Journal of Micromanufacturing最新文献_第3页

Analytical study for the selection of mask size and shape for obtaining high machining quality of complex features 为获得复杂特征的高加工质量，对掩模尺寸和形状的选择进行了分析研究

Journal of Micromanufacturing Pub Date : 2023-06-02 DOI: 10.1177/25165984231172007

Gaganpreet Singh, Bhawandeep Sharma, R. Kumar, J. Ramkumar, S. A. Ramakrishna

{"title":"Analytical study for the selection of mask size and shape for obtaining high machining quality of complex features","authors":"Gaganpreet Singh, Bhawandeep Sharma, R. Kumar, J. Ramkumar, S. A. Ramakrishna","doi":"10.1177/25165984231172007","DOIUrl":"https://doi.org/10.1177/25165984231172007","url":null,"abstract":"In this article, an analytical study of the effect of the shape and size of the mask on the machining quality of complex shapes has been carried out. For this study, we considered square and circular masks of varying sizes with varying overlap for the machining of square, inclined, and circular features. Mask size varied from 1 to 20 mm, while overlap varied from 10% to 90%. The machining quality of the aforementioned features was evaluated by studying the unmachined area “An” (in the machining zone) and the machining time “Tm.” For machining a similar feature, it was observed that the square mask performed much better than the circular mask in minimizing the machining time. However, the circular mask is much more suitable for minimizing the unmachined area. For validation, the experiment was conducted to machine the inclined lines with square and circular shape masks with varying overlap percentages. The experimental results were found to be in good agreement with the analytically obtained results, with an error of 2.5%. This study is relevant for the industrial-scale manufacturing of complicated features using the mask projection approach in laser machining.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122389350","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Influence of energy input parameters on wire feed rate and surface characteristics during WECM of Nitinol SMA 能量输入参数对镍钛诺SMA平轧过程中送丝速度和表面特性的影响

Journal of Micromanufacturing Pub Date : 2023-02-10 DOI: 10.1177/25165984231151303

Naresh Besekar, B. Bhattacharyya

{"title":"Influence of energy input parameters on wire feed rate and surface characteristics during WECM of Nitinol SMA","authors":"Naresh Besekar, B. Bhattacharyya","doi":"10.1177/25165984231151303","DOIUrl":"https://doi.org/10.1177/25165984231151303","url":null,"abstract":"Nitinol shape memory alloy (SMA) has outstanding chemical and mechanical properties which make the machining of Nitinol SMA more difficult than other materials due to super-elasticity and multiphase transformation. Wire electrochemical machining (WECM) is a nontraditional process, which removes conductive material through anodic dissolution despite of material’s properties. In this paper, the mathematical model is presented for slit width calculation for the influence of different parameters using vibration-assisted nozzle jet flushing. In this experimental investigation, the effect of prominent energy input parameters on wire feed rate to achieve better homogeneity, machining accuracy, and surface quality with a 300 µm thick sheet of Nitinol SMA micro-slits has been presented using an in-house developed WECM set-up. Experimental results revealed that the wire feed rate and surface roughness drastically increases with an increase in the most influencing energy input parameter, that is, pulse voltage with minimum average surface roughness (Ra) of 0.1076 µm and 123.60 µm average slit width at 7 V pulse voltage. Finally, the curved complex micro-feature of a 120 µm thick sheet of Nitinol SMA was fabricated successfully with a 137.795 µm average slit width under the controlled process parameter combination using WECM.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116703451","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 2

Finishing the surface micro-layer of additively manufactured TiAl alloy using electro-thermal discharge assisted post-processing 利用电热放电辅助后处理技术对增材制造TiAl合金表面微层进行精加工

Journal of Micromanufacturing Pub Date : 2023-02-07 DOI: 10.1177/25165984231151745

Jibin Boban, Afzaal Ahmed

{"title":"Finishing the surface micro-layer of additively manufactured TiAl alloy using electro-thermal discharge assisted post-processing","authors":"Jibin Boban, Afzaal Ahmed","doi":"10.1177/25165984231151745","DOIUrl":"https://doi.org/10.1177/25165984231151745","url":null,"abstract":"Selective laser melting (SLM) of titanium–aluminium (TiAl) alloy components has gained significant attention in the modern industrial world. The flexibility of the SLM process in producing complex shapes with minimum utilization of material and energy makes it dominant over other manufacturing techniques. As aerospace and biomedical industries demand complex-shaped TiAl alloy components, part fabrication using SLM becomes the ultimate solution. However, the unacceptable level of surface integrity and anisotropic behavior of SLM components demand post processing operations such as laser polishing, chemical polishing, and conventional polishing methods. In this study, a recently developed polishing method called wire electrical discharge polishing (WEDP) is performed on TiAl alloys for obtaining a smooth and defect-free surface. This study aims to investigate the micro-layer modification occurring to the WEDP-processed surface in detail. The experimental results establish the effectiveness of WEDP method in terms of improved surface integrity. The surface finish (Sa) got enhanced by ~88% after WEDP processing. In addition, the thickness of recast layer formed by WEDP was found to be minimum. Moreover, post-processing of TiAl alloy resulted in better surface morphology specifically at lower settings of peak current. It is noteworthy that the migration of wire material was minimum with zinc-coated brass electrode compared to the normal brass electrode. Hence, coated wire electrodes are recommended for WEDP process. In short, an excellent surface integrity can be achieved using WEDP process through favorable surface modification aided by lower peak current and coated wire electrodes. Furthermore, less electrode wear observed in WEDP process enables the deployment of lower feed rates leading to minimal electrode consumption.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129219042","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 3

Hybrid machining of P20 die steel masters for the development of polymer-based microfluidic devices to study the effect of surface roughness on bacterial activity 以混合加工P20模型钢为主，开发基于聚合物的微流控装置，研究表面粗糙度对细菌活性的影响

Journal of Micromanufacturing Pub Date : 2023-01-24 DOI: 10.1177/25165984221148564

P. Pandit, G. Samuel

{"title":"Hybrid machining of P20 die steel masters for the development of polymer-based microfluidic devices to study the effect of surface roughness on bacterial activity","authors":"P. Pandit, G. Samuel","doi":"10.1177/25165984221148564","DOIUrl":"https://doi.org/10.1177/25165984221148564","url":null,"abstract":"Compared to the traditional machining and finishing process, a hybrid technique consisting of mechanical micro-milling and electropolishing is advantageous in maintaining dimensional accuracy and fine surface quality without compromising the form. This is a cost-effective, less tedious technique that can fabricate high-quality masters for microfluidic devices. P20-die steel masters are fabricated to evaluate the method with this technique. The dimensional accuracy and surface quality of the masters are studied. It is found that the peak-to-valley surface roughness (Rt) of the masters is reduced by 50%. These die steel masters are then used to make polydimethylsiloxane (PDMS)-based microfluidic devices that could be used for particle separation. As biofouling and bacterial growth are undesirable in most of the microfluidic devices, the fabricated PDMS devices are tested for bacterial growth and adhesion. The growth of DH5α Escherichia coli bacteria in the devices fabricated using the electropolished masters is evaluated. Bacterial growth and adhesion are monitored for 0, 4 and 12 h, and it is found that the growth and adhesion in these devices are reduced by 15–20% and 40–50%, respectively, compared to the devices produced using non-electropolished masters. Enumeration of the bacterial cells in the samples flown is carried out by evaluating the optical density of the sample fluids by UV-visible spectroscopy and quantifying the bacterial cells using the McFarland 0.5 standard.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"76 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133069918","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Maximum spreading behavior of a water droplet on the aluminium surfaces with different wettabilities 水滴在不同润湿性铝表面的最大扩散行为

Journal of Micromanufacturing Pub Date : 2023-01-11 DOI: 10.1177/25165984221143866

Poonam Chauhan, Aditya Kumar

引用次数: 0

An experimental investigation and multi-objective optimization of abrasive jet machining on Ti-6Al-4V ELI bio-material 磨料射流加工Ti-6Al-4V ELI生物材料的实验研究及多目标优化

Journal of Micromanufacturing Pub Date : 2022-12-19 DOI: 10.1177/25165984221139615

Anu Tomy, S. Hiremath

引用次数: 1

Thermoplastic micro-forming process of bulk metallic glass surgical blades using drawing velocity regulation 大块金属玻璃手术刀片的热塑性微成形工艺

Journal of Micromanufacturing Pub Date : 2022-12-09 DOI: 10.1177/25165984221136706

N. Dancholvichit, S. Salapaka, S. Kapoor

{"title":"Thermoplastic micro-forming process of bulk metallic glass surgical blades using drawing velocity regulation","authors":"N. Dancholvichit, S. Salapaka, S. Kapoor","doi":"10.1177/25165984221136706","DOIUrl":"https://doi.org/10.1177/25165984221136706","url":null,"abstract":"Drawing velocity is essential in the manufacturing of the multi-facet bulk metallic glass (BMG) knife edges used in corneal surgery since it is one of the factors that can determine good blade profiles in the thermoplastic forming process. The goal of this article is to determine and regulate drawing velocity based on the viscoelastic filament stretching and knowledge of the thermoplastic forming map of BMG. The generation of drawing velocity profile is done in two stages: the initial transient stage before the extensional viscosity stage is fully developed, and the extensional viscosity stage. The controller based on the system identification of the testbed is then optimized from the requirements of the drawing velocity and its implementation feasibility. The control objectives of regulation performance and robustness to modeling uncertainties are posed and solved in an optimal control (H∞) framework. The proposed controller shows an improvement over other controllers including proportional-integral-derivative controllers in terms of robustness to uncertainties and tracking performance. BMG samples processed from this study result in good quality with improvement of 20% and 54% in X–Y ( 2.2 ± 0.1 µm) and X–Z ( 1.3 ± 0.1 µm) straightness and 25% more consistent edge radii ( 46 ± 3 nm).","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"50 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-12-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114889226","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Mechanical peck drilling of Inconel 625: Parametric analysis and grey fuzzy logic based multi-response optimization Inconel 625机械钻削:参数分析和基于灰色模糊逻辑的多响应优化

Journal of Micromanufacturing Pub Date : 2022-11-28 DOI: 10.1177/25165984221135713

P. P, S. Hiremath

{"title":"Mechanical peck drilling of Inconel 625: Parametric analysis and grey fuzzy logic based multi-response optimization","authors":"P. P, S. Hiremath","doi":"10.1177/25165984221135713","DOIUrl":"https://doi.org/10.1177/25165984221135713","url":null,"abstract":"Nickel-based superalloy Inconel 625 is considered a hard-to-cut material due to characteristics such as high hardness, strain hardening behavior, and affinity with tool materials. It is challenging to machine through micro-holes of less than Ø 500 µm with the desired quality on Inconel 625 using the mechanical micro-drilling (MMD) process under dry conditions. The machining parameters must be selected optimally to enhance hole quality and to avoid frequent drill breakages. In this study, through micro-holes are machined on Inconel 625 by the MMD process using solid carbide micro-drills under dry conditions using a peck drilling strategy. Experiments are carried out by varying machining parameters such as spindle speed (8000 rpm, 11000 rpm, and 14000 rpm), feed (5 µm/rev, 7.5 µm/rev, and 10 µm/rev), and drill diameter (Ø 300 µm, Ø 400 µm, and Ø 500 µm) at three levels based on full factorial design. Thrust force and hole quality features such as exit burr height, radial overcut, and taper angle are measured as output responses. The mean effect plots are used to study the influence of machining parameters on output responses. The drill diameter had a significant effect on thrust force and radial overcut. Whereas feed and spindle speed had a major influence on exit burr height and taper angle, respectively. Finally, multi-response optimization is carried out using the grey fuzzy logic method, and an optimal machining parameter setting for multiple responses is ascertained.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128436767","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

An experimental study on laser ablation of Ultra-thin SiN x layer of PERC solar cell PERC太阳能电池超薄sinx层激光烧蚀的实验研究

Journal of Micromanufacturing Pub Date : 2022-11-24 DOI: 10.1177/25165984221129958

Pinal Rana, D. P. Khatri, A. Kottantharayil, D. Marla

{"title":"An experimental study on laser ablation of Ultra-thin SiN x layer of PERC solar cell","authors":"Pinal Rana, D. P. Khatri, A. Kottantharayil, D. Marla","doi":"10.1177/25165984221129958","DOIUrl":"https://doi.org/10.1177/25165984221129958","url":null,"abstract":"In this work, a nanosecond green laser (532 nm) is used to generate narrow openings by removing an ultra-thin (85 nm) SiN x layer that is coated on a silicon substrate for application in the fabrication of Passivated Emitter and Rear Contact (PERC) solar cells. An experimental analysis is presented to identify the optimal range of laser parameters for an efficient ablation with minimal damage to the silicon substrate. The ablated samples were characterized using a 3D profilometer to obtain the surface profiles and scanning electron microscope imaging to observe the surface quality. Further, energy-dispersive X-ray line analysis and atom probe tomography were performed to evaluate the nitrogen content on the surface and along the depth, respectively. The experimental results suggest that the SiN x layer starts to ablate only above a threshold laser fluence of 1.4 J/cm2, while the surface bulged out for laser fluence slightly below the ablation threshold. The central part of the ablated region was clean with a negligible nitrogen concentration at the surface, about ∼0.03% at a fluence of 2.4 J/cm2. Nitrogen concentration reduces continuously and almost becomes zero at 80 nm depth, suggesting complete ablation of the SiN x layer for establishing electrical contacts. The ablation width was close to the laser spot diameter only at lower values of the laser fluence. The lowest value of ablation depth was about 180 nm, suggesting that only about 95 nm layer of the silicon is ablated. The study demonstrates that nanosecond laser ablation is a potential technique for ablation of the SiN x layer of PERC solar cells but requires choosing the optimal parameters.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"112 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130097109","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 1

Multi-criteria optimization of micro-hole on glass using developed µ-abrasive jet machine set-up 利用开发的微磨料射流装置对玻璃微孔进行多准则优化

Journal of Micromanufacturing Pub Date : 2022-11-19 DOI: 10.1177/25165984221135047

V. V. Vanmore, U. Dabade

{"title":"Multi-criteria optimization of micro-hole on glass using developed µ-abrasive jet machine set-up","authors":"V. V. Vanmore, U. Dabade","doi":"10.1177/25165984221135047","DOIUrl":"https://doi.org/10.1177/25165984221135047","url":null,"abstract":"In non-traditional machining, micro-abrasive jet machining (MAJM) is a cost-effective machining process. MAJM has been used for fabricating electronic devices and microfluidic channels. This work has made an effort to utilize MAJM for glass. A new design and fabrication of the Laval type of nozzle have been proposed to improve machining accuracy. A nozzle is conceived to ensure specific characteristics of the mixture (compressed air and abrasive particles) pass through it. The abrasive particle force is converted to kinetic energy, increasing the mixture’s velocity. The cross-sectional area of the nozzle can be circular, rectangular, square, or oval. A circular cross-sectional nozzle has been developed for high velocity, precise etching, and patterning on difficult-to-machine materials such as steel alloys. A circular cross-sectional micro-nozzle with a large aspect ratio is proposed, and the flow characteristics and cutting performance are examined precisely by the experiment. Efforts are being made to make machining processes sustainable, productive, and efficient. Here, the Taguchi-grey relational analysis integration approach has been used to analyze the machining parameters such as air pressure, stand-off distance, and abrasive mesh size (AMS). The top hole diameter, bottom hole diameter, material removal rate, and radial overcut are the response variables in this investigation. Analysis of variance (ANOVA) results showed that the AMS was the most efficient parameter, which followed the processing condition on the total input of the multi-purpose function. The reported optimized process parameters are air pressure of 8 bar, stand-off distance of 2 mm, and AMS mix (50%+100%) micron, which significantly affects the top and bottom micro-hole diameters.","PeriodicalId":129806,"journal":{"name":"Journal of Micromanufacturing","volume":"41 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114236001","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0