by

    Arbaz Khan
    Precision engineering involves creating products with greater precision and value through micro- and nanotechnology. It forms the foundation of modern civilization. There are four categories of machining accuracy: normal, precision, high-precision, and ultra-precision machining. Microtechnology and nanotechnology allow creating miniature features and components through techniques originally developed for integrated circuits. Micromanufacturing is multi-disciplinary and involves physics, materials science, electrical, mechanical, chemical, and industrial engineering principles.

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    Precision & Micromanufacturing

    [Course code: MEL7430]

    By,
    Ankur Gupta
    IIT Jodhpur
    Precision engineering is the science of creating, directly and indirectly, greater-value-
    added products in various fields, which form the foundations of our modern
    advanced civilization.

    Precision Technology

    Microtechnology Nanotechnology
    1/16/2023 Dr. Ankur Gupta
    Taniguchi has classified machining accuracy into four categories, namely,

    1. Normal machining
    2. Precision machining
    3. High-precision machining, and
    4. Ultra-precision machining

    Normal Machining:

    In this class of machining, the conventional engine lathe and milling machines are the most appropriate machine tools
    that can be used to manufacture products such as gears and screw threads to an accuracy of, for example, 50 μm.

    Precision Machining:

    The two processes that are used in precision machining are diamond grinding of Integrated Circuit (IC) chips and
    precision manufacture of spherical and aspherical surfaces on plastics and glass.
    High Precision Machining

    High-precision CNC diamond turning machines are available for diamond mirror machining of components such
    as:

    (a) Computer magnetic memory disc substrates


    (b) Convex mirrors for high output carbon dioxide laser resonators
    (c) Spherical bearing surfaces made of beryllium, copper, etc.
    (d) Infrared lenses made of germanium for thermal imaging systems
    (e) Scanners for laser printers
    (f) X-ray mirror substrates

    Both lapping and polishing are considered to be high-precision machining operations.


    Ultra-precision machining

    Taniguchi has referred to “ultra-precision machining” as a process by which the highest possible dimensional
    accuracy is or has been achieved at a given point in time. Also, it is referred to as the achievement of
    dimensional tolerances of the order of 0.01 µm and a surface roughness of 0.001 µm (1 nm). The dimensions of
    the parts or elements of the parts produced may be as small as 1µm, and the resolution and the repeatability of
    the machine used must be of the order of 0.01 µm (10 nm).
    Venkatesh - Precision Engineering-Mcgraw_Hill (2007)
    Venkatesh - Precision Engineering-Mcgraw_Hill (2007)
    Miniaturization Makes Engineering Sense!!!
    • Small systems tend to move or stop more quickly due to low mechanical inertia. It is thus ideal for precision
    movements and for rapid actuation.
    • Miniaturized systems encounter less thermal distortion and mechanical vibration due to low mass.
    • Miniaturized devices are particularly suited for biomedical and aerospace applications due to their minute
    sizes and weight.
    • Small systems have higher dimensional stability at high temperature due to low thermal expansion.
    • Smaller size of the systems means less space requirements.
    • This allows the packaging of more functional components in a single device.
    • Less material requirements mean low cost of production and transportation.
    • Ready mass production in batches.

    1/16/2023 Dr. Ankur Gupta


    INTRODUCTION TO MICROMANUFACTURING
    • In today’s high tech engineering industries, the requirement for the component are stringent, such as:

     Extraordinary properties of materials


    (say, high Strength, high heat resistant, high hardness, corrosion resistantetc.).
     Complex 3D component (say, turbine blade).

    Miniature features ( filters for food processing and textile industries having a few tens of micrometer as hole
    diameter and thousands in numbers).

    Nano level surface finish on complex geometries which are impossible to achieve by any traditional
    methods (say, thousands of turbulated cooling holes in a turbine blade, making & finishing of microfluidic channels
    in the electrically conducting and non-conducting materials (say, glass, quartz, ceramics)).

    •Such features on a component can be achieved only through the advanced manufacturing processes in
    general and micromanufacturing processes in particular.
    PRESENT DAY DEMAND TRENDS IN INDUSTRIES
    (AEROSPACE , MISSILES , AUTOMOBILES, NUCLEAR REACTORS, ETC.)

    Ultrahigh Strength, Hardness


    ENGG. MATERIALS HAVING MUCH Very High Temperature Resistance
    SUPERIOR PROPERTIES
    Difficult To Machine By Conventional Machining
    Methods

    WORK PIECE MATERIAL HARDNESS >> TOOL MATERIAL HARDNESS

    HOW TO SOLVE THE PROBLEM


    ?
    MICRO MANUFACTURING PROCESSES
    WORKPIECE HARDNESS DOES NOT MATTER IN AMMPs
    Unique Features in MICROMANUFACTURING
    - A great challenge to engineers
    • Components are in micrometers with complex geometry using silicon, Si-
    compounds and polymers:

    25 µm

    A micro gear-train by Sandia National Laboratories

    1/16/2023 Dr. Ankur Gupta


    Commercial Products

    Microsensors Micro Actuators

    • Acoustic wave sensors • Grippers, tweezers and tongs


    • Biomedical and biosensors • Motors - linear and rotary
    • Chemical sensors • Relays and switches
    • Optical sensors • Valves and pumps
    • Pressure sensors • Optical equipment
    • Stress sensors (switches, lenses & mirrors, shutters, phase
    • Thermal sensors modulators, filters, waveguide splitters, latching &
    fibre alignment mechanisms)

    Dr. Ankur Gupta


    1/16/2023
    Evolution of Micromanufacturing
    • There is no machine tool with today’s technology can produce any device or MEMS component of the size in
    the micrometer scale (or in mm sizes).
    • The complex geometry of these minute MEMS components can only be produced by various physical-
    chemical processes – the microfabrication techniques originally developed for producing integrated circuit
    (IC) components.
    • Significant technological development towards miniaturization was initiated with the invention of transistors
    by three Nobel Laureates, W. Schockley, J. Bardeen and W.H. Brattain of Bell Laboratories in 1947.
    • This crucial invention led to the development of the concept of integrated circuits (IC) in 1955, and the
    production of the first IC three years later by Jack Kilby of Texas Instruments.
    • ICs have made possible for miniaturization of many devices and engineering systems in the last 50 years.
    • The invention of transistors is thus regarded as the beginning of the 3rd Industrial Revolution in human
    civilization.
    1/16/2023 Dr. Ankur Gupta
    The Multi-disciplinary Nature of Small scale manufacturing

    Natural Science:
    Physics & Biochemistry

    Electrochemical Quantum physics


    Processes
    Solid-state physics Material Sciences
    Scaling laws

    Electrical Engineering Mechanical Engineering


     Machine components design
    Materials Engineering
     Power supply
     Precision machine design  Materials for substrates
     Electric systems for  Mechanisms & linkages
    electrohydro-dynamics & package
     Thermomechanical:
    and signal transduction  Materials for signal mapping
    (solid & fluid mechanics, heat
     Electric circuit and transduction
    transfer, fracture mechanics)
    design  Materials for fabrication
     Intelligent control
     Integration of MEMS processes
     Micro process equipment
    and CMOS
    design and manufacturing
     Packaging and assembly design

    Chemical Engineering Industrial Engineering


     Process design
     Micro fabrication processes
     Production control
     Thin film technology  Micro assembly

    1/16/2023 Dr. Ankur Gupta


    Thank You

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