Micro and Precision Manufacturing (eBook)

Dr. Kapil Gupta is a Senior Lecturer in the Department of Mechanical and Industrial Engineering Technology at the University of Johannesburg, South Africa. His research interests include advanced machining processes, sustainable manufacturing, micro-fabrication, precision engineering and gear technology.

Preface 6
Contents 8
About the Editor 9
1 Machining of Microshapes and Features 10
Abstract 10
1 Introduction 10
2 Details on Fabrication Techniques for Microshapes and Features 12
2.1 Micromachining 12
2.1.1 Micromilling 12
2.1.2 Microturning 14
2.1.3 Microdrilling 16
2.2 Electrochemical Machining 18
2.3 Electrodischarge Machining 19
2.4 Laser Machining 22
2.5 Ultrasonic Machining 24
2.6 Hybrid Machining 24
3 Summary 26
References 26
2 Electrochemical Methods of Micropart’s Manufacturing 29
Abstract 29
1 Specificity of Electrochemical Micromachining (ECMM) 30
2 Localization of Electrochemical Dissolution 32
3 Pulse Electrochemical Micromachining (PECMM) 35
3.1 Millisecond and Microsecond Pulse Electrochemical Micromachining 35
3.2 Nanosecond Pulse Electrochemical Micromachining (Ns-PECMM) 36
4 Electrochemical Machining Integration with Other Technologies 37
4.1 Hybrid Electrochemical Micromachining Processes 38
4.1.1 Electrochemical and Mechanical Interaction 38
4.1.2 Electrochemical Machining Supported by Electrode Vibrations 39
4.1.3 Electrochemical–Electrodischarge Machining 40
4.1.4 Jet-Assisted Electrochemical Machining 41
4.1.5 Laser-Assisted Electrochemical Machining 41
4.2 Sequential Electrochemical Micromachining Processes 42
4.2.1 Laser and Electrochemical Processing Sequence 42
4.2.2 Sequential Electrochemical—Electro Discharge Processes 43
5 Summary 45
References 45
3 Precision Photochemical Machining 49
Abstract 49
1 Introduction 50
2 Need of PCM 50
3 Steps in PCM 51
3.1 Phototool Manufacturing 51
3.2 Photoresist Coating 52
3.3 Photoresist Processing 52
3.4 Workpiece Etching 53
4 Fine Line Challenges (Precision) Requirement 54
5 Photoresist Adhesion for Fine Line 56
6 Dry-Film Resist 56
6.1 Dry-Film Chemistry 57
7 Exposure Techniques 61
7.1 Exposure System 62
7.2 Trends in Image Transfer 62
7.2.1 Collimated Exposure Systems 63
7.2.2 Laser Direct Imaging 64
7.2.3 Projection Imaging 65
7.2.4 Contact Printing 66
8 Developing 67
8.1 Developer Control Parameters 67
8.2 Developer Sprays 67
9 Etching 68
10 Tolerances in PCM Process 69
11 Magnetic Field-Assisted Photochemical Machining 70
12 Ultrasonic-Assisted Photochemical Machining 72
13 Grey Photochemical Machining 74
14 Conclusions 77
References 77
4 Nano-Machining, Nano-Joining, and Nano-Welding 79
Abstract 79
1 Nano-Machining 80
2 Nano-EDM and ECM 82
2.1 Nano-EDM Process Details 83
2.2 Introduction to Nano-ECM 85
2.3 Nano-Machining Prospects of Other Advanced Processes 85
3 Nano-Joining and Welding 86
3.1 Introduction 86
3.2 Nano-Soldering 87
3.3 Nano-Welding 88
3.4 Mechanical Bonding 91
3.5 Fastening 91
4 Summary 91
References 92
5 Fabrication of Optical Components by Ultraprecision Finishing Processes 95
Abstract 95
1 Introduction 96
2 Precision Finishing Techniques Used for Fabrication of Optical Components 99
2.1 Single-Point Diamond Turning (SPDT) 100
2.2 Grinding 100
2.2.1 Deterministic Micro/ Ultraprecision Grinding 103
2.2.2 Nanogrinding 104
2.2.3 Piezoelectric Nanogrinding 104
2.3 Ion Beam Figuring (IBF) 107
2.4 Nanoparticle Colloid Jet Machining (NCJM) 110
2.5 Elastic Emission Machining (EEM) 113
2.6 Magnetorheological Finishing (MRF) 117
2.6.1 Experimentation 118
3 Summary 121
Acknowledgements 122
References 122
6 Condition Monitoring in Micro-Injection Moulding 128
Abstract 128
1 Introduction 129
2 Condition Monitoring of Cavity Pressure 130
2.1 Understanding Cavity Pressure 130
2.2 An Experimental Case Study for Pressure Monitoring 132
2.3 Validation, Verification and Results Using Pressure Monitoring 133
3 Condition Monitoring of Forces 135
3.1 Understanding Demoulding Forces 135
3.2 An Experimental Case Study for Force Monitoring 136
3.3 Validation, Verification and Results Using Force Monitoring 138
4 Condition Monitoring of Temperature 139
4.1 Understanding Cavity Temperature 139
4.2 An Experimental Case Study for Temperature Monitoring 142
4.3 Validation, Verification and Results Using Temperature Monitoring 143
5 Condition Monitoring of Airflow 144
5.1 Understanding Cavity Air Evacuation 144
5.2 An Experimental Case Study for Cavity Airflow Monitoring 145
5.3 Validation, Verification and Results Using Monitoring 147
6 Conclusions 148
References 149
7 Surface Finish Improvement of Additive Manufactured Metal Parts 151
Abstract 151
1 Introduction 152
2 Metal Additive Manufacturing Techniques 152
3 Surface Finish Improvement Techniques for AM Parts 157
3.1 AM Process Optimisation 157
3.2 Laser Re-melting and Laser Polishing 159
3.3 Chemical and Electropolishing 160
3.4 Microelectrical Discharge Machining 162
4 Conclusion 166
References 167
8 Precision Coatings 171
Abstract 171
1 Introduction 171
2 Functions of Coatings 172
3 Classification of Coatings 174
4 Precision Coating Technologies 177
4.1 Electrochemical Deposition 177
4.2 Electroless Plating 178
4.3 Thermal Spraying 179
4.4 Vapour Deposition (VD) 183
4.5 Cladding 185
4.6 Fluoropolymer Coatings 186
5 Precision Coatings—a Matter of Quality 187
5.1 Hardness Measurement 190
5.2 Thickness Measurement 191
6 Examples of Precision Coatings 194
6.1 Effect of Tungsten Carbon Carbide (WC/C) Coating on the Wear Resistance of Gears 194
6.2 Fluoropolymer Coating of Gears for Noise Reduction 195
7 Summary 197
References 198
9 Erratum to: Nano-Machining, Nano-Joining, and Nano-Welding 200
Erratum to:& #6
Index 201