Micro and Nano Manufacturing

Micro and Nano Manufacturing (7ME6.1A)- Part IMohit OstwalAssistant ProfessorDepartment of Mechanical EngineeringJodhpur Institute of Engineering and Technology- Coed, Jodhpur

Nano scale cutting

Nano scale cutting

Nano scale cutting

Chip formation in micro cutting

Chip formation in micro cutting

Chip formation in micro cutting

Diamond cutting tool

Example of nano scale cutting

Micro turning

Micro turningCharacteristic Features and applicationSwiss-type machine tools, ultra-precision lathes for diamond turning and miniature desktop machines, are used to perform micro turning operations on parts made of different materials.

Maximum Machining Diameter 7 mmMaximum Machining Length 40 mm

Hard to machine surfaces such as electroless nickel, glass , ceramics, quartz etc. without any subsurface damage.

Mirror surfaces of less than 10 nm surface finish can be obtained.

Ultra-precision diamond turning electroless nickel dies plastic optical parts for LCD Tvs (less than 6 nm)

Micro turningMicro turning tools and tooling systemMiniaturized tools with clamping Swiss type lathe or multi purpose tooling system Used as a tool block

Monolithic carbide tools boring and grooving smallest diameter of 0.2 mm to 4 mm maximum.

Micro turningMicro turning tools and tooling system (contd.)Special tooling system turning, boring, cutt-off and drilling.System consists of clamping unit and cutting unit.Machine uptime reduce to 25-40%

Rotating tool head for micro turning operation

Micro turning

Machine tools for micro turningIn general CNC automatic lathe, sliding head mechanismSwiss type LatheSwiss type turning centers with milling, drilling, boring single setup with lower cost upto 4mm dia.. Sliding head stock 32 mm max. dia. with bar feeder.12000 rpm with guide bushes and 16000 rpm without guide bushes.10000 rpm sub spindles for milling, drilling.

Micro turning

Micro turning

Micro turning

Micro drilling

Micro drillingCharacteristic Features and applicationHoles tens of micrometers PCBInkjet printers single row of 251 holes 50 m dia.Used below 0.5 mm.Minimum diameter of micro drills -> 5-50 m.

Advantages of micro drilling:Metals, plastics and composites can be drilled electrical properties do not influence the workpiece (wire EDM).ControllabilityDisadvantages of micro drilling:Inclination of holesBrittle and hard materials break micro drills diamond drills.

Micro drillingMicrodrills and tooling systemHSS(resistant to breaking) to carbide(stiffer but brittle).Diameter range 0.12 mm to 2.8 mm.Drilling of Aircraft Al, Titanium, SS, Steel.10 mm length with shank.

Micro drillingMicrodrills and tooling system0.3 mm HSS micro drill

Micro drilling (contd.)

Micro drills of the smallest obtainable diameter of approximately 6 m with a D-shapecross-section and a cutting edge radius of 0.5 m can be fabricated by wireelectro-discharge grinding

Micro drill

Machine tools for microdrilling

Micro drillMachine tools for microdrilling (contd.)Precision to eliminate hand finishing Air bearing spindle 500000 rpm(max.) 180000(current) 160000(ball bearing).

Micro drillMachine tools for microdrilling (contd.)Precision to eliminate hand finishing Air bearing spindle 500000 rpm(max.) 180000(current) 160000(ball bearing).

Micro drill -USM

Micro Drilling

Burr formation

MEMS Parts- silicon mirror assembly

Micro milling exampleUsed to create 3D features in the range of a few microns to a few hundred microns.Micro milling is capable of the fabricating holes several tens of micrometers in size for practical applications.

Micro manufacturing exampleA mite measuring 500m long sits on a mirror array used for optical data switching.The mirror [flat in the left image, folded in the right] is positioned with a gear mechanism

A focused ion beam created this two-micron-wide gear,seen here at 50,000x magnification